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1. Figure 12 31 Battery Water Level 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 29 ELECTRICAL COMPONENTS Battery 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 which 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 fol lowing table See following NOTE NOTE Contact your local water department for mineral content analysis wen E Suspended matter Trace Total solids 100 0 SE and Magnesium 40 0 Iron 5 0 Ammonia 8 0 Organic matter 50 0 Nitrates 10 0 Nitrites 5 0 Chloride 5 0 Battery Removal See General Warnings Section 1 Page 1 1 See also DANGER on page 12 28 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the battery hold down clamp from the battery 3 Lift the battery from the vehicle See fo
2. 18 YELLOWAWHT 18 YELLOW NS SONIC WELD REVERSE BUZZER E 006688888 18 REDWVHITE DEE Figure 11 5 Precedent Gasoline Vehicle Instrument Panel Wiring Diagram Page 11 10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Electrical System ELECTRICAL SYSTEM The electrical system on the gasoline vehicle is 12 volts DC with negative ground to frame and consists of nine 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 Recognizing and understanding the function of each of these circuits will help to quickly isolate the source of an electrical problem Use the troubleshooting flow charts in the circuit testing section to find the proper test procedure to correct the electrical problem See Test Procedures on page 11 11 TEST PROCEDURES INDEX OF TEST PROCEDURES 1 Battery 2 Fuse 3 Ground Cables 4 Key Switch Starter Circuit 5 GCOR 5A Accelerator Pedal Limit Switch 5B Kill Limit Switch 6 Solenoid 7 Neutral Lockout Limit Switch 8 Starter Generator Starter Function 9 Wire Continuity 10 Starter Generator Generator Function
3. 4 2 minor scratches and surface blemishes 4 2 stress lines or streaks suusss 4 2 i Mac E te Rare aa 8 3 reverse buzzer ssesee 11 11 11 32 installation eeeeeeeeenn 12 19 limit switch installation Deep removal removal 5 22 15 wd enaesneenie ni testing uA UPS RPM adjustment RPM limiter installation i DUIS 12 24 removal 65 D engen taie 12 24 testing S ENEE 1 1 2 1 pre operation and daily safety checklist 10 1 safety committee coocooocccnonccccnocnnnnannncnancnnnoncnnnnns 3 2 SAM installation EE 4 10 removal ee 4 10 schematic diagram ssseeseese 11 6 seat back four passenger installation eeseeeeeeennnnnnns 4 13 A iss 4 12 seat support four passenger installation eeseeeeeeennnn nnne 4 13 removal EE EAE OBEN Le sees 4 13 serial number vehicle sss 3 1 service schedule see periodic service schedule see also periodic lubrication schedule service tools torque converter Kit lessees 17 1 unitized transaxle occccccccnccccnnninancananannnononos 16 2 shock absorber See suspension front and suspension rear solenoid installation tint ettet 12 14 removal TOSUNG EE spark plug cleaning inspection and repair 13 2 gap adjustment s e 13 2 14 1 EE E
4. SYMPTOM Engine starts but does not run smoothly POSSIBLE CAUSES Spark plug is fouled or in poor condition REFER TO Section 13 FE290 Engine Spark plug wire is damaged or loose Section 13 FE290 Engine Intermittent ignition coil failure Section 11 Troubleshooting and Electrical System Test Procedures 13 14 and 15 Water or dirt in the fuel system and or carburetor dirty or clogged fuel filter Section 14 Fuel System Fuel pump malfunction fuel pressure to carburetor too low Section 14 Fuel System Engine turns but fails to start Engine overheats Engine pre ignites Fuel tank is empty Section 14 Fuel System Fuel line or filters clogged Section 14 Fuel System Fouled spark plug Section 13 FE290 Engine Spark plug wire damaged or loose Loose wire connection at ignition coil or RPM limiter Section 18 FE290 Engine Section 11 Troubleshooting and Electrical System Test Procedures 13 14 and 15 Ignition coil or RPM limiter failed Engine flooded with fuel as result of excess choking Kill circuit grounded Section 11 Troubleshooting and Electrical System Test Procedures 13 14 and 15 Section 3 General Information in the appropriate maintenance and service manual See Choke Section 11 Troubleshooting and Electrical System Test Procedures 5B 17 18 Fuel pump malfunction or failure Fan
5. Page 16 10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual UNITIZED TRANSAXLE Unitized Transaxle Removal 16 Figure 16 20 Shock Absorbers Figure 16 21 Floor Jack 8 Raise vehicle just enough to relieve tension from leaf springs then remove the bolts securing the leaf springs to the shackles Figure 16 22 Page 16 11 9 Remove the bolts securing the leaf springs to their front mounts Figure 16 23 Page 16 11 Remove bolt then rotate shackle up and away from spring Figure 16 22 Rear Shackle Figure 16 23 Spring Retainer Bolts 10 Continue raising vehicle until frame 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 24 Page 16 12 11 Position jack stands adjusted to support the vehicle at this height under the aluminum frame rails for ward of the spring mounts Lower the floor jack to allow the jack stands to support the vehicle Figure 16 25 Page 16 12 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 11 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal Continued JACK STAND Figure 16 24 Raise Vehicle Figure 16 25 Position Jack Stands 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 Fig
6. cesseeeeeeeeeeee 7 13 removal shock absorber instalation eren octets do gedd 7 17 removal eana imet ee testet estre 7 17 tie rod installation WEE 7 12 tie rod end removal nees ege ee NEE 7 12 wheel bearings and hub INSPOCHOMN ege Eege EE installation removal rrt e cae Weave lubrication iai is toe in adjustment wheel alignment A suspension rear shock absorber inspection and removal ssss 9 1 NET le EE 9 1 suspension rear four passenger leaf spring instalation EE 9 6 removal ton ert eeu dere 9 4 suspension rear two passenger leaf spring installation ioci nea e ettet 9 4 removal EE 9 1 sweater basket ooooccccccccccccccoooooccncccnnnnnnnnnnono 4 10 T test procedure accelerator pedal limit switch 11 17 battery scs eec toe ides 11 12 11 33 2005 Precedent Gasoline Golf Car Maintenance and Service Manual engine kill circuit ssse engine kill circuit wire fuel gauge A a A De fuel level sending unit Uc tethers ground straps aae aaaea eieaa iaeia ignition coil ignition test key switch engine kill circuit n e 11 31 low oil warning light A 11 33 neutral lockout e EE 11 33 limit Switch siii orien 11 20 oil level sensor sesssseeeeeeeee 11 32 reverse buzzer sssssssssese 11 32 reverse buzzer limit switch 11 32 RPM limiter NER 11 26
7. Figure 6 19 Loosen Brake Cables 6 Rotate the bolt 5 and equalizer bracket 4 to the upright position then slip the cable heads out of the bracket 7 Remove nut 1 from the bolt 2 that secures front of the leaf spring Figure 6 21 Page 6 11 Do not remove bolt 2 8 Remove the mounting tab 3 of the brake cable from the bolt 9 Using brake cable release tool CCI P N 102555501 compress the retaining clips on the end of the cable housing enough to slide the cable end out of the hole in the frame 10 Remove bow tie locking pin 1 and the clevis pin 2 from the brake lever on each wheel and pull the cle vis 3 away from the lever Figure 6 20 Page 6 11 11 Using brake cable release tool CCI P N 102555501 compress the retaining clips on the end of the cable housing enough to slip the cable end out of the bracket 3 and remove the brake cable from the vehicle AS SEEN FROM DRIVER SIDE OF REAR OF VEHICLE Figure 6 20 Disconnect Cables at Rear Brakes Figure 6 21 Brake Cable Mounting Tab 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 6 11 EN WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation Brake Cable Installation NOTE The driver side and passenger side brake cables are not interchangeable Make sure the correct cable is used on the correct side 1 Insert the end of the new brake cable through the hole in the frame Figure 6 19 Page 6 11 Push on the cable housi
8. 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 See General Warnings Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Ensure that the wires are connected correctly and are tight If they are not rewire or tighten as necessary Disconnectthe yellow wire from the DF terminal on the starter generator Cover the connector on the yel low 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 20 Page 11 22 YELLOW WIRE QA JUMPER M ee oM WIRE ONSE FS owe Figure 11 20 Jumper Wire Ground DF to A2 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 Turn the key switch to ON position press the accel erator pedal to 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 Test Proce dure 11 Vo
9. Battery failed Transmission shifter linkage is binding or is out of adjustment Test Procedure 1 Battery on page 11 12 Section 16 Unitized Transaxle Idle RPM setting is set too high Section 14 Fuel System Insufficient low level of lubricant or wrong type of lubricant in transmission Internal gears are damaged or worn Section 16 Unitized Transaxle Section 16 Unitized Transaxle Synchronizer rings are worn damaged or jammed Section 16 Unitized Transaxle Excessive vehicle vibration Engine mounting nuts or bolts are loose Section 13 FE290 Engine Snubber on frame is worn or damaged Misaligned muffler mounting clamp Section 13 FE290 Engine Section 15 Exhaust System Damaged drive belt or starter belt Section 17 Torque Converter Damaged drive clutch Section 17 Torque Converter Damaged driven clutch Section 17 Torque Converter Damaged starter generator pulley RPM setting is incorrect Starter Generator Section 12 Page 12 1 Engine RPM Adjustment Section 14 Page 14 9 Torque converter does not shift smoothly Page 11 4 Drive belt is worn cracked glazed or frayed Section 17 Torque Converter Drive clutch malfunction Section 17 Torque Converter Driven clutch malfunction Section 17 Torque Converter Governor is sticking Troubleshooting Guide continued on next
10. INSTRUMENT PANEL INSTALLATION 1 Position dash assembly 1 on vehicle Make sure tabs on the forward edge engage to front underbody Secure assembly in place with three screws 2 Figure 4 3 Page 4 5 Tighten screws to 8 8 ft Ib 12 N m 2 Position dash tray 6 in dash and secure with two barrel fasteners 7 3 Install the instrument panel 3 1 Connect the electrical connector on the instrument panel to the harness connector 3 2 Position the instrument panel 3 on the dash assembly Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly Ensure that there are no wires exposed or pinched during positioning 3 83 Secure instrument panel to the dash assembly with screws 4 and 5 Tighten screws to 1 8 ft Ib 2 5 N m FLOOR MAT AND RETAINERS See General Warnings Section 1 Page 1 1 The floor mat retainers secure the floor mat to the vehicle and also provide a clean appearance to the side of the vehicle Normally if only the floor mat 3 needs to be removed the screws 2 can be loosened slightly to allow the floor mat to be slid from beneath the retainers 1 Figure 4 4 Page 4 6 EA TRIM CLIPS 4 PLACES Figure 4 4 Floor Mat Retainer Page 4 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual BODY AND TRIM Kick Plate and Choke Button FLOOR MAT RETAINER REMOVAL 1 Remove screws 2 from top of retainer 1 Figure 4 4 Page 4 6 2 Remove
11. Ignition Coil on page 11 26 Page 11 24 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures IGNITION GAP A TEST TOOL SPARK PLUG WIRE Figure 11 23 Ignition Spark Test 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 BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL WHITE BLACK FEMALE BULLET KILL CIRCUIT WIRE TERMINAL BROWN WIRE BLACK WIRE Figure 11 24 RPM Limiter 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 25 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 14 RPM LIMITER See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Disconnect both of the bullet terminals Figure 11 24 Page 11 25 3 Using a multimeter set on 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
12. Neutral Lockout During normal vehicle operation the neutral lockout feature prevents the engine from running when the For ward 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 approx imately 3 8 inch 10 mm and then rotated one half turn until it snaps into place the cam will be in the MAIN TENANCE position When the cam is in the MAINTENANCE position it will allow the technician to run the engine in NEUTRAL for certain maintenance procedures 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 To put the cam back into the OPERATE position pull the cam out approximately 3 8 inch 10 mm and rotate it one half turn until it snaps into place 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 1 UNITIZED TRANSAXLE Governor System General Information 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 read justment of the governor linkage is required Se
13. The GCOR contains two limit switches the accelerator pedal limit switch and the kill limit switch These two switches are sealed and cannot be repaired or replaced A four pin connector provides electrical connections to both switches Test procedures for the two switches are found in test procedures 5A and 5B If either test is failed the GCOR must be replaced Test Procedure 5A Accelerator Pedal Limit Switch See General Warnings Section 1 Page 1 1 The green and orange wires from the connector are adhered to the accelerator pedal limit switch 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Check for proper wiring and tight connections Figure 11 1 Page 11 6 and Figure 11 2 Page 11 7 3 Set the multimeter to 200 ohms Separate the electrical connector and place the red probe on the green wire pin of the limit switch and place the black probe on the orange wire pin of the limit switch Figure 11 14 Page 11 18 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 17 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 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 either reading
14. probe against the housing place the red probe one at a time on the A1 A2 F1 F2 and DF terminals respectively Figure 11 19 Page 11 21 The readings should be no continuity If the readings are incorrect the starter generator will need to be removed from the vehi cle and disassembled by a qualified technician See Starter Generator Removal Section 12 Page 12 1 An incorrect reading from 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 f the F1 or F2 reading is incorrect it indicates a possible grounded F1 or F2 terminal or a grounded field coil f 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 p dde YELLOW WIRE STARTER GENERATOR Figure 11 19 Check Terminal Continuity 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 Section 12 Page 12 1 6
15. 1 Oo oc A CO ND Remove the two nuts 12 two bolts 11 and spacers 10 from the canopy 9 and each front canopy support 1 Figure 4 13 Page 4 19 Remove the nuts 14 and bolts 13 from the canopy 9 and the rear support 6 Lift canopy 9 away from front canopy supports 1 and rear support 6 Remove screws 5 securing front canopy support covers to front body Slide canopy support covers 4 up front canopy supports 1 to gain access to bolts 2 Remove two bolts 2 from each front canopy support 1 and remove the canopy supports from the vehi cle Remove two bolts 8 from the rear support 3 and remove rear support from vehicle FOUR PASSENGER CANOPY INSTALLATION 1 Install the front canopy supports 1 1 Ensure the front supports are properly oriented to the correct side of the vehicle as shown Figure 4 13 Page 4 19 The lower profile of each support follows the profile of the vehicle If the supports are placed on the wrong side of the vehicle they will not follow the vehicle s profile 1 2 Align the holes in the lower portion of each front support 1 with the corresponding holes in the vehicle Insert two bolts 3 through each front support into the threaded holes in the vehicle The bolts are color coded with gold thread lock Only finger tighten the bolts at this time 1 3 Slide the front support covers 4 over the front supports 1 The covers are marked DRIVER and PASS
16. Figure 10 1 Engine Oil Level Check Figure 10 2 Fuel Tank 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 10 5 PERIODIC MAINTENANCE Fueling Instructions OIL VISCOSITY Choose the viscosity according to the temperature as indicated by the oil viscosity chart Figure 10 3 See follow ing NOTE 20C 10 C P SAE 10W 30 SAE 10W 40 ea AE 14 F 32 F 50 F 68 F 86F 104 F Figure 10 3 Oil Viscosity Chart NOTE Using multi grade oils 5W 20 10W 30 and 10W 40 will increase oil consumption Check oil level more frequently when using multi grade oils FUELING INSTRUCTIONS See General Warnings Section 1 Page 1 1 A DANGER Turn key switch to the OFF position before fueling Do not pour gasoline 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 Be sure the fuel tank ground wire located next to the fuel shut off valve is properly connected before fueling the vehicle e If the vehicle has an all weather enclosure installed the fuel tank must be properly vented as shown Figure 10 2 Page 10 5 To avoid the possibility of fire clean up any spilled fuel before operating the vehicle A CAUTION To allow for expansion do not fill higher than one i
17. Figure 4 6 Universal Accessory Mounting Page 4 8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual BODY AND TRIM Rear Body Two Passenger Vehicles TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 4 7 Backrest and SAM 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 9 BODY AND TRIM Rear Body Two Passenger Vehicles BACKREST AND STRUCTURAL ACCESSORY MODULE SAM SAM Removal 1 Ifthe vehicle has a canopy the rear upright supports must be removed from the SAM 2 Remove four bolts 4 to release the SAM 3 from the vehicle Figure 4 7 Page 4 9 SAM Installation 1 Position the SAM 3 over its mounting holes and secure with four screws 4 Tighten screws to 53 in Ib 6 N m Figure 4 7 Page 4 9 Backrest The backrest 1 is secured to the SAM 3 with two screws 2 Figure 4 7 Page 4 9 When replacing the backrest tighten screws 2 to 5 9 ft lb 8 N m Bag Rack Removal 1 Remove two screws 10 to release the bag hoop 6 and related components from the SAM 3 Figure 4 7 Page 4 9 2 Bag strap 8 may be released by removing two plastic barrel connectors 9 and one screw 12 3 Bag strap buckles 7 may be snapped out of bag hoop 6 Bag Rack Installation Installation is the reverse of removal Tighten screw 12 to 4 8 ft Ib 6 5 N m and screws 10 to 11 8 ft Ib 16 N m Figure 4 7 Page 4 9 S
18. Page 12 22 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Fuel Level Sending Unit FUEL LEVEL SENDING UNIT See General Warnings Section 1 Page 1 1 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 Section 11 Page 11 34 HOUR METER See General Warnings Section 1 Page 1 1 Testing the Hour Meter See Test Procedure 16 Hour Meter on page 11 30 The hour meter displays the number of hours of use in increments of 0 1 hour Hour Meter Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Disconnect the wires from the hour meter 1 Figure 12 23 Page 12 23 3 Remove screw 2 to release bracket 3 4 Remove keeper 4 from hour meter to release meter 1 from bracket 3 Hour Meter Installation 1 Install a new hour meter into bracket 3 and secure it by sliding the keeper 4 onto it Figure 12 23 Page 12 23 2 Connect wires to the hour meter 3 Position bracket 3 on the vehicle and secure in place with screw 2 Figure 12 23 Hour Meter Installation 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 23 ELECTRICAL COMPONENTS RPM Limiter RPM LIMITER
19. Test Procedure 15B Ignition Coil Bench Test 1 Remove the coil from the engine See Ignition Coil Removal Section 12 Page 12 25 2 Using a multimeter set to 20k 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 31 Page 11 29 2 2 f the resistance is not between 0 6k 1 7k 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 that normally connects to the spark plug 3 and place the black probe on the core 2 Figure 11 32 Page 11 29 3 2 If the resistance is between 6 0k 11 0k ohms the secondary coil and spark plug cap are within acceptable limits proceed to step 6 on page 11 30 If the resistance is not between 6 0k 11 0k ohms the spark plug cap and secondary coil must be tested independently from each other SECONDARY COIL Figure 11 31 Primary Coil Resistance Bench Test Figure 11 32 Secondary Coil and Cap Resistance Bench Test 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 27 Page 11 27 2005 Precedent Gasoline Golf
20. Use the following checklist as a guide to inspect the vehicle and check daily for proper operation Any prob lems should be corrected by a Club Car distributor dealer or a trained technician Forward Reverse shifter Check for proper operation See Controls and Indicators in the vehicle owner s manual Brakes Be sure the brakes function properly When brake pedal is pressed using moderate pressure the vehicle should come to a smooth straight stop If the vehicle swerves or fails to stop stops abruptly or makes a grinding or squeaking noise have the brake system checked and adjusted as required Continued moderate brake pedal pressure should be able to lock the wheels but using lesser pressure should also permit a slow gradual deceleration 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 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 perfor mance Have a Club Car distributor dealer or a trained technician investigate anything unusual Accelerator With the key switch in the ON position and the Forward Reverse handle in th
21. 9 in the keyway 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 17 13 TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH DISASSEMBLY 1 Using external snap ring pliers remove the retaining ring 4 Figure 17 20 Page 17 14 See following WARNING A 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 CCI P N 1014507 Figure 17 21 Page 17 14 into the shaft bore and use a driven clutch cam puller CCI P N 1014508 to remove the cam 4 from the fixed face shaft 8 Figure 17 22 Page 17 15 3 Remove the spring 5 Figure 17 22 Page 17 15 4 Retain the key 3 5 Slide the moveable face 7 off the fixed face shaft 8 DRIVEN CLUTCH CAM PULLER Figure 17 20 Remove Retaining Ring Figure 17 21 Driven Clutch Disassembly Page 17 14 2005 Precedent Gasoline Golf Car Maintenance and Service Manual se af eye SK a o NEN LI A TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH INSPECTION 1 2 Inspect the cam 4 for excessive wear Replace it if necessary Figure 17 22 Page 17 15 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 Inspect the smooth surface on the fixed and moveable face assemblies As
22. Brake Shoe Installation Continued 7 2 Using 90 internal snap ring pliers 0 090 tip CCI 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 A 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 A 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 arum 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 10 Install the wheel See Wheel Installation Section 8 Page 8 1 11 Adjust brake cable equalizer See Brake Cable Equalizer Adjustment on page 6 8 BRAKE CABLE EQUALIZER ADJUSTMENT See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 1 After maintena
23. N o oc P cable to the vehicle When installed cable must be routed and secured as it was originally 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 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Loosen lock nut 26 where the cable attaches to the shifter Figure 16 55 Page 16 23 Push in the end of the ball joint socket 27 to release the cable from the ball stud 17 Loosen retaining nuts 28 to release cable from bracket 10 Release the wire tie 25 that is clipped to the bucket and secure the cable Use a screwdriver or flat blade to pry cable end off the stud on the lever arm Compress clips on boot enough to push boot through the cable bracket 24 Remove cable from vehicle FORWARD REVERSE SHIFTER CABLE INSTALLATION 1 From the Forward Reverse shifter route the cable toward the passenger side of the vehicle so it lies against the side of the front body turns 90 and passes over the battery through the opening to the engine and through the cable bracket to the shifter arm Figure 16 55 Page 16 23 Make sure cable does not touch muffler Place cable in bracket 10 and secure in position with two retaining nuts 28 Tighten retaining nuts to 43 in Ib 4 9 N m Attach ball joint socket 27 to stud 17
24. Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Turn the key switch to ON and record the current hour meter reading 3 Press and hold the accelerator pedal to run the engine for at least six minutes the meter records in six minute increments See following DANGER Page 11 30 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures A DANGER Do not operate vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 4 lf the reading does not change after six minutes then replace the hour meter TEST PROCEDURE 17 KEY SWITCH ENGINE KILL CIRCUIT See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Remove the instrument panel assembly See Key Switch Removal Section 12 Page 12 13 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 conti nuity If either
25. 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 in this maintenance and service manual TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine does not start easily Spark plug is partially fouled or in poor condition Section 13 FE290 Engine Spark plug wire is damaged or loose Section 13 FE290 Engine Loose wire connection at ignition coil or RPM limiter Section 11 Troubleshooting and Electrical System Test Procedures 13 14 and 15 Intermittent ignition coil failure Section 11 Troubleshooting and Electrical System Test Procedures 13 14 and 15 Low cylinder compression Section 18 FE290 Engine Water or dirt in the fuel system and or carburetor dirty or clogged fuel filter Section 14 Fuel System Engine does not start easily continued Carburetor improperly adjusted Starter generator belt is slipping Section 14 Fuel System Belt Tension Adjustment Section 12 Page 12 11 Troubleshooting Guide continued on next page 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 1 EB TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE
26. engine kill circuit See following WARNING A 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 press and hold the choke cover closed until the engine stops running 5 If the engine does not run proceed to Test Procedure 13 Ignition Spark on page 11 24 WHITE BLACK UN ENGINE RPM KILL bae K EN SC Figure 11 22 ANA a Kill Wire TEST PROCEDURE 13 IGNITION SPARK See General Warnings Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Remove the plug wire from the spark plug Using an ignition spark gap test tool Thexton 4049 or equiv alent check for correct spark Figure 11 23 Page 11 25 2 1 Adjustthe tester probes to approximately to 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 Turn the key switch to the ON position and crank the engine by pressing the accelerator There should be a strong blue spark between the probes of the spark gap tester If there is no spark or ifthe spark is a faint yellow or red color test components of the ignition circuit See Test Procedure
27. interval with the proper lubricant See Periodic Lubrication Schedule Section 10 Page 10 4 CAUTION To ensure proper lubrication raise front of vehicle to lubricate See General Warnings Section 1 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 NOTE Prior to making any front suspension adjustments inspect components for wear or 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 14 Page 7 11 2 Loosen but do not remove the four bolts 17 that secure the leaf spring 13 to the bottom spring plate 16 Figure 7 19 Page 7 16 See also Figure 7 15 Page 7 11 3 Loosen but do not remove the hex nut 8 on the adjustment eccentric 7 Figure 7 15 Page 7 11 in the center of the spring See also Figure 7 19 Page 7 16 4 Use a 7 mm deep well socket to rotate the eccentric Figure 7 15 Page 7 11 5 After adjusting camber use a crisscross pattern to tighten the four spring retaining bolts 17 Figure 7 19 Page 7 16 to 23 ft Ib 31 N m Then roll the vehicle forward one full tire revolution and recheck the camber See also Figure 7 14 Page 7 11 6 Tighten the hex nut 8 on the adjustment eccentric 7 to 10 ft Ib 18 5 N m Figure 7
28. 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 17 Page 11 19 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 19 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 6 Solenoid Continued 9 Disconnect the 10 gauge black cables from the negative post of the battery before reconnecting the wires to the solenoid TEST PROCEDURE 7 NEUTRAL LOCKOUT LIMIT SWITCH See General Warnings Section 1 Page 1 1 This switch is located on the Forward Reverse switch assembly There is a black wire a green wire and a white wire connected to this limit switch 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 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 termi nal 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 con tinuity If either readin
29. 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 A CAUTION Dispose of wastewater and fuel tank in accordance with local state and federal laws and ordinances ORANGE WIRE BLACK WIRE TO GROUND BLACK W WIRE TO e lt GROUND WITHOUT SENDING UNIT Figure 14 11 Fuel Level Sending Unit FUEL TANK STORAGE 1 Remove the cap from the tank and thoroughly rinse it with water 2 Ina well ventilated area flush the fuel tank with water to remove any remaining fuel 3 Ina 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 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 19 FUEL SYSTEM Fuel Tank FUEL TANK INSTALLATION 1 2 Place the fuel tank in the vehicle Secure the tank with the fuel tank hold down 2 Figure 14 8 Page 14 13 2 1 Insert the tabs on the rear of the hold down into the slots on the back of the fuel bucket 2 2 Pivot hold down to place the front edge over mounting holes Install two screws 2 to secure the hold down Tighten screws to 31 in Ib 3 5 N m Connect the vent tube 14 to the fuel tank vent Figure 14 8 Page 14
30. 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 Page 12 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Starter Generator Flared armature windings e 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 BENT LLL CEE SET HOUSING FIELD COIL TERMINAL FIELD COIL 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 commu tator outside diameter is less than 1 535 inches 39 mm replace the armature and bearings Figure 12 11 Page 12 8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 7 ELECTRICAL COMPO
31. 1 1 A WARNING See General Warnings Section 1 Page 1 1 GENERAL INFORMATION The rear suspension of the Precedent vehicle is completely independent It consists of two leaf springs con trolled by two shock absorbers mounted between the springs and the vehicle frame SHOCK ABSORBERS See General Warnings Section 1 Page 1 1 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 or Figure 9 4 Page 9 5 2 To remove a shock absorber remove the nut 5 cup washer 9 and rubber bushings 10 from the stem at the top of the shock absorber 3 Remove the nut 5 cup washer 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 LEAF SPRINGS TWO PASSENGER VEHICLES See General Warnings Section 1 Page 1 1 LEAF SPRING REMOVAL TWO PASSENGER VEHICLES 1 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 t
32. 10 that comes from the fuel filter 7 Install a new clamp 6 Route the fuel lines as shown Figure 14 8 Page 14 13 NOTE Be sure to connect the fuel line 10 that comes from the fuel filter 7 to the inlet nipple on the pump Direction of fuel flow is indicated by the arrows on the fuel pump Figure 14 8 Page 14 13 See also Figure 14 10 Page 14 16 2 Connect to the output side of the fuel pump the fuel line 13 that goes to the carburetor Figure 14 8 Page 14 13 3 Connect the impulse line 12 to the bottom nipple on the fuel pump Use a new clamp 6 4 Install the fuel pump on the fuel bucket with screws 11 Tighten screws to 2 7 ft Ib 3 5 N m 5 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 6 Turn the fuel shut off valve on top of the fuel tank to the open position Figure 14 13 Page 14 22 7 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and place the neutral lockout cam in the MAINTENANCE position 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 See following DANGER A DANGER Repair all fuel leaks before operating the vehicle 8 Place the neutral lockout cam in the OPERATE position 2005 Precedent Gasol
33. 13 Remove the vent cap Using a battery thermometer CCI P N 1011767 record the electrolyte temperature of a center cell Squeeze the rubber bulb of the hydrometer and insert into the cell Slowly release the bulb drawing elec trolyte up into the glass tube of the hydrometer 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 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 7 Page 11 13 Record the reading Return the electrolyte to the cell from which it was taken Replace vent cap Repeat steps 2 through 8 on all cells BATTERY CAP PLATES Y EY ELECTROLYTE LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR Figure 11 6 Battery Electrolyte Level Figure 11 7 Hydrometer Test 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
34. 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 16 Page 16 9 WHITE WIRE YELLOW SHIFTER Figure 16 15 Shifter Cable Figure 16 16 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 17 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 18 Page 16 10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 9 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal Continued STARTER GENERATOR OIL SENDING UNIT JUMPER WIRE WHITE BLACK RN e AN WIRE IK nr d Figure 16 17 Oil Level Sensor Jumper Wire Figure 16 18 lgnition Kill Wire 5 Disconnect the brake cables Remove bow tie locking pins 1 and brake cable clevis pins 2 and using tool CCI P N 1025555 compress tangs on cable end and remove cable from bracket 3 Figure 16 19 Page 16 10 AS SEEN FROM DRIVER SIDE OF VEHICLE REAR OF VEHICLE Figure 16 19 Brake Cable 6 Remove the lower shock mounting hardware from both rear shocks Figure 16 20 Page 16 11 7 Position a floor jack under the rear of the vehicle Figure 16 21 Page 16 11
35. 2 Position the instrument panel 2 on the dash assembly Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly Ensure that there are no wires exposed or pinched during positioning 3 3 Secure instrument panel to the dash assembly with three screws 1 Tighten screws to 1 8 ft Ib 2 5 N m 4 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion FUEL GAUGE See General Warnings Section 1 Page 1 1 Testing the Fuel Gauge See Test Procedure 26 Fuel Gauge on page 11 35 With the key switch in the OFF position the fuel gauge reads empty When the key switch is turned to ON the fuel gauge becomes active Fuel Gauge Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the instrument panel See Key Switch Removal on page 12 13 3 Disconnect the three wires from the fuel gauge Figure 12 22 Page 12 22 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 21 ELECTRICAL COMPONENTS Fuel Gauge Fuel Gauge Removal Continued 4 Remove the two hex nuts 3 and lock washers 4 from the threaded studs on the back of the gauge Remove the mounting bracket 5 from the back side of the fuel
36. 21 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion OIL LEVEL SENSOR See General Warnings Section 1 Page 1 1 Testing the Oil Level Sensor See Test Procedure 21 Section 11 Page 11 32 Oil Level Sensor Removal See Oil Level Sensor Removal Section 13 Page 13 5 Oil Level Sensor Installation See Oil Level Sensor Installation Section 13 Page 13 6 BATTERY See General Warnings Section 1 Page 1 1 A DANGER Due to the danger of an exploding battery wear a full face shield and rubber gloves when working around a battery 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 General Information Club Car gasoline vehicles are equipped with 12 volt low maintenance batteries When c
37. 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 10 Connect spark plug wire to spark plug 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 11 ELECTRICAL COMPONENTS Voltage Regulator VOLTAGE REGULATOR See General Warnings Section 1 Page 1 1 Testing the Voltage Regulator See Test Procedure 11 Section 11 Page 11 23 Voltage Regulator Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Disconnect the voltage regulator connector 3 from the wire harness Figure 12 15 Page 12 12 3 Remove the voltage regulator mounting screw 2 and remove the voltage regulator 1 Figure 12 15 Voltage Regulator Voltage Regulator Installation 1 Position the voltage regulator 1 and install the mounting screw 2 Figure 12 15 Page 12 12 Tighten screw to 23 in Ib 2 6 N m 2 Connect the voltage regulator three pin connector 3 to the wire harness 3 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 4 Place Forward Reverse handle in NEUTRAL and place the neutral lockout cam in the MAINTENANCE position Start the engine and check regulator for proper functioning as described in
38. 4 Page 16 3 under the inside lip of the seal and pull the oil seal out Figure 16 5 Page 16 4 See following CAUTION A 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 BRAKE CLUSTER REMOVED FOR CLARITY Figure 16 5 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 6 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 CCI P N 1012812 on the axle shaft between the wheel mounting flange and the bearing Figure 16 6 Page 16 5 See also Figure 16 7 Page 16 7 See following CAUTION 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 6 Page 16 5 See also Figure 16 7 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 6 Page 16 5 Since the inner diameter of the retaining ring 70 is smaller than the outer diameter of the beari
39. Accelerator Spring Pin Removal PEDAL GROUP INSTALLATION 1 Place the GCOR on the pedal group and secure with two screws 1 Figure 5 3 Page 5 3 Tighten the screws to 23 in Ib 2 6 N m 2 Insert the end of the accelerator cable 10 into position on the pedal group Figure 5 2 Page 5 2 3 Connect the wire harness 12 to the GCOR 11 Figure 5 2 Page 5 2 NOTE Connector will only fit together in one orientation 4 Position the pedal group in vehicle and secure with two screws 2 on the driver side and two screws 1 on the passenger side Tighten driver side screws 2 to 12 ft Ib 16 3 N m Tighten passenger side screws 1 to 5 ft Ib 6 8 N m 5 Usethe turnbuckle 6 to connect the rod from the pedal group to the brake actuator rod Ensure the ends of the brake cables do not slip out of the brake equalizer during this procedure Page 5 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group 8 i ae TURNBUCKLE Figure 5 8 Brake Pedal Adjustment 6 Adjust brake cable equalizer See Brake Cable Equalizer Adjustment Section 6 Page 6 8 7 Position accelerator cable in its bracket Ensure there is a nut 1 on each side of the mounting tabs Figure 5 9 Page 5 7 8 Adjust the position of the accelerator cable sleeve in the bracket until there is no slack in the wire portion of the cable Tighten both nuts 1 to 9 in Ib 1 N m to secure the cab
40. Car Maintenance and Service Manual Page 11 29 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 5 Testt 6 4 2 4 3 5 1 Remove the cap from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire Figure 11 28 Page 11 27 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 29 Page 11 28 If the multimeter does not indicate continuity the cap has failed and must be replaced Proceed to the next step with the spark plug cap still removed he secondary coil separately from the spark plug cap Using a multimeter set to 20k ohms place the red probe of the multimeter into the end of the spark plug wire and place the black probe on the core 2 Figure 11 33 Page 11 30 If the resistance is between 6 0k 11 0k ohms the secondary coil is within acceptable limits If the resis tance is not between 6 0k 11 0k ohms the ignition coil has failed and must be replaced 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 Figure 11 33 Secondary Coil Resistance Bench Test TEST PROCEDURE 16 HOUR METER See General Warnings Section 1
41. Cuca Maintenance 2005 And PRECEDENT Service Ingersoll Rand Gasoline Vehicles Manual No 102680402 Edition Code 0205A00000 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 Precedent gasoline vehicle This manual also provides detailed information for removing and replacing FE290 engines and transaxles but does not contain information for the disassembly repair or rebuilding of FE290 engines or transaxles For complete detailed disassembly repair or rebuild procedures see the Engines and Drivetrain Components Repair and Rebuild Manual CCI P N 102396501 The procedures provided herein must be properly implemented and the DANGER WARNING and CAU TION statements must be heeded This manual was written for the trained technician who already possesses knowledge and skills in electrical and mechanical repair f 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 Inc to
42. Figure 3 2 Page 3 3 1 1 Remove the plug from the fuel tank vent 1 2 Connect the vent tube to the fuel tank vent 2 Connect battery cables positive cable first 3 Completely open the fuel shut off valve Figure 3 4 Page 3 4 Make sure the valve is fully open A par tially closed fuel shut off valve Figure 3 5 Page 3 4 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 MAINTE NANCE position Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts Turn the engine off and return neutral lockout cam to the OPERATE position See following NOTE NOTE Due to the oil added to the engine in preparation for storage the 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 Section 2 Vehicle Specifications 6 Perform the Pre Operation and Daily Safety Checklist on page 10 1 FULL OPEN ON PARTIALLY CLOSED POSITION POSITION VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE Figure 3 4 Fuel Shut Off Valve Open Position Figure 3 5 Incorrect Fuel Shut off Valve Setting Page 3 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SECTION 4 BODY AND TRIM A DANGER See General Warnings Section 1 Page 1 1 A WARN
43. SUSPENSION Front Suspension Components Toe in Adjustment Continued 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 5 16 inch 7 8 mm 6 If adjustment is necessary proceed as follows 6 1 Loosen the jam nut on each tie rod end 1 Figure 7 17 Page 7 11 6 2 Remove the retaining pin 2 and nut 3 that secure the tie rod to the spindle Raise the male threads out of the spindle 6 3 Rotate tie rod end in or out as required 6 4 Attach male thread to spindle tab and recheck the toe in 6 5 As necessary repeat steps 6 1 through 6 4 6 6 Secure tie rod ends with nuts 3 and tighten to 70 ft Ib 95 N m Install retaining pins 2 6 7 Tighten jam nuts Tighten to 26 ft lb 35 N m 6 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 FRONT SUSPENSION COMPONENTS See General Warnings Section 1 Page 1 1 TIE ROD END REMOVAL 1 Loosen jam nuts 13 to allow later rotation of the tie rod ends 12 Figure 7 18 Page 7 15 Remove the retaining pins 15 and retaining nuts 14 2 3 Lift male thread of tie rod from the hole in the spindle tab 4 Remove the tie rod ends from the steering gear 5 To minimize corrosion apply a light coat of anti seize lubricating compound to
44. See General Warnings Section 1 Page 1 1 Testing the RPM Limiter See Test Procedure 14 Section 11 Page 11 26 RPM Limiter Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Disconnect the white black wire from the black wire at the bullet connector located near the RPM limiter Figure 12 24 Page 12 24 3 Disconnect the other black wire at the other bullet connector near the RPM limiter 4 Remove the flange head bolts from the RPM limiter band and remove the RPM limiter and the damper Figure 12 24 Page 12 24 RPM Limiter Installation 1 Place the RPM limiter damper on the front of the RPM limiter mounting bracket Figure 12 24 Page 12 24 2 Place the RPM limiter on the damper squarely so that RPM limiter fits tightly against the damper 3 Place the band over the RPM limiter and align the holes Place the brown wire ring connector onto the flange head bolt 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 black wire at the bullet connector to the white black wire 5 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protecto
45. See following CAUTION A 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 Ib 34 N m 3 Tighten nuts 2 on spring mounting bolts 17 to 15 ft Ib 20 3 N m Figure 9 4 Page 9 5 Page 9 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SECTION 10 PERIODIC MAINTENANCE A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 GENERAL INFORMATION To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that can result from neglect Use the Pre Operation and Daily Safety Checklist on page 10 1 and the following Periodic Service Schedule and Periodic Lubrication Schedule to keep the vehicle in proper working condition 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 Use the following checklist as a guide to inspect the vehicle This
46. Solenoid ege oc reed cs 11 18 starter generator suusss 11 20 11 22 voltage regulator AN 11 23 wire continuity sseeeeen 11 22 test procedures index of 11 11 testing spark plug estocada 13 2 starter generator ground fest sidii ieoa anai 12 8 tie rod and drag link installation cita 7 12 le VIE 7 10 tire installation sesh Avie tied 8 3 ele 8 2 Mcr EE 8 3 tools see service tools torque converter troubleshooting AAA 17 1 troubleshooting torque converter ENNEN 17 1 vehicle troubleshooting guide 11 1 U unitized transaxle installation lubrication removal dre medeno EE EIER acti sass teh ade ee Ee INDEX universal accessory mounting 4 8 V voltage regulator installation sesinin 12 12 removal 52 5 caes ui 12 12 testirig talon 11 23 VW WARNING definition Of ee 1 1 wheel installation idee tette neces 8 1 remov l 5 dec 8 1 see also tire wheel liner installation eeeeeeeeeenn nnn 4 12 removal 4 5 tocco 4 12 wheel steering See steering wheel wire continuity testing eeeeeeeeeee 11 22 wiring diagram see 11 6 Page i 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Your Comments Are Appreciated Please select qur cdegory Distributor Dealer Technician In
47. a low oil warning light circuit lubrication front suspension eeeeene 7 10 M maintenance battery aria 12 29 periodic service schedule 10 2 muffler see also exhaust system installation enne 15 1 removal ent lee 15 1 N neutral lockout 11 20 11 33 16 1 cam installation 12 18 A BS e a 12 18 testing uode iul 11 33 limit switch installation remoVal 5 ied aina TESTING ii ed eee ce eder neutral lockout circuit sssss 11 11 O oil level sensor installation eeeeeeeeeeeeee 12 28 13 6 removal cuco dci 12 28 13 5 testing iii ninas 11 32 oil light see low oil warning light P pawl assembly neben Ens 5 4 pedal group ACCESS AE ta 5 1 EC UEL EE 5 6 urge 5 1 Page i 3 INDEX periodic service schedule 10 2 10 4 R rack and PINION eerren 7 4 Eu 7 8 disassembly zresa aa eae 7 5 7 7 EC UE len TEE 7 9 Ve CIE 7 4 rear beauty panel installation removal rear Dody dee eee qe testes see body rear rear body two passenger ssesssse 4 8 rear suspension See suspension rear rear underbody installation rara ata 4 12 4 16 removal 4 5 aaa 4 12 4 16 repair front and rear body gouges punctures tears ssss 4 2 minor impact damage deformations
48. choke assembly mounted at the center of the kick plate An air filter housing draws clean cool air from beneath the vehicle via an opening between the kick plate and the fuel bucket The air passes through an air filter through the choke assembly and through a hose to the carburetor Figure 14 5 Page 14 10 The choke system aids in starting the engine in cold weather When starting a cold engine the spring loaded choke cover is pushed in by hand This restricts the air flow creating a fuel rich mixture in the carburetor The choke cover is held in until the engine starts and then is released The air flow to the engine is no longer restricted and the engine operates normally The choke assembly is adjusted at the factory and does not require field adjustment however if the choke assembly is subjected to abuse or damaged it may become necessary to replace the assembly 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 9 FUEL SYSTEM Choke and Air Intake System AIR BOX CHOKE BUTTON WITH ON KICK PLATE FILTER INSIDE AIR INTAKE Figure 14 5 Air Intake and Choke Assembly Figure 14 6 Air Intake and Choke Assembly Page 14 10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FUEL SYSTEM Choke and Air Intake System CHOKE BUTTON The choke button actuates the choke mechanism via a rod that connects to the button and the choke Figure 14 5 Page 14 10 Pressing in
49. 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 GENEE 70 F 20 C and above 9 6V 60 F 16 C 9 5 V 50 F 10 C 94V 40 F 4 C 9 3 V 30 F 1 C 9 1 V 20 F 7 C 89V 10 F 12 C 87V 0 F 18 C 8 5 V 4 Ifthe 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 Page 11 14 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 2 FUSE See General Warnings Section 1 Page 1 1 The fuse red 10 amp is located in the wiring harness Figure 11 8 Page 11 15 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 Remove the cover from in line fuse Ensure that the wires are connected correctly and are tight If they are not rewire or tighten as necessary Remove fuse to be tested
50. drive clutch hub and on the moveable face casting Figure 17 8 Page 17 7 2 Remove the drive clutch hub 1 Figure 17 7 Page 17 6 2 1 Remove the plugs 22 from the clutch puller attachment holes Figure 17 7 Page 17 6 2 2 Thread the center bolt of the Drive Clutch Hub Puller CCI P N 1014497 into clutch until the stop nut touches the clutch then back the bolt out one half turn Figure 17 9 Page 17 7 2 3 Thread the three small bolts of the puller 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 9 Page 17 7 2 4 Unscrew the puller center bolt out of the clutch to pull drive clutch hub off DRIVE CLUTCH HUB PULLER por TOOL CCI P N 1014497 Figure 17 8 Mark Drive Clutch Hub Figure 17 9 Remove Drive Clutch Hub 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 17 7 TORQUE CONVERTER Drive Clutch Drive Clutch Disassembly Continued 3 Remove the thrust washer 11 from the moveable face 14 Figure 17 7 Page 17 6 4 Remove the drive buttons Figure 17 10 Page 17 8 4 1 Remove the screws flat washers drive button take up springs and drive buttons as shown Figure 17 10 Page 17 8 Remove these C items from ribs N ue 1 4 20 scREW E 10 24 SCREW AS FLAT WASHER FLAT WASHER DRIVE BUTTON St WEIGHT DRIVE BUTTON Pd TAKE UP SPRING WEIGHT SLOTS IN HUB CA
51. each 10 F 5 6 C below 80 F 27 C subtract 0 004 from the reading 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 13 EB TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined by referring to the following table GRAVITY TEMPERATURE EIERE CORRECTED 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
52. 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 17 12 Page 17 9 9 Install the secondary weights onto the mounting pins with the weight pins on the secondary weights pointing away from the primary weights The wave washers should be between the primary and second ary weights Figure 17 13 Page 17 9 10 Install white plastic flat washers on each end of the mounting pin and push them against the outside sur faces of the weights Center the weights and washers on the mounting pin Figure 17 16 Page 17 11 11 Install the weight assemblies into the slots in the hub casting Figure 17 11 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 16 Page 17 11 WHITE WASHER Figure 17 16 Install White Washers 12 Install the 1 4 20 bolts and washers 2 and tighten them to 10 ft Ib 18 N m Figure 17 7 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 a spring on the right side of each of the three button mounting posts when looking into the interior of the clutch cover with the rib at the twelve o clock position as shown Figure 17 17 Page 17 12 14 While c
53. 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 17 FRONT HUB REMOVAL Remove the front wheels See Wheel Removal Section 8 Page 8 1 Remove dust cap 12 and lock nut 11 Figure 7 19 Page 7 16 Slide the hub assembly 9 off of the spindle shaft 3 Lightly sand spindle shaft to clean away any light rust a FF A N Inspect the surface of the spindle shaft for surface damage It should be clean and smooth If severe pit ting from rust or corrosion has occurred replace the spindle assembly See Kingpin and Steering Spin dle Removal on page 7 13 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7 17 STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs HUB INSTALLATION 1 BON o NO gi Clean and apply a light coat of anti seize lubricant to the spindle shaft 3 Slide the hub assembly 9 onto the spindle shaft Figure 7 19 Page 7 16 Install a new flanged lock nut 11 and tighten to 36 ft Ib 50 N m Rotate the hub The hub should rotate smoothly without binding side play or any indication of rough spots during rotation Install t
54. 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 Ib 10 2 N m Figure 12 27 Page 12 26 15 Install the stiffener with four hex head bolts and lock nuts Tighten the hardware to 23 ft lb 30 5 N m Figure 12 26 Page 12 25 16 Install the fan shroud with four pan head bolts 5 Tighten to 50 in Ib 5 7 N m Figure 12 27 Page 12 26 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 25 CAUTION Make sure wire harness is routed and secured away from the muffler 18 Install the muffler See Muffler Installation Section 15 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 Ib 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 Ib b 7 N m Figure 12 25 Page 12 25 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 27 ELECTRICAL COMPONENTS Oil Level Sensor Ignition Coil Installation Continued 20 Connect the spark plug wire to the spark plug
55. gauge 2 and remove the fuel gauge from the instrument panel ORANGE gt Ce BLUE Figure 12 22 Fuel Gauge Installation Fuel Gauge Installation 1 Install a new fuel gauge into hole in instrument panel until flange seats against panel Figure 12 22 Page 12 22 2 Slide the mounting bracket 5 onto the two threaded studs on the fuel gauge and secure with two lock washers 4 and two hex nuts 3 Tighten to 2 5 in Ib 0 28 N m Place one drop of Loctite on each hex nut Do not allow Loctite to come into contact with the fuel gauge casing 3 Connect the blue wire from the wire harness to the I terminal the orange wire from the wire harness to the S terminal and the black wire from the wire harness to the G terminal See Wiring Diagrams Section 11 Page 11 6 4 Install the instrument panel 4 1 Connect the electrical connector 3 Figure 12 16 Page 12 13 4 2 Position the instrument panel 2 on the dash assembly Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly Ensure that there are no wires exposed or pinched during positioning 4 3 Secure instrument panel to the dash assembly with three screws 1 Tighten screws to 1 8 ft lb 2 5 N m 5 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion
56. higher amp rating is used damage to the vehicle electrical system may occur 2 Install the cover on the fuse holder 3 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion GCOR See General Warnings Section 1 Page 1 1 The GCOR is mounted on the passenger side of the pedal group The GCOR houses two limit switches the kill limit switch and the accelerator pedal limit switch The two switches are actuated by motion of the GO pedal and are instrumental in safe vehicle operation GCOR Removal 1 Remove the pedal group See Pedal Group Removal Section 5 Page 5 1 2 Remove two screws 1 that secure the GCOR to the pedal group Figure 12 17 Page 12 16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 15 ELECTRICAL COMPONENTS GCOR Figure 12 17 GCOR GCOR Installation 1 Position the GCOR on the pedal group 2 Secure the GCOR with two screws 1 Figure 12 17 Page 12 16 Tighten screws to 23 in Ib 2 6 N m 3 Install pedal group See Pedal Group Installation Section 5 Page 5 6 Accelerator Pedal Limit Switch See General Warnings Section 1 Page 1 1 Testing the Accelerator Pedal Limit Switch See Test Procedure 5A Section 11 Page 11 17 The accelerator pedal limit switch is housed inside the GCOR The GCOR is mounte
57. in 0 051 mm Limit depth of cut when machining commutator If undercut of segment insulator is less than 0 016 inch 0 406 mm then it should be undercut to 0 007 in 0 2 mm 0 031 in 0 8 mm 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 Place the field coil into the housing The two insulators that look alike fit into the slots next to the F1 and F2 markings on the outside of the housing The insulator that looks different slides into the slot next to the DF marking After the insulators are seated in the slots install the threaded terminals through the wire connectors and then through the insulators Install a flat washer lock washer and nut onto each threaded terminal on the outside of the housing Tighten nuts to 47 5 in Ib 5 4 N m Figure 12 10 Page 12 7 CAUTION Route the field terminal wires so that they will not contact the armature Install the four pole pieces into the housing Use the four screws to secure pole pieces to the inside of the housing to retain the field wires Tighten screws to 9 ft Ib 12 2 N m Figure 12 10 Page 12 7 Slide the bearing retainer onto the output end of the armature shaft 33 so that it will hold the outside of the bearing 35 only Press a new ball bearing
58. insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring 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 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 Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 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 for proper location of all vehicle safety and operation decals and make sure they a
59. is incorrect replace the GCOR BLACK BLACK ORANG Figure 11 14 GCOR Test Procedure 5B Kill Limit Switch See General Warnings Section 1 Page 1 1 The black and black white wires from the connector are adhered to the kill limit switch is located inside the GCOR 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Check for proper wiring and tight connections 3 Separate the electrical connector at the GCOR and test the limit switch for continuity Place the red probe of the multimeter on the black wire pin of the limit switch Place the black probe on the black white wire pin 4 With accelerator pedal in fully raised position there should be continuity With accelerator pedal pressed there should be no continuity If either reading is incorrect replace the GCOR Figure 11 14 Page 11 18 5 Connect wires to GCOR and check for tight connections TEST PROCEDURE 6 SOLENOID See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Ensure thatthe wires are connected correctly and are tight If they are not rewire or tighten as necessary Page 11 18 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 3 Setamultimet
60. 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 follow ing WARNING A WARNING f the battery is frozen or the container is bulged discard battery A frozen battery can explode 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 31 ELECTRICAL COMPONENTS Ground Cables Battery Storage Continued 6 The frequency of recharging required depends on the temperature of the storage area but it is recom mended 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 See General Warnings Section 1 Page 1 1 See also DANGER on page 12 28 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 A WARNING Do not jump start a dead battery using another battery and ju
61. mounted on the side of the pedal group The GCOR houses two limit switches the kill limit switch and the accelerator pedal limit switch The two switches are actuated by motion of the GO pedal DEBRIS SHIELDS Debris shields on the top face of the pedal group prevent excessive debris from contacting the moving parts of the pedal group Both shields 3 and 4 are held in place with screws 1 and washers 2 Figure 5 4 Page 5 5 When shields are replaced tighten screws 1 to 53 in Ib 6 N m BRAKE RETURN SPRING A CAUTION Spring is under tension Use caution when working with springs The brake return spring 5 provides the pressure needed to return the brake pedal to its upright position Figure 5 4 Page 5 5 One end of the spring attaches to a hook on pedal 11 and the other end attaches to pedal base 12 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 5 3 ES ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group PAWL ASSEMBLY The pawl assembly 6 serves to lock the brakes when the PARK pedal is pressed The pawl assembly also releases the brakes when either the STOP or GO pedal is pressed Figure 5 4 Page 5 5 The pawl assem bly is serviced as a unit The replacement unit includes two snap rings 7 pin 8 spring 9 and pawl unit 6 When replacing the unit ensure spring 9 is properly positioned to be held in place when the pin 8 is installed Secure the pin with two snap rings 7 ACCELE
62. on shifter Tighten lock nut 26 to 43 in Ib 4 9 N m Position cable near the clip and secure it with wire tie 25 Push cable boot through cable bracket 24 Clips on boot should snap in place to secure the cable in position Place end of cable over stud on lever arm Push down on cable end to snap the cable onto the stud Page 16 22 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Forward Reverse Shifter Cable UNITIZED TRANSAXLE Figure 16 55 Forward Reverse Cable Page 16 23 2005 Precedent Gasoline Golf Car Maintenance and Service Manual UNITIZED TRANSAXLE Forward Reverse Shifter Cable FORWARD REVERSE SHIFTER CABLE ADJUSTMENT With the shifter lever of the unitized transaxle in the NEUTRAL position Figure 16 55 Page 16 23 the For ward Reverse handle 20 should be straight up For minor adjustments the lock nut 26 may be loosened and the ball joint socket 27 rotated to get the proper adjustment See following CAUTION A 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 For major adjustments the cable retaining nuts 28 must be loosened and adjusted When the cable is prop erly adjusted with the Forward Reverse handle 20 Figure 16 56 Page 16 24 in the NEUTRAL p
63. page 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Section 16 Unitized Transaxle TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine won t stop running Kill circuit wire is disconnected from the Test Procedure 12 Disconnected Kill ignition coil Wire on page 11 23 Section 11 Troubleshooting and sy Ssteh danure Electrical System Test Procedures 4 5A Carburetor is too lean check main and pilot jet sizes Section 14 Fuel System Carburetor throttle stop screw out of adjustment Section 14 Fuel System 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 5 TROUBLESHOOTING AND ELECTRICAL SYSTEM WIRING DIAGRAMS NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES 3 PIN CONNECTORS 16 BLK WHITE 18 BLK 16 BRN 18 BRN LEFT TAILLIGHT 18 RED 16 BLK WHITE 18 BLK 16 BRN 18 BRN 18 RED RIGHT TAILLIGHT 16 BRN 16 WHITE 16 BLKIWHITE v 16 BRNMHITE e 16 YELLOW 12 BLUE CONNECTS TO 9 PIN CONNECTOR FOR LIGHTS SEE Pa 3 PIN CONNECTORS Wiring Diagrams 18 ORANGE 18 YELLOW FIGURES 11 3 AND 11 4 312 BLK 18 RED 88808000008 6 BLKWHITE BRAKE LIGHT SWITCHES 18 BLUE WHITE 18 B
64. patch that will prevent the bolt from loosening Tighten the bolt 11 to 18 ft Ib 24 4 N m Install access panel Connect the spark plug a A C I Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Page 17 18 2005 Precedent Gasoline Golf Car Maintenance and Service Manual INDEX A accelerator cable installation A AL ee pedal limit switch Testing tcs te 11 17 accelerator return spring ssssss 5 4 access panel sss 4 12 4 16 air box removal et ecrire ere 14 11 air filter ooooonocccnncnonoccccccnonocaccnnnono 14 1 14 11 replacement seen 14 11 axle bearing installation ooccccccccccccnnononanananananonononononos 16 6 removal shaft installation ee 16 6 oil Seal WEE na 16 3 removal t 16 3 B backrest cocoa 4 10 backrest and structural accessory module 4 10 bag rack installation c ET ue VT basket sweater b ttery ege d beast eene charging i oie ees hydrometer test oocccoonncccnoncccnnacnnnnarnnnnnnncnnnnnos installation ee load test maintenance mineral content cccccnnnnnnnnananonononnnononcnnononononons TC ue CT WEE self discharge ooocoioccononcccnnnccnnnnnecnnannnnnrnnnnnns Storage
65. reading is incorrect replace the key switch Figure 11 34 Page 11 31 5 Connect wires to key switch Make sure wires are connected correctly and are tight If they are not rewire or tighten as necessary 6 Install instrument panel in reverse order of removal TEST PROCEDURE 18 ENGINE KILL WIRE See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Disconnect white black wire bullet connector located at the engine RPM limiter Figure 11 22 Page 11 24 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 is allowing the wire to ground to the vehicle frame KEY SWITCH OFF KEY SWITCH ENGINE KILL CIRCUIT Figure 11 34 Test Key Switch Engine Kill Circuit 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 31 EB TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 19 REVERSE BUZZER LIMIT SWITCH See General Warnings Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure The reverse buzzer li
66. ring terminal with the two 10 gauge red wires to the other large post on the solenoid See Wiring Diagrams Section 11 Page 11 6 Connect the 16 gauge blue wire from the main harness to a small post on the solenoid Connect the 16 gauge orange wire from the main harness to the other small post on the solenoid See Wiring Diagrams Section 11 Page 11 6 Tighten the hex nuts on the large solenoid posts to 60 in Ib 6 8 N m Tighten the nuts on the small sole noid posts to 22 in Ib 2 5 N m Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat solenoid and battery terminals with Battery Terminal Protec tor Spray CCI P N 1014305 to minimize corrosion Page 12 14 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Fuse FUSE See General Warnings Section 1 Page 1 1 Testing the Fuse See Test Procedure 2 Section 11 Page 11 15 Fuse Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove cover from fuse holder 3 Remove the fuse from the fuse holder Fuse Installation 1 Install the fuse See following WARNING A WARNING e 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
67. screw 4 from lower rear corner of retainer This screw threads into a J clip 5 that is attached to the rear underbody 3 Carefully pull on retainer to separate the trim clips from their respective slots Trim clips do not normally need to be removed from the retainer FLOOR MAT RETAINER INSTALLATION 1 Position the retainer on the vehicle and press firmly to engage the trim clips to the vehicle Figure 4 4 Page 4 6 2 Install one screw 4 at the lower rear of the retainer Tighten screw to 1 8 ft Ib 2 5 N m 3 Ensure the floor mat is properly positioned beneath the top flange of the retainer and install two screws 2 Tighten screws to 4 4 ft Ib 6 0 N m KICK PLATE AND CHOKE BUTTON See General Warnings Section 1 Page 1 1 KICK PLATE AND CHOKE BUTTON REMOVAL 1 Access the inside of the fuel bucket and disconnect hair spring cotter pin 2 from choke rod 3 Remove rod from the choke Figure 4 5 Page 4 8 2 Remove floor mat See Floor Mat and Retainers on page 4 6 3 Remove three screws 1 that hold the kick plate 4 to the vehicle 4 Remove the two front screws 7 that hold the beauty panel to the vehicle Raise the forward portion of the rear beauty panel to disengage it from the tabs on the upper portion of the kick plate 5 Remove kick plate from vehicle 6 Disengage the choke rod 3 from the button 5 7 Press in on the tabs on the top and bottom of button 5 to free the button from the kick pl
68. 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 25 Page 11 26 2 2 If the resistance is not between 0 6 1 7 ohms bench test the ignition coil See Test Procedure 15B Ignition Coil Bench Test on page 11 29 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 26 Page 11 27 3 2 If the resistance is between 6 0 11 0 k ohms the secondary coil and spark plug cap are within acceptable limits proceed to step 6 on page 11 28 If the resistance is not between 6 0 11 0 k ohms the spark plug cap and secondary coil must be tested independently from each other Figure 11 27 Ignition Coil and Cap Figure 11 28 Spark Plug Cap Removal 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 27 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 4 Test the spark plug cap separately from the secondary coil 4 1 4 2 4 3 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the spark plug wire 3 Figure 11 27 Page 11 27 Remove the cap from the wire by turning the cap count
69. the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 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 3 Gain access to the pedal group by removing the floor mat and access panel See Pedal Group Removal Section 5 Page 5 1 4 Loosen the two jam nuts 1 and 3 on either side of turnbuckle 2 Figure 6 1 Page 6 2 Note that the forward jam nut 1 is a left hand thread Thread each nut approximately 1 2 inch 12 7 mm away from the turnbuckle 5 Loosen turnbuckle 2 to release tension on the equalizer bracket 4 that pulls on the heads of the brake cables 6 Remove the rear wheels and then the brake drums If the brake drums were easily removed proceed to step 8 A 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 7 to minimize damage to the brake cluster and brake compo nents 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 6 1 EN WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal Continued 7 Remove brake drums and badly worn brake shoes 7 1 On the back of each br
70. the large snap ring 4 Figure 7 7 Page 7 7 8 Remove pinion 5 from the housing 17 If removal is difficult install the universal joint onto the pinion and place a fork or a large open end wrench under the universal joint Figure 7 8 Page 7 7 Gently pry the pinion from the housing 9 Remove the universal joint from the pinion 5 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7 5 STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7 5 Steering Gear Page 7 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly Continued 10 If the ball bearing 4 Figure 7 5 Page 7 6 has been damaged remove the C type stop ring 16 Figure 7 7 Page 7 7 and press the bearing off Figure 7 9 Page 7 7 11 Inspect the bushing 7 and needle bearing 6 for excessive wear If wear is excessive replace the entire assembly Figure 7 5 Page 7 6 12 Inspect the ball joints 8 for wear If one or both of the ball joints 8 are excessively worn remove and replace the ball joint from the rack 18 13 Remove the rack 18 from housing 17 MAUI A uud if IH AUS SM Ry Figure 7 6 Remove Dust Seal Figure 7 7 Pinion Snap Rings a PRESS RAM PINION GEAR n K gt Figure 7 8 Remove Pinion from Housing Figure 7 9 Remove Bearing from Pinion 2005 P
71. the threads where the tie rod ends are installed TIE ROD INSTALLATION 1 Thread tie rod ends 12 onto steering gear to a depth of 1 2 inch 12 5 mm Figure 7 18 Page 7 15 A WARNING The tie rod ends must be threaded into the rod at least 5 16 of an inch 8 mm Failure to thread deep enough may cause tie rod ends to separate from the rod during adjustment or while being operated possibly resulting in loss of vehicle control and severe personal injury 2 Install tie rod ends 12 into the spindle tabs Install the retaining nuts 14 and retaining pins 15 Figure 7 18 Page 7 15 3 Adjust wheel toe in See Toe in Adjustment on page 7 11 Page 7 12 2005 Precedent Gasoline Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION Front Suspension Components LEAF SPRING REMOVAL 1 om E OD Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack Place jack stands under the aluminum rails of the vehicle frame just aft of the front suspension Lower the vehicle onto the jack stands See General Warnings Section 1 Page 1 1 Remove both front wheels Remove the bolts 8 from the bottom of each kingpin 7 Figure 7 19 Page 7 16 Remove the four bolts 17 and bottom spring plate 16 Remove leaf spring 13 Check the condition of the urethane bushings 15 and steel sleeves 14 Replace any that are worn or damaged LEAF SPRING INSTALLATION oa e
72. the voltage regulator test procedure See Test Procedure 11 Section 11 Page 11 23 Page 12 12 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Key Switch KEY SWITCH See General Warnings Section 1 Page 1 1 Testing the Key Switch See Test Procedure 17 Section 11 Page 11 31 See Test Procedure 4 Section 11 Page 11 17 Key Switch Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the instrument panel 2 1 Remove three screws 1 from the instrument panel 2 Figure 12 16 Page 12 13 2 2 Rotate the instrument panel up and away from the dash to disengage the tabs at the top of the instrument panel 2 3 Disconnect the electrical connector 3 to the instrument panel Figure 12 16 Instrument Panel Removal 3 Disconnect the wires from the key switch 4 Remove the key switch 4 1 Remove the key switch cap by pressing in on the cap tabs on the back of the panel 4 2 Remove key switch from the instrument panel by holding the key switch and turning the nut on the outside of the panel with a 1 inch socket wrench Remove the keyed washer with key switch 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 13 ELECTRICAL COMPONENTS Solenoid Key Switch Installation 1 Reverse removal procedures to install key switch in the instrument panel Connect
73. wires to key switch See Figure 11 5 Section 11 Page 11 10 Install the instrument panel 2 1 Connect the electrical connector 3 Figure 12 16 Page 12 13 2 2 Position the instrument panel 2 on the dash assembly Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly Ensure that there are no wires exposed or pinched during positioning 2 3 Secure instrument panel to the dash assembly with three screws 1 Tighten screws to 1 8 ft lb 2 5 N m 3 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion SOLENOID See General Warnings Section 1 Page 1 1 Testing the Solenoid See Test Procedure 6 Section 11 Page 11 18 Solenoid Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 Disconnect all the wires from the solenoid Remove the two screws securing the solenoid in place Remove the solenoid Solenoid Installation Install the solenoid in the vehicle Use two screws to secure the solenoid and tighten to 14 in Ib 1 6 N m Connect the ring terminal with the 10 gauge white wire and the 16 gauge red wire on a large post on the solenoid See Wiring Diagrams Section 11 Page 11 6 Connect the
74. 11 Voltage Regulator 12 Disconnected Kill Wire 13 Ignition Spark 14 RPM Limiter 15 Ignition Coil 16 Hour Meter 17 Key Switch Engine Kill Circuit 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 11 EA OUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Index of Test Procedures Continued 18 19 20 21 22 23 24 25 26 Engine Kill Wire Reverse Buzzer Limit Switch Reverse Buzzer Oil Level Sensor Low Oil Warning Light Neutral Lockout Cam Battery Test Under Load Fuel Level Sending Unit Fuel Gauge TEST PROCEDURE 1 BATTERY See General Warnings Section 1 Page 1 1 A DANGER Due to the danger of an exploding battery wear a full face shield and rubber gloves when working around a battery 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 NOTE The battery must be properly maintained and full
75. 12 Page 12 13 3 Disconnect the orange wire from the fuel gauge 4 Seta 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 5 Seta multimeter to 20 volts DC and place the red probe of the multimeter on the G terminal of the fuel gauge with the blue wire Place the black probe on the S terminal of the fuel gauge with the black wire Figure 11 36 Page 11 35 6 Connect the battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m 7 Turnthe 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 36 Page 11 35 8 The orange wire should remain disconnected for this step With the black probe still on the terminal S of the fuel gauge place the red probe of the multimeter on the I terminal of the fuel gauge The volt age reading should be the same as the full battery voltage reading obtained in step 4 If the reading is incorrect replace fuel gauge Figure 11 37 Page 11 35 REAR VIEW OF REAR VIEW OF FUEL GAUGE M FUEL GAUGE e 18 GAUGE BLUE WIRE TO NO 1 ON KEY SWITCH 18 GAUGE 18 GAUGE REMOVE Ke 18 GAUGE WIRE TO ORANGE GROUND WIRE Figure 11 36 Fuel Gauge Test Figure 11 37 Fue
76. 13 Connect the fuel line 9 to the fuel tank shut off valve 5 Use new clamps 6 Figure 14 8 Page 14 13 If vehicle is equipped with fuel level sending unit 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 Ib 2 0 N m Slide the rubber boot over the stud Figure 14 11 Page 14 19 If not equipped with fuel level sending unit connect black wire to ground screw on fuel tank Tighten to 18 in Ib 2 0 N m A WARNING 10 Static electricity on fuel tank can cause arching and ignite fuel vapors Ensure that ground wire is properly connected Add fuel to the tank Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Ensure that the wheels are chocked the Forward Reverse handle is in the NEUTRAL position and that the neutral lockout cam is in the MAINTENANCE position Checkto be sure the fuel shut off valve on top of the fuel tank is in the open ON position Figure 14 13 Page 14 22 Turn the key switch to the ON position and press the accelerator pedal to start the engine See following DANGER A DANGER 11 12 Do not operate gasoline vehicle in an enclosed area without proper ventila
77. 15 EXHAUST SYSTEM A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 GENERAL INFORMATION The exhaust system is designed to provide quiet vehicle operation If the muffler should ever need to be removed for repairs or replacement follow the instructions below MUFFLER MUFFLER REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Disconnect the spark plug wire from the spark plug See WARNING To avoid unintentionally start ing in General Warnings Section 1 Page 1 1 Remove the hex nuts 10 and lock washers 11 Figure 15 1 Page 15 2 Remove the hex head cap screw 7 lock washer 8 and flat washer 9 Remove the muffler clamp 6 from the muffler bracket 2 oa P oa Remove the muffler 1 and muffler clamp 6 from the vehicle MUFFLER INSTALLATION NOTE Any time the muffler is removed from the vehicle install a new muffler clamp 6 CCI P N 1017689 and muffler gasket 12 Figure 15 1 Page 15 2 1 Place a new gasket 12 on the exhaust port mounting studs on engine 2 Use the muffler clamp 6 to attach the muffler 1 to the muffler bracket 2 as shown Figure 15 1 Page 15 2 Leave the muffler clamp loose enough to allow the muffler to move as the mounting hard ware is tightened If installing a new muffler use the old muf
78. 15 Page 7 11 See also Figure 7 19 Page 7 16 Page 7 10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION Front Suspension PROPER ADJUSTMENT hc NA e re gi eg i Y A S Al EQUAL SPACE BETWEEN TIRES AND FRAMING SQUARES IMPROPER CAMBER ADJUSTMENT UNEQUAL SPACE BETWEEN TIRES AND FRAMING SQUARES Figure 7 14 Check Camber Figure 7 15 Adjust Camber 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 3 Measure the distance between the marks on the rear facing surfaces of the tires and then roll the vehicle forward one and one half wheel revolution until the marks appear on the forward facing surfaces of the tires at about the same height from the floor Figure 7 16 Page 7 11 Figure 7 16 Check Toe In Figure 7 17 Adjust Toe In 4 Measure the distance between the marks on the forward facing surfaces of the tires Figure 7 16 Page 7 11 NOTE The front measurement must be less than the rear measurement 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7 11 STEERING AND FRONT
79. 16 5 See also Figure 16 3 Page 16 3 Page 16 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual UNITIZED TRANSAXLE Unitized Transaxle Removal E 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 A 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 BEARING PULLER WEDGE ATTACHMENT AXLE SEAL AXLE SEAL REMOVED FOR CLARITY Figure 16 7 Bearing and Collar Figure 16 8 Axle Seal Tool UNITIZED TRANSAXLE REMOVAL See General Warnings Section 1 Page 1 1 1 Turn the key switch to the OFF position and remove the key and place the Forward Reverse handle in the NEUTRAL position 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 3 Close the fuel shut off valve on fuel tank See Figure 14 12 Section 14 Page 14 21 4 Detach all wires hoses etc connecting the powertrain to the vehicle 4 1 Disconnect the carburetor vent tube from the carburetor Figure 16 9 Page 16 8 4 2 Disconnect the air intake hose from the carburetor Figure 16 10 Pag
80. 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 13 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal Continued RETAINING BOLT Figure 16 30 Driven Clutch Figure 16 31 Governor Arm 19 Remove screws 1 securing the governor cable bracket to transaxle Figure 16 32 Page 16 14 20 Remove screws 1 securing the accelerator cable bracket to transaxle Figure 16 33 Page 16 14 Figure 16 32 Governor Cable Bracket Figure 16 33 Accelerator Cable Bracket 21 Remove screws securing the transmission shift cable bracket to transaxle 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 and flat washers one at each corner of the transaxle mount ing plate Figure 16 34 Page 16 15 22 2 Remove two middle transaxle mounting nuts from the engine block studs Figure 16 34 Page 16 15 23 Remove leaf springs wheels and brake assemblies from the transaxle Page 16 14 2005 Precedent Gasoline Golf Car Maintenance and Service Manual UNITIZED TRANSAXLE Unitized Transaxle Installation E TRANSAXLE MOUNTING aee BOLT AND NUT TYPICAL 4 PLACES TRANSAXLE MOUNTING NUT TYPICAL 2 PLACES Figure 16 34 Transaxle Mounting UNITIZED TRANSAXLE INSTALLATION See General Warnings Section 1 Pag
81. 25 CM A EE 12 28 Battery ali A A eMe 12 28 Grond AA A NN 12 32 SECTION 13 FE290 ENGINE General Information E ee a tees Pe HER een ree ede M Re neta eee 13 1 Before Servicing etc vertu eet om ee A e REC e obe eot ee 13 1 Engine apto 13 1 Spark RIUJ orante eu pe tus cte su eege 13 1 Cylinder Head Zeiss DEE ARI IM eic 13 3 General Bleu LI NEE 13 3 Breather Valve Reed Valve 0oooocoonooccccnnoococccconoonccnnnanenoncnnnnnnncnnnnnn nn cnn naar nr nr ennt arc r rra nennen nennen 13 3 GrankCaSe coto a edie de eee Beer east avy e ENEE iia 13 3 Engine Removal ig t det EE sence ENEE AER ati Cot v K EN 13 3 Crankcase Cover Removal sse nennen enne nennen nnne nnn nennen enne nnns nnns 13 5 Oil Level Sensot 3 A deae 13 5 Crankcase Cover Installation saries aesan aaa aaa Ene Ee adar E aa aaaea a nennen nnns 13 6 Ignition Goil and Gin GE 13 7 Elywheel Installatiori in iia a ati ed be un ER e Penes 13 9 Engine Installation TE 13 9 Torque Specifications sssssssssssssessseseeeeee ceases ener nnne eren enn nns nennen ennt s enne 13 11 Adjustments and Settings e a aa r a P aa aa a ae A IER Taai 13 11 SECTION 14 FUEL SYSTEM General Informati0N REM 14 1 Carburetor cc dai a ad 14 1 Main Jet Elevation Size Chart oocccinocccononononcnnnononnnnnnonnnnnnnncnnnonnnnnnnnnnnnnnnnnnnnnnnn ran nnne nnn nnne nnns 14 2 Changing the Main Jet ito alada lie 14 2 2005 Precedent Gasoline Golf Car Main
82. 290 ENGINE Ignition Coil and Flywheel Figure 13 6 Crankcase Cover Installation Figure 13 7 Fan and Flywheel Assembly IGNITION COIL AND FLYWHEEL See General Warnings Section 1 Page 1 1 Ignition Coil and Flywheel Removal 1 Loosen three screws and remove the remaining four screws attaching the flywheel housing as shown then remove the housing Figure 13 8 Page 13 8 2 Disconnect the ignition coil 1 from its primary lead wire at the connector 2 Remove the two bolts 3 and take out the ignition coil Figure 13 9 Page 13 8 3 Hold the flywheel 4 not the fan 7 with a strap wrench 5 and using a 25 mm socket remove the fly wheel nut and flat washer by turning it counterclockwise Figure 13 10 Page 13 8 See following CAUTION 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 CCI P N 1016627 5 Remove the flywheel key from its groove 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 13 7 FE290 ENGINE Ignition Coil and Flywheel I Loosen Remove Figure 13 8 Flywheel Housing Figure 13 9 lgnition Coil Figure 13 10 Flywheel Nut Removal Figure 13 11 Adjust Ignition Coil Air Gap Flywheel Installation See Flywheel Installation on page 13
83. 35 onto the output end of the armature Figure 12 7 Page 12 5 Press a new ball bearing onto the commutator end of the armature shaft See following CAUTION 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 9 Starter Generator ELECTRICAL COMPONENTS Starter Generator Starter Generator Assembly Continued CAUTION 7 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 Install the output end cover 36 onto the armature Secure the bearing retainer 32 to the cover and tighten the screws 43 to 39 in Ib 4 4 N m Figure 12 7 Page 12 5 Slide the housing with field coils over the armature Use the locating pin to align housing to the cover NOTE The terminal insulators should be on the commutator end of the housing 8 10 11 To prevent contact between the brushes and commutator as the commutator cover is installed and pos sible 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 Install the commutator end cover 23 onto the armature shaft Align the locating pin with the pin hole in the cover Install the two M
84. 5 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Reverse Buzzer Limit Switch REVERSE BUZZER VIEWED FROM UNDERSIDE OF INSTRUMENT Figure 12 20 Reverse Buzzer Reverse Warning Buzzer Installation 1 Install the screws 3 through the buzzer bracket tabs and tighten to 3 5 in Ib 0 40 N m Figure 12 20 Page 12 19 2 Connect the black wire 1 from the wire harness to the negative terminal on the buzzer 3 Connect the red white wire 4 from the wire harness to the positive terminal on the buzzer 4 Install the instrument panel 4 1 Connect the electrical connector 3 Figure 12 16 Page 12 13 4 2 Position the instrument panel 2 on the dash assembly Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly Ensure that there are no wires exposed or pinched during positioning 4 3 Secure instrument panel to the dash assembly with three screws 1 Tighten screws to 1 8 ft Ib 2 5 N m 5 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 6 Shift the Forward Reverse handle to the REVERSE position The buzzer should sound REVERSE BUZZER LIMIT SWITCH See General Warnings Section 1 Page 1 1 Testing the Reverse Buzzer Limit Switch See Test Procedure 19
85. 6 x 180 mm bolts 20 and tighten to 100 in Ib 11 3 N m Figure 12 2 Page 12 2 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 2 Slide the spacer 37 onto the end ofthe shaft Insert the shaft key 34 into the shaft Install the belt pulley 39 onto the shaft and install the lock washer 40 and M14 nut 41 Tighten the nut to 28 ft Ib 38 0 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 1 Install a flat washer lock washer and nut onto each terminal and tighten to 48 in Ib 5 4 N m 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 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 Tighte
86. 8 L of water Rinse with water Do not allow solution to enter bat tery through the vent cap holes See Self Discharge on page 12 29 3 Maintain proper water level See Water Level on page 12 29 4 Check battery periodically to see that it is in a full state of charge See Charging the Battery on page 12 30 5 Keep battery hold down clamp tight See Vibration Damage on page 12 30 Self Discharge Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery To mini mize 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 the battery should be checked more often When storing the battery keep in a cool place See Battery Storage on page 12 31 Water Level The water level should be checked semi annually to be sure water is at the proper level Figure 12 31 Page 12 29 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 BATTERY CAP PLATES Y EY WATER LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR
87. 9 Ignition Coil Inspection and Repair See Test Procedure 15 Section 11 Page 11 26 Ignition Coil Installation 1 Installation is the reverse of removal 2 While tightening the two bolts 3 use a bronze feeler gauge to adjust the ignition coil air gap to 0 012 inch 0 304 mm Figure 13 11 Page 13 8 3 Tighten the two ignition coil bolts to 30 in Ib 3 4 N m Crankcase Cover Installation See Crankcase Cover Installation on page 13 6 Page 13 8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FE290 ENGINE Flywheel Installation 13 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 fly wheel nut to 63 ft Ib 85 4 N m Figure 13 12 Page 13 9 See following CAUTION A 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 Ibs 10 N m Figure 13 12 Fan and Flywheel Installation ENGINE INSTALLATION See General Warnings Section 1 Page 1 1 1
88. Anas 17 2 Drive Bet Removal iia tica 17 2 Drive Belt Installation sinea 5 a tereti dd 17 3 Drive CIUICh 24008 EE 17 4 Drive Clutch Removal et eege tte ao ied E EPA HERR R Rd cy do Hist eiae 17 4 Drive Clutch Cleaning and Inspection nennen nennen nnne 17 7 Drive Clutch Disassembly AA 17 7 Inspection of Drive e He RTE 17 10 Drive Clutch Assembly geo e P eet ob ERR UR 17 10 Drive ClutchiInstallationr uei dte reet ertet batte eed tie eed att loce tul eese ede es 17 12 DrivenGlBtehi ai eo dio ettet iat EES A AT 17 13 Driven Clutch HemovVval arret uet ree Leni id ey eurer tae 17 13 Driven Clutch Disassembly coooocccinnccconocccononcccnnccnnonc corona corno nara cnn nennen nnns nennen nenne nns nnne nnns 17 14 Driven Clutch Inspection ssssssssssssseseeeene nennen ener nnn nnn n etre rennes nennen nnne enne 17 16 Driven Clutch Assembly AAA 17 16 Driven Clutch EE EE 17 18 SECTION 1 SAFETY 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 CAU TION 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 ser vice or maintenan
89. Car Maintenance and Service Manual UNITIZED TRANSAXLE Unitized Transaxle Installation 16 WHITE BLACK WIRE BLACK WIRE 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 19 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 Ib 5 4 N m Connect the 16 gauge yellow wire to the DF post on the starter gener ator and tighten to 30 in Ib 3 4 N m Figure 16 47 Page 16 19 WHITE WIRE D YELLOW Vo STARTER MESS GENERATOR Y NO WIRE 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 securing the Forward Reverse shifter cable bracket to the transaxle and tighten them to 135 in Ib 15 3 N m 22 2 Place the woodruff key 10 on the shifter shaft 9 Figure 16 35 Page 16 16 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 Ib 2 6 N m 23 Route shifter cable through the shifter cable bracket Ensure the cable boot is properly positioned through the bracket The clips on the boot should hold the cable in place Connect shi
90. Check for coil located in groove above both ears then adjust Check for spring to look spring seated like this by in recess of float body Figure 14 2 Changing the Main Jet 7 Selectthe proper size main jet See Main Jet Elevation Size Chart on page 14 2 Check the size des ignation on the jet to make sure it is the correct part 8 Install the new main jet and tighten it to 12 in Ib 1 4 N m See following CAUTION and NOTE Page 14 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FUEL SYSTEM Carburetor 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 Heplace 9 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 2 Page 14 4 Install the fuel bowl Make sure that it is positioned properly by aligning the marks applied in step 4 See following CAUTION A CAUTION 10 11 17 Make sure the fuel bowl is properly seated against the carburetor fuel bowl gasket and the gasket is not pinched Install the fuel bowl retaining screw and tighten it to 61 in Ib 6 9 N m Write the size of the main jet on the fuel bowl with an indelible in
91. E 13 3 Ee EE 13 1 TESTING WEE 13 2 specifications Leite UE 13 11 starter generator armmatur 5 e De gerendis 12 4 ground KEE 12 8 armature inspection seeeee 12 6 assembly eee 12 4 12 9 bearing e ET Une WEE 12 5 INSPOCHON seen gees erected 12 5 removal etal ik Redi 12 6 belt tension adjustment 12 11 brush spring inspection iios ace ertet e replacement essseeeeeeeeennes OT inspection x droite ris replacement comimutator eoe citan irc armature replacement AA 12 7 cleaning iia Ale el es 12 7 inspection E 12 7 disassembly field coil INSPECTION ee tevin a ane Dantes 12 9 Ee EE 12 6 installation iicet re terit 12 10 removal eee aia edid 12 1 IOWOIK ui sto et enit et 12 9 Testing e eub a eco 11 20 11 22 steering column disassembly ET 7 4 Page i 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual INDEX installation essere 7 4 removal alicatado al ela 7 2 steering wheel installation 3 amete 7 2 IT ue VT 7 1 storage gasoline vehicle eseeeeeeees 3 2 stress lines see repair front and rear body suspension front Camber adjustment eeeeeeeeeeeee 7 10 components control arm installation ee 7 17 removal iii eric bent 7 14 kingpin and steering spindle installation ICT le UCNE leaf spring installation
92. Figure 12 4 Page 12 3 Page 12 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Starter Generator STARTER GENERATOR HOLDER WEAR LINE 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 2 Using a spring scale test brush spring tension If any spring has a tension less than 24 ounces 6 67 N replace all four springs Figure 12 5 Page 12 3 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 Figure 12 5 Brush Spring Tension Test 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 3 ELECTRICAL COMPONENTS Starter Generator Starter Generator Assembly 1 Connect the brush wires to the holders using four lock washers 26 and four screws 25 making sure the crossover leads are connected also Tighten the screws to 31 in lb 3 5 N m Figure 12 3 Page 12 2 To prevent contact between the brushes and commutator as the commutator is installed and possible damage to the
93. Front Suspension Components Figure 7 18 Upper Front Suspension Assembly 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7 15 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7 19 Lower Front Suspension Assembly Page 7 16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs CONTROL ARM INSTALLATION 1 Install the control arm in reverse order of removal Tighten the control arm bolts 11 and 19 to 20 ft Ib 27 N m Figure 7 18 Page 7 15 Tighten three rack and pinion mounting bolts 17 to 22 ft lb 30 N m 2 Install the wheels and adjust the wheel alignment as instructed on page 7 10 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 upper bolt 18 Figure 7 18 Page 7 15 3 Remove the lower bolt 10 4 Remove the shock absorber SHOCK ABSORBER INSTALLATION NOTE When installing shock absorbers make sure front shocks have identical part numbers 1 Install the shock absorber by reversing the removal procedure 2 Tighten the bolts to 20 ft Ib 27 N m FRONT WHEEL BEARINGS AND HUBS See General Warnings Section 1 Page 1 1 NOTE The front wheel bearings are pressed into the spindle and are not serviceable If
94. G AND ELECTRICAL SYSTEM Test Procedures ENGINE GROUND RETAINING NUT Figure 11 9 Starter Generator Ground Cable Test Figure 11 10 Engine Ground Cable Test 4 Check the battery ground cable 4 1 Four 10 gauge black wires are crimped together and connected to the negative battery post One of these wires is connected via a single position in line connector to the frame The frame con nection 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 4 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 11 Page 11 16 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 check that the in line connector is secure repair or replace the cable 5 Check the fuel tank ground 5 1 A 16 gauge wire runs from the fuel tank to the wire harness where it is sonically welded to the other ground wires Check the ground connection at the fuel tank 5 2 Setthe multimeter to 200 ohms Place the red probe on the terminal for the fuel tank ground con nection a
95. IFFERENT THAN THAT SHOWN TYPICAL 2 PLACES 8 NOT REQUIRED FOR SOME SCORECARD HOLDERS 0 TYPICAL 4 PLACES D Figure 7 3 Steering Column 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7 3 STEERING AND FRONT SUSPENSION Rack and Pinion Steering Column Removal Continued 4 Loosen the bolt 11 that attaches the steering column universal joint to the stud on the steering gear Figure 7 3 Page 7 3 5 Remove the four bolts 10 that attach the steering column to the frame 6 Remove the steering column from the vehicle STEERING COLUMN INSTALLATION 1 For ease of assembly and to prevent corrosion apply a light coat of anti seize or lubricating compound to the splined stud extending from the steering gear Insert the end of the steering column with the universal joint through the front underbody Position uni versal joint over splined stud on the steering gear Leave bolt 11 loose until steering column is mounted to frame in step 3 Figure 7 3 Page 7 3 Align the holes in the steering column mounting bracket with holes in the vehicle frame Secure column to frame with four bolts 10 Tighten bolts to 18 4 ft Ib 25 N m 4 Tighten universal joint bolt 11 to 18 4 ft lb 25 N m Verify bolt 12 torque is 18 4 ft lb 25 N m 5 Install front bumper dash assembly dash insert and instrument panel See Section 4 Body and Trim RACK AND PINION See General War
96. ING See General Warnings Section 1 Page 1 1 CLEANING THE VEHICLE See General Warnings Section 1 Page 1 1 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 Precedent vehicles are equipped with Surlyn front and rear bodies Use only commercially avail able 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 a Surlyn 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 Do not use abrasive leveling or rubbing compounds these will permanently dull the gloss Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains NOTE Dispose of waste water properly SEAT 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 guid
97. ISTANCE READING FUEL GAUGE READINGS Lower position tank empty 240 x 20 ohms Empty Center position tank half full 120 20 ohms Half full Upper position tank full 60 20 ohms Full TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 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 18 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 Leave the battery disconnected while checking continuity Also check the continuity of the blue wire from the fuel gauge to the key switch and the black ground wires at the fuel level sending unit and at the fuel gauge See Fuel Gauge Removal Section 12 Page 12 21 7 Ifthe readings are correct according to the position of the float but give an incorrect reading on the fuel gauge test the fuel gauge See Test Procedure 26 Fuel Gauge on page 11 35 TEST PROCEDURE 26 FUEL GAUGE See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Remove the dash assembly to gain access to the back of the fuel gauge See Key Switch Removal Section
98. K 18 BLK VOLTAGE REGULATOR SONIC WELD 3 PIN CONNECTORS 16 BLACK STARTER GENERATOR GREEN 101837301 16 RED H E OUR METEI 12 BLUE Figure 11 2 Precedent Gasoline Vehicle Wiring Diagram N 20 PI 12 BLUE AMP SE 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 7 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES USED WHEN THERE ARE LIGHTS BUT NO TURN SIGNAL NORMALLY OPEN MOMENTARY PUSH BUTTON FOR HORN 9 POSITION CONNECTOR 16 ORANGE 16 BLUE WHITE 16 WHITE 16 YELLOW SONIC 16 BROWNMHITE WELD e oco oo FLASHER UNIT 16 BLACK 7 N 16 BROWN 16 YELLOW 16 ORANGE 16 BLACK 16 GREEN 16 ORANGE 16 RED 16 GREEN 16 BLUE WHITE 16 BLACK 16 BLUE 16 GREEN 16 RED 16 BROWN TURN SIGNAL 16 GREY SWITCH 16 WHITE 16 GREY BLK 16 RED 16 BLUEWHITE 16 WHITE 16 WHITE 16 YELLOW 16 YELLOW 16 BROWNIWHITE 16 BROWNMWHITE 88888088880 8 68838980 NORMALLY OPEN MOMENTARY PUSH BUTTON FOR HORN 9 POSTION CONNECTORS USED WHEN THERE ARE TURN SIGNALS Figure 11 3 Preced
99. LUE 16 RED 18 ORANGE 2 18 ORANGE CONNECTS TO 9 PIN CONNECTOR FOR INSTRUMENT PANEL CONTROLS 16 RED WHT 16 YELLOW 16 BLK 18 RED WHITE 18 WHITE BLACK 18 BLACK AND INDICATORS 18 WHITE BLK SEE FIGURE 11 5 ooeeeeeos Figure 11 1 Precedent Gasoline Vehicle Wiring Diagram 18 BLACK Page 11 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual 18 BLUE WHITE 18 BLUE 12 BLUE TROUBLESHOOTING AND ELECTRICAL SYSTEM 18 ORANGE 18 YELLOW 16 ORANGE bin Y LEVEL 16 BLACK Ree 18 ORANGE 16WHT BLK 9 OIL LEVEL SENSOR 9 ENGINE KILL HOOK UP 10 BLACK SINGLE POSITION CONNECTOR Wiring Diagrams Q FRAME GROUND CK RER gR 16 BLACK FORWARD REVERSE LIMIT SWITCHES 16 GREEN 16 WHITE 16 ORANGE 18 RED WHITE 18 WHITE BLACK 18 BLACK 18 BLACK 18 BLUE WHITE 18 BLUE 16 RED WHT BLACK ENGINE GROUND au BATTERY 3H0 BLACK 10 RED 18 YELLOW 10 WHITE 18 ORANGE 16 BLUE 18 BLUE 12 BLUE 18 BLK 16 RED 16 ORANGE F SOLENOID 18 ORANGE 18 WHT BLK 16 RED SONIC WELD 18 YEL O 18 RED BBL
100. NENTS Starter Generator Measure each position O in two places 90 apart 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 neg ative 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 8 ARMATURE COMMUTATOR ARMATURE SHAFT Figure 12 12 Armature Ground Test Page 12 8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS 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 1 535 in 39 mm Concentric with armature shaft within 0 002
101. ONTROL LINKAGE See General Warnings Section 1 Page 1 1 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 es Improper adjustment can result in poor vehicle performance and or damage to the engine components 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 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 3 Remove the governor guard 5 Figure 14 1 Page 14 3 4 Release the governor cable 8 from brackets 10 and 11 Figure 14 3 Page 14 7 5 Remove the ends of cable 8 from the governor lever arm and the carburetor and remove the cable from the vehicle Governor Cable Installation and Adjustment 1 Insert the ends of cable 8 into the respective holes on the carburetor and the governor lever arm Figure 14 3 Page 14 7 2 Press on the cable 8 to snap it in place in brackets 10 and 11 3 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
102. OVA icoocooniniinasiici darian 13 5 INDEX cylinder head ae a aeaa aeaaea eae a Eaha 13 3 D DANGER definition Ofi Serene debris shields eeu diagram schematic differential see unitized transaxle drive belt INSPectiO ien m ra 17 2 installation ecrire 17 3 removal d ata eem 17 2 drive clutch assembly eri te pee 17 10 cleaning and inspection 17 7 17 10 disassembly installation removals eeta tote ronde estne drive unit see unitized transaxle driven clutch assembly 25 nan ad eet disassembly uti eraa aaa aae INSPECHION cuide aci installation removal coco aii da E electrical system engine ignition circuit see also ignition coil and ignition testing engine kill circuit oooooocccononococanacananaconanannnnno 11 11 fuel gauge sending unit circuit 11 11 generator circuit l enn hour meter circuit eeseesssessssssss low oil warning light circuit neutral lockout circuit reverse buzzer circuit oooococconcccccocnccccaccccnnnnnos Starter CIRCUIT see eege e tou engine ignition circuit installation snn eie lU EE 13 3 rotatiONn sine LE 13 1 RPM adjustment AAA 14 9 exhaust system esses 14 1 15 1 see also muffler F floor mat and retainers ssss 4 6 floor m
103. Page 2 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SECTION 3 GENERAL INFORMATION A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 Important features unique to the different models covered in this manual are highlighted Club Car Inc rec ommends 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 passenger side inner dash Figure 3 1 Page 3 1 NOTE Have the vehicle serial number available when ordering parts or making inquiries Cie SERIAL NUMBER mw PQ0501 123456 Figure 3 1 Serial Number Decal 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 3 1 E GENERAL INFORMATION Safety Committee 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 c
104. Place engine onto engine mounting plate and tighten the mounting hardware 1 2 and 5 to 13 ft Ib 17 7 N m Tighten nuts 6 to 17 ft Ib 23 1 N m Figure 13 2 Page 13 4 Install drive clutch See Drive Clutch Installation Section 17 Page 17 12 Install drive belt See Drive Belt Installation Section 17 Page 17 3 Install muffler See Muffler Installation Section 15 Page 15 1 Install starter generator and belt See Starter Generator Installation Section 12 Page 12 10 oa 5o m Install the powertrain See Unitized Transaxle Installation Section 16 Page 16 15 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 13 9 FE290 ENGINE Engine Installation Engine Installation Continued 7 Install oil drain plug in the crankcase and tighten to 20 ft Ib 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 cor rect type of oil This engine should be regarded as a new engine for next scheduled oil change See Section 10 Periodic Maintenance 8 Check all hardware for proper torque tightness 9 Check engine oil level Figure 13 13 Page 13 10 9 1 With vehicle on level surface remove dip stick and clean with cloth Figure 13 13 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 Figure 13 13 Check Engine Oil L
105. R TIRE BEADS SS VALVE STEM SIDE UP a Figure 8 1 Tire Removal Page 8 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual WHEELS AND TIRES Tires ES TIRE REPAIR 1 Determine the location and cause of the air leak 1 1 1 2 1 3 NOTE Remove the wheel See Wheel Removal on page 8 1 Inflate the tire to no more than 20 psi 1 38 Bars Immerse the tire in water and then mark the point where bubbles are formed by escaping air Determine the cause of the air leak See following 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 avail able at your local Club Car dealer 2 Whenthe cause ofthe air leak has been determined remove tire from the rim and repair as required See Tire Removal on page 8 2 TIRE INSTALLATION A 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 ti
106. RATOR RETURN SPRING The accelerator return spring assembly 10 consists of two springs and three T shaped bars secured by two crosspins Figure 5 4 Page 5 5 The assembly is replaced as a unit The replacement unit includes a pin that keeps the spring compressed so it can be installed in the pedal group Replace the assembly as follows A CAUTION Spring is under tension Use caution when working with springs 1 With the pedal group removed from the vehicle remove the debris shield and then remove the accel erator return spring assembly 2 Toinstall accelerator return spring assembly position the accelerator return spring unit in the pedal group with the lower crosspin of the assembly positioned in the pedal group and secure it in place with the clip 1 Figure 5 5 Page 5 6 3 Position upper crosspin in the tab on the pedal group Figure 5 6 Page 5 6 4 Push accelerator pedal forward to compress the springs in the assembly While the springs are com pressed pull pin from both T shaped bars then release the pedal Figure 5 7 Page 5 6 Page 5 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group ES OPPOSITE 4 jop SIDE VIEW V L7 Figure 5 4 Pedal Group 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 5 5 ES ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Figure 5 6 Accelerator Spring Upper Crosspin Figure 5 7
107. 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 Figure 11 25 Primary Coil Resistance In Vehicle Test TEST PROCEDURE 15 IGNITION COIL See General Warnings Section 1 Page 1 1 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 Test Procedure 15A Ignition coil In Vehicle Test 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Using a multimeter set to 200 ohms measure the primary coil resistance Page 11 26 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 2 1 Disconnect both of the bullet terminals at the RPM limiter Figure 11 24 Page 11 25 Place the red 4 probe of the meter on the male bullet
108. Removal Section 12 Page 12 18 TEST PROCEDURE 21 OIL LEVEL SENSOR See General Warnings Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position turn the key switch to the OFF position disconnect the spark plug wire and chock the wheels Ensure that the low oil warning light and all connecting wires are functioning correctly See Test Proce dure 22 Low Oil Warning Light on page 11 33 Drain the engine oil into an approved container and properly dispose of used oil Turn the key switch ON closing the circuit The low oil warning light should illuminate If the low oil warn ing light does not illuminate the oil level sensor needs to be replaced See Oil Level Sensor Removal Section 13 Page 13 5 Install a new oil filter and fill the engine with new oil before returning the vehicle to service See Engine Oil Section 10 Page 10 5 Page 11 32 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures EB TEST PROCEDURE 22 LOW OIL WARNING LIGHT See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the instrument panel assembly See Key Switch Removal
109. STING Figure 17 10 Drive Button Mounting Figure 17 11 Weight Position 5 Remove the clutch weights Figure 17 11 Page 17 8 5 1 Remove the screws and flat washers attaching the weights as shown Figure 17 11 Page 17 8 5 2 Pull the weight assemblies with pins from the clutch 5 3 Before removing note the orientations of the wave washer and of the primary and secondary weights to one another Figures 17 12 and 17 13 Page 17 9 Remove the plastic washers weights and wave washer from the pin Retain all parts Page 17 8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TORQUE CONVERTER Drive Clutch SECONDARY WEIGHT PRIMARY WEIGHT Y SMALL PIN Figure 17 12 Install Pin and Washer Figure 17 13 Install Secondary Weight 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 7 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 7 Page 17 6 7 Remove the spacer 16 spring 4 and retainer 5 The spring retainer can be removed from the spring if necessary Figure 17 7 Page 17 6 8 If necessary remove idler bearing Use a press to remove the bearing Figure 17 14 Page 17 9 See following NOTE NOTE Do not remove the idler bearing unless it needs to be replaced If idler be
110. Section 11 Page 11 32 Reverse Buzzer Limit Switch Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 19 ELECTRICAL COMPONENTS Low Oil Warning Light Reverse Buzzer Limit Switch Removal Continued 2 Disconnect the wires from the reverse buzzer limit switch 4 located on the back of the Forward Reverse assembly Figure 12 18 Page 12 17 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 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 2 Install the reverse buzzer limit switch 4 and then install two spacers 9 against the limit switch Figure 12 18 Page 12 17 Install the neutral lockout limit switch 5 with two washers 6 and two nuts 2 Tighten to 5 in Ib 0 6 N m See following CAUTION CAUTION Do not overtighten the retaining nuts If the nuts are over tightened limit switches could be damaged Place the Forward Reverse handle in REVERSE and make sure that both switches actuate Connect the orange wire to the common COM terminal and the red white wire to the normally open NO terminal of the re
111. Section 12 Page 12 13 3 Ensure that the wires are connected correctly and are tight If they are not rewire or tighten as necessary Figure 11 5 Page 11 10 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 between the yellow white wire connection on the low oil warning light and the blue wire connection at the key switch If there is no continuity in the wire correct the problem Then test the key switch See Test Procedure 4 Key Switch Starter Circuit on page 11 17 If the yellow white wire and the key switch test okay then replace the low oil warning light TEST PROCEDURE 23 NEUTRAL LOCKOUT CAM See General Warnings Section 1 Page 1 1 1 Checkto 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 TES
112. Section 14 Fuel System Torque converter is not backshifting properly Section 17 Torque Converter Spark plug fouls repeatedly Incorrect plug Section 13 FE290 Engine Spark plug wire is damaged Section 13 FE290 Engine Unsuitable fuel or incorrect rich fuel mixture Section 14 Fuel System Ignition coil failed Dirt entering combustion chamber Section 11 Troubleshooting and Electrical System Test Procedures 13 14 and 15 Check intake system for leaks Section 14 Fuel System Rings are heavily worn low cylinder pressure Section 13 FE290 Engine Carburetor floods Starter fails to operate Inlet valve or seat is leaking dirty worn or damaged Section 14 Fuel System Float is damaged and filled with fuel Section 14 Fuel System Float needle valve not functioning properly Section 14 Fuel System Carburetor vent is clogged Neutral lockout cam is in the wrong position Section 14 Fuel System Test Procedure 7 Neutral Lockout Limit Switch on page 11 20 Fuse is blown Test Procedure 2 Fuse on page 11 15 Battery is dead Test Procedure 1 Battery on page 11 12 Starter control circuit is not operating Starter generator failed Test Procedure 8 Starter Generator Starter Function on page 11 20 Test Procedure 8 Starter Generator Starter Function on page 11 20 Starter so
113. T UNDER LOAD See General Warnings Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Seta 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 Place battery under load 3 1 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 4 Ifthe 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 CL At lower electrolyte temperatures the voltage reading will be lower 5 If the reading is below 9 6 volts with an electrolyte temperature of 70 F 21 C check the battery See Test Procedure 1 Battery on page 11 12 6 If the reading is zero there may be no continuity across the large posts of the solenoid See Test Pro cedure 6 Solenoid on page 11 18 7 Ifall 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 Test Procedure 8 Starter Gener
114. TION To prevent damage to the canopy do not remove the canopy supports 3 7 and 10 from the vehicle without first removing the canopy 1 Figure 4 12 Page 4 17 TWO PASSENGER CANOPY REMOVAL 1 Remove the two nuts 9 and two bolts 8 from the canopy 1 and each front canopy support 7 and 10 Figure 4 12 Page 4 17 Remove the nuts 5 and bolts 4 from the canopy 1 and each rear support 3 Lift canopy 1 away from front canopy supports 7 and 10 and rear supports 3 Remove screws 14 securing front canopy support covers to front body Slide canopy support covers 12 and 13 up front canopy supports 7 and 10 to gain access to bolts 11 o mF o LD Remove two bolts 11 from each front canopy support 7 and 10 and remove canopy supports from the vehicle 7 Remove two bolts 6 from each rear support 3 and pull rear supports from vehicle Page 4 16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual BODY AND TRIM Canopy Two Passenger Figure 4 12 Precedent Two Passenger Canopy 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 17 BODY AND TRIM Canopy Two Passenger TWO PASSENGER CANOPY INSTALLATION 1 Install the front canopy supports 1 1 Ensure the front supports are properly oriented to the correct side of the vehicle as shown Figure 4 12 Page 4 17 The lower profile of each support follows the profile of the vehicle If the supports ar
115. 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 1 and 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 Section 12 Page 12 1 7 With the wires still disconnected using a multimeter set on 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 techni cian See Starter Generator Removal Section 12 Page 12 1 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 21 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 9 WIRE CONTINUITY See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 To test a wire for continuity disconnect either end from the electrical component it is attached to Setthe multimeter to 200 ohms and place the red
116. age 10 4 General vehicle Check for loose hardware and tighten if necessary Two year service by trained technician only every 200 hours of operation or every 400 rounds of golf Fuel filters Replace Dispose of used filters properly A WARNING e 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 personal injury or death 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 10 3 PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE Periodic Lubrication Schedule See General Warnings Section 1 Page 1 1 PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE LUBRICATION RECOMMENDED LUBRICANT Semiannually by owner or trained technician Shifter cable pivots Dry Moly Lube CCI P N 1012151 every 50 hours of operation i ES O k y or every 100 rounds for golf cars Brake system per maintenance Dry Moly Lube CCI P N 1012151 and service manual O white lithium grease NLGI 2 Front suspension two fittings O Chassis Lube EP NLGI Grade 2 Annually by trained BEE 27 oz 8 liter 80 90 WT API Class technician only Check fill unitized transaxle to GL 3 or 80 90 WT AGMA Class EP every 100 hours of plug level O Gear Lube operation or every 200 rounds of golf Pedal Dupont Performance Multi Use eda gr
117. ake 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 1 2 IN X 5 8 IN COLD CHISEL Figure 6 1 Loosen Turnbuckle Figure 6 2 Shoe Retainer Pins 7 2 Insert a 1 2 inch x 5 8 inch cold chisel under the head 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 which should then allow the brake drum to be pulled free After completing step 8 skip step 9 NOTE Although step 8 allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes 8 Remove the axle 8 1 Using 90 snap ring pliers CCI P N 1012560 remove the axle retaining ring 1 Figure 6 3 Page 6 2 8 2 Pull the axle shaft 2 from the axle tube Figure 6 3 Page 6 2 Figure 6 3 Remove Axle Retaining Ring Page 6 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Brake Shoe Removal e WHEEL BRAKE ASSEMBLIES Figure 6 4 Self adjusting Wheel Brake Assembly Page 6 3 2005 Precedent Gasoline Golf Car Maintenance and Service Manual EN WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal Continued 9 Using needle nose pliers turn the clip retainer pin 1 90 to remove the shoe retainer clip 2 Figure 6 5 Page 6 4 A CAUTION The brak
118. al Warnings Section 1 Page 1 1 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 2 2 Loosen the starter generator mounting and adjusting hardware and then remove the starter belt See WARNING Moving parts Do not in General Warnings Section 1 Page 1 1 Use Club Car clutch holder VEHICLE BODY REMOVED FOR while tightening or loosening drive CLARITY clutch retaining bolt DRIVEN CLUTCH DRIVE CLUTCH RETAINING BOLT Insert drive clutch puller into drive clutch then tighten Hook clutch holder puller to remove 3 on boss of pully hub 4 located behind drive clutch push down on adjacent boss with holder NN THREE BOSSES i D IN GRAY DRIVE CLUTCH PULLER CCI P N 1014496 Figure 17 3 Loosen Retaining Bolt Figure 17 4 Drive Clutch Removal Page 17 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TORQUE CONVERTER Drive Clutch 3 Remove the lower shock mounting hardware from both rear shocks Figure 17 5 Page 17 5 4 Place chocks at the front wheels and lift the rear of the vehicle just enough to relieve tension from leaf springs then remove the bolts securing the leaf springs to the shackles Figure 17 6 Page 17 5 Rem
119. al Warnings Section 1 Page 1 2 Page 17 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TORQUE CONVERTER Drive Belt 2 Disconnect the spark plug wire from the spark plug See WARNING To avoid unintentionally start ing in General Warnings Section 1 Page 1 2 3 Grasp the belt midway between the drive and driven 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 counterclock wise Figure 17 2 Page 17 3 See following CAUTION A CAUTION Make sure fingers are not underneath the belt when rolling the belt off the driven clutch 4 Remove the belt from the drive clutch DRIVEN CLUTCH 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 3 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 4 Connect the spark plug wire to the plug 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 17 3 TORQUE CONVERTER Drive Clutch DRIVE CLUTCH See Gener
120. and 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 See General Warnings Section 1 Page 1 1 See also DANGER on page 12 28 1 Place the battery into the vehicle Make sure the battery posts are facing the engine 2 Secure the battery to the vehicle with the clamp Install bolt washer and lock nut and tighten to 12 ft Ib 16 3 N m 3 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Battery Storage See General Warnings Section 1 Page 1 1 See also DANGER on page 12 28 1 Keep the battery clean and free of corrosion See Preventive Maintenance on page 12 29 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 3 Fully charge the battery prior to storage 4 Store in a cool area The colder the area in which the battery is stored the less the battery will self dis charge A battery stored at 0 F 17 8 C will discharge very little over a four
121. ar Maintenance and Service Manual Page 16 17 UNITIZED TRANSAXLE Unitized Transaxle Installation 14 15 16 17 18 19 Position the floor jack under the rear bumper and raise the jack high enough to support the vehicle Figure 16 42 Page 16 18 Make sure the vehicle is stable on the jack then remove the jack stands 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 Ensure the brackets on the brake cables are placed over the bolts before the lock nuts are installed Tighten lock nuts to 15 ft Ib 20 3 N m Figure 16 42 Page 16 18 Using the floor jack adjust vehicle height to position the leaf springs for mounting in the shackles Install the mounting bolts and lock nuts Figure 16 43 Page 16 18 Figure 16 42 Leaf Springs Figure 16 43 Leaf Springs and Shackles Position shocks in the shock mounts and install cushions mounting washers and nuts Figure 16 44 Page 16 19 Tighten nuts until cushions expand to be the same diameter as the mounting washers Connect brake cables See Brake Cable Installation Section 6 Page 6 12 Route the engine kill switch wire 18 gauge white black through the same retainers that hold the accel erator cable Connect the wire to the bullet connector at the lower right front of the engine Figure 16 45 Page 16 19 Page 16 18 2005 Precedent Gasoline Golf
122. aring 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 7 Page 17 6 See also Figure 17 15 Page 17 9 Discard the rings M PRESS RAM IDLER BEARING Y d BEARING PULLER FIXED FACE ASSEMBLY Figure 17 14 Remove Idler Bearing Figure 17 15 Spiral Back up Rings 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 17 9 TORQUE CONVERTER Drive Clutch INSPECTION OF DRIVE CLUTCH PARTS 1 Inspect the idler bearing 6 for smooth rotation or seal damage Figure 17 7 Page 17 6 See follow ing NOTE NOTE It is normal for a small amount of grease to be present at the edge of seal 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 7 Page 17 6 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 Inspect the thrust washer 11 for wear If itis worn more than 0 030 inch 0 76 mm turn it over or replace it with a new one 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 specificati
123. ars should be driven Ensuring that proper warnings of driving hazards are displayed and visible See below for list of signs available from Club Car Service Parts Department 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 Warning signs available from Club Car are listed below WARNING SIGN CCI P N Sharp Left S9911211 Sharp Right 9921211 Steep Hill 9931211 STORAGE See General Warnings Section 1 Page 1 1 A DANGER Do not drain gasoline when the engine is hot or while it is running Be sure to clean up any spilled gasoline before operating the vehicle Store gasoline in an approved gasoline container only Store in a well ventilated area away from sparks open flames heaters or heat sources Keep gasoline out of the reach of children Do not siphon gasoline from the vehicle A WARNING Turn the key switch OFF 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 fuel shut off valve to closed OFF position Figure 3 3 Page 3 3 Do not attempt to charge frozen batteries or batteries with bulged cases Discard the batt
124. assist its distributors and dealers in continually updating their service knowl edge and facilities so they can provide prompt and efficient service for vehicle owners Regional technical rep resentatives vehicle service seminars periodic service bulletins maintenance and service manuals and other service publications also represent Club Car s continuing commitment to customer support This manual covers all aspects of typical vehicle service unique situations however do sometimes occur when servicing a vehicle If it appears that a service question is not answered in this manual you may write to us at Club Car Inc P O Box 204658 Augusta Georgia 30917 Attention Technical Services or contact a Club Car Technical Service Representative at 706 863 3000 ext 3580 Copyright O 2005 Club Car Inc Club Car is a registered trademark of Club Car Inc This manual effective August 2 2004 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page i A WARNING e Read 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 Inc is continually working to further improve its vehicles and other products These improvements may affect servicing procedures Any modificati
125. at retainer installation oec 4 7 removal aeta ether deese eee 4 7 flywheel installation aeree ees 13 9 Ee LEE 13 7 foot deck four passenger installation ceteros 4 14 Ee UI 4 14 forward reverse cable adjustment installation removal 2 3 e deeem a aaa handle lever front DOY sico ritos see body front front bumper ENEE front suspension camber adjustment f el Tilter ied needs installation o eoi ote toos removal 2 2 enses fuel gauge hour meter fuel gauge circuit loeser 11 11 testing tia 11 35 fuel level sending unit E tata 11 34 installation ir ti 12 22 12 23 removal eocccccccncnncccccnnononncnnnnnnonononinonanon 12 21 12 23 fuel level sending unit 12 23 testing fuel lines 14 1 14 21 fuel pump 14 1 14 15 assembly nic en n Rete de 14 17 cleaning and inspection 14 16 disassembly eee 14 15 installation eae 14 17 removal arial 14 15 fuel shut off valve ssuussssuss 14 21 fuel tank disposal iem ata 14 19 installatiom EE 14 20 removal storage fueling instructions A 10 6 fuse Installation doceret ott tinet 12 15 removal iie etit tn 12 15 TOSUING iiiter 11 15 Page i 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual INDEX G Inge NOU o atte hice ates 5 3 governor governor s
126. ate Remove button 5 and spring 6 KICK PLATE AND CHOKE BUTTON INSTALLATION 1 Place spring 6 in kick plate 4 and orient the tabs on the button 5 with the slots in the kick plate Press in the button until it snaps in place in the kick plate Figure 4 5 Page 4 8 2 Insert the tabbed end of the choke rod 3 into the rear slot on the button 5 3 Position the kick plate 4 on the vehicle and secure with three screws 1 Ensure front lower edge of rear beauty panel mates with the kick plate Tighten screws to 3 3 ft Ib 4 5 N m 4 Insert choke rod 3 through the choke actuator Secure the rod with hair spring cotter pin 2 5 Install two front screws to secure the rear beauty panel Tighten screws to 3 7 ft Ib 5 N m 6 Install floor mat See Floor Mat and Retainers on page 4 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 7 BODY AND TRIM Rear Body Two Passenger Vehicles TYPICAL CONNECTION Figure 4 5 Kick Plate and Choke Button REAR BODY TWO PASSENGER VEHICLES See General Warnings Section 1 Page 1 1 UNIVERSAL ACCESSORY MOUNTING The Structural Accessory Module SAM includes two threaded inserts on both the driver side and the pas senger side Figure 4 6 Page 4 8 These inserts serve as common attachment points for various accessor ries Accessories that can be mounted to the SAM include single or dual sand bottles sand bucket and the club cleaner
127. ator Starter Function on page 11 20 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 33 TROUBLESHOOTING AND ELECTRICAL SYSTEM TEST PROCEDURE 25 FUEL LEVEL SENDING UNIT See General Warnings Section 1 Page 1 1 A WARNING Test Procedures To avoid the possibility of fire or explosion make sure the fuel tank cap is securely in place while performing this test procedure 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Disconnect the orange wire from the center post of the fuel level sending unit 3 With a multimeter set to 2 k 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 35 Page 11 34 TANK CONNECTION eo T SENDING UNIT Figure 11 35 Fuel Level Sending Unit Test 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 Page 11 34 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FLOAT POSITION RES
128. axle Installation Continued 8 Install the governor cable bracket on transaxle case Tighten the mounting screws to 134 in Ib 15 1 N m Figure 16 38 Page 16 17 9 Install governor lever arm on governor shaft Figure 16 39 Page 16 17 9 1 With the governor lever arm loose on the governor shaft turn the governor arm shaft counterclock wise 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 17 9 2 While holding the arm and shaft in the fully counterclockwise position tighten the governor arm lever nut to 35 in Ib 4 0 N m Figure 16 39 Page 16 17 Figure 16 38 Governor Cable Bracket Figure 16 39 Governor Arm 10 Install the key onto the input shaft Figure 16 40 Page 16 17 11 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 17 12 Install the drive belt See Drive Belt Installation Section 17 Page 17 3 13 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 17 SNUBBER ZB SNUBBER BRACKET La Figure 16 40 Driven Clutch Figure 16 41 Snubber 2005 Precedent Gasoline Golf C
129. bolts to 25 ft Ib 34 N m 3 Tighten nuts 2 on spring mounting bolts 17 to 15 ft Ib 20 3 N m Figure 9 1 Page 9 2 LEAF SPRINGS FOUR PASSENGER VEHICLES See General Warnings Section 1 Page 1 1 LEAF SPRING REMOVAL FOUR PASSENGER VEHICLES 1 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 forward of the spring mounting tabs Lower the vehi cle to let the jack stands support the vehicle Figure 9 2 Page 9 3 See following WARNING A WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 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 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 3 Remove the tire and wheel assembly on the side from which the spring is to be removed Remove the bow tie locking pin 1 and the cle
130. 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 Install the commutator end cover 23 onto the armature shaft Align the locating pin with the pin hole in the cover Install two M6 x 180 mm bolts 20 and tighten to 100 in Ib 11 3 N m Figure 12 2 Page 12 2 Push the brushes down into the holders Position 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 cov ers 29 in the openings in the commutator end cover 23 Figure 12 3 Page 12 2 BRUSH BEING HELD BY BRUSH SPRING Figure 12 6 Pull Brushes Away from Center of the Commutator End Cover Disassembly of the Starter Generator to Service the Armature Commutator 1 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 1 1 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 Remove the two bolts 20 and pull commutator end cove
131. ce Manual SECTION 16 UNITIZED TRANSAXLE A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 GENERAL INFORMATION All gasoline powered Club Car vehicles manufactured since the beginning of the 1997 model year are equipped with heavy duty fully synchronized Unitized Transaxles The unitized transaxle utilizes fully syn chronized internal gearing to change vehicle direction Because the unitized transaxle is used to reverse vehi cle 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 This section contains information for removing and replacing the unitized transaxle For complete instruction on unitized transaxle disassembly repair rebuilding and reassembly see the Engines and Drivetrain Com ponents Repair and Rebuild Manual CCI P N 102396501 Shifter Lever A shifter lever connected to a shifter arm is used to change the gears to one of three shift positions FOR WARD F NEUTRAL N or REVERSE R Figure 16 1 Page 16 2 Bring the vehicle to a complete stop before changing FORWARD or REVERSE direction
132. ce and Service Manual Page 4 15 BODY AND TRIM Canopy Two Passenger Rear Beauty Panel Installation 1 Install rear beauty panel 12 on vehicle Make sure body clips on the rear of the beauty panel engage the mating slot in the rear underbody Secure beauty panel in place with four screws 13 Tighten screws to 3 7 ft Ib 5 N m Figure 4 8 Page 4 11 2 Position the shift cover 16 on the front of beauty panel 12 and secure with two screws 17 Tighten screws to 22 in lb 2 5 N m 3 Position handle 14 on shift mechanism Secure handle in place with screw 15 Tighten screw to 14 in Ib 1 6 N m 4 Install seat support See Seat Support Installation on page 4 13 Access Panel Access panel 6 is secured to the rear underbody 4 with two expanding screws 7 Figure 4 8 Page 4 11 When replacing the panel tighten screws 7 enough to hold the panel in place Rear Underbody Removal 1 Remove four screws 5 attaching the rear underbody 4 to vehicle Figure 4 8 Page 4 11 2 Liftthe rear edge of the rear underbody 4 until the front portion slides out from beneath the front under body Remove the rear underbody from the vehicle Rear Underbody Installation 1 Install rear underbody 4 on the vehicle Figure 4 8 Page 4 11 Install four screws 5 to secure the underbody to its vehicle Tighten screws 5 and 18 to 3 7 ft Ib 5 N m CANOPY TWO PASSENGER See General Warnings Section 1 Page 1 1 CAU
133. ce information A DANGER ADANGER indicates an immediate hazard that will result in severe personal injury or death A WARNING AWARNING indicates an immediate hazard that could result in severe personal injury or death A 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 ser viced Other specific safety statements appear throughout this manual and on the vehicle A 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 Gasoline Flammable Explosive Do not smoke Keep sparks and flames away from the ve
134. ced 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 CCI P N 1014510 Figure 17 1 Page 17 2 Scribe or small pick not included in torque converter tool kit TROUBLESHOOTING See General Warnings Section 1 Page 1 1 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 Club Car 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 1 Check the governor and throttle settings See Section 14 Governor Cable 2005 Prec
135. checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Periodic Service Schedule on page 10 2 Any problems should be corrected by a Club Car dealer or a trained technician 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 General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight Safety and information decals Check to ensure that all safety and information decals are in place See the vehicle owner s manual Tires Check for proper tire pressure Visually inspect tires for wear damage and proper inflation on a daily basis Section 2 Vehicle Specifications Battery Check electrolyte to ensure it is at the proper level See Figure 11 6 Section 11 Page 11 13 Check battery posts Wires should be tight and free of corrosion and battery should be fully charged Engine Check for proper engine oil level See Engine Oil on page 10 5 Fuel Check fuel level See Fueling Instructions on page 10 6 Check fuel tank lines cap pump fuel filters and carburetor for leakage Exhaust system Check for leaks 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 10 1 PERIODIC MAINTENANCE Periodic Service Schedule PERFORMANCE INSPECTION
136. closer than 6 inches 15 cm to the body 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 a Surlyn 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 Surlyn 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 com pound on body assemblies 3 Waxthe 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 w
137. d sto a RM best Testing a inier es vibration damage voltage test water level belt drive See drive belt body front see also repair front and rear body installation ee 4 4 removal 2s dette rettet ates 4 4 body rear see also repair front and rear body 2005 Precedent Gasoline Golf Car Maintenance and Service Manual e IN 4 8 brake return Spring AN 5 3 brakes adjustment d ice Dee DA es 6 8 cable installation ek Ed ees cee 6 12 removal ish S 6 10 cleaning assembly AAA 6 5 cluster installation ai 6 10 Ee LE 6 9 shoe installation etat tate tee 6 6 removal 1 32 EE 6 1 breather valve reed valve 13 3 bumper TIODL 6 ctore ee dtt dte 4 4 C camber adjustment AAA 7 10 canopy four passenger installation El LEE canopy two passenger installation removal carburetor closed throttle or idle adjustment 14 8 jet main aie ended dede 14 2 elevation size chart seesssssssss 14 2 CAUTION definition ofc uie tette ic ttes 1 1 choke choke and air intake system 14 1 14 9 cleaning brake assembly sees 6 5 Seal Lone eU ote EE eee 4 1 Vehicle body A c edet 4 1 clutch torque converter troubleshooting 17 1 clutch drive see drive clutch clutch driven see driven clutch column steering See steering column crankcase cover instalation scheit renarena ei ens 13 6 TOM
138. d Pinion 1 To minimize corrosion apply a light coat of anti seize lubricating compound to the splined portion of the steering column universal joint 2 Align the flat portion of the shaft 13 spline with the bolt hole in the upper universal joint and then slide the shaft into the universal joint Install the bolt and tighten to 18 4 ft Ib 25 N m Figure 7 3 Page 7 3 3 Simultaneously position the assembly over the mounting holes and slide the universal joint over the square end of the steering column 4 Install three screws to secure the assembly to the vehicle Tighten screws to 22 ft Ib 30 N m 5 Install the tie rod ends 3 into the left and right hand spindle tabs 4 and then install the retaining nuts 2 Figure 7 4 Page 7 5 See following WARNING A WARNING Do not operate vehicle until toe in is adjusted and ball joints are secured 6 Adjust the toe in See Toe in Adjustment on page 7 11 RUBBER MALET 15 16 INCH DEEP WELL Los SOCKET DUST SEAL Figure 7 12 Rack and Pinion Adjustment Figure 7 11 Install Ball Joint E py e AU df Figure 7 13 Rack and Pinion Resistance 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7 9 STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings Section 1 Page 1 1 LUBRICATION Two grease fittings are provided one in each spindle housing Lubricate these fittings at the recommended
139. d on the pedal group and cannot be repaired but can be replaced Kill Limit Switch See General Warnings Section 1 Page 1 1 Testing the Kill Limit Switch See Test Procedure 5B Section 11 Page 11 18 The kill limit switch is housed inside the GCOR The GCOR is mounted on the pedal group and cannot be repaired but can be replaced Neutral Lockout Limit Switch See General Warnings Section 1 Page 1 1 Testing the Neutral Lockout Limit Switch See Test Procedure 7 Section 11 Page 11 20 Neutral Lockout Limit Switch Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Disconnect the wires from the neutral lockout limit switch 5 located on the back of the Forward Reverse shifter assembly Figure 12 18 Page 12 17 3 Remove two nuts 2 and washers 6 from the neutral lockout limit switch 5 and slide the neutral lock out limit switch off of the screws Page 12 16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS GCOR Neutral Lockout Limit Switch Installation 1 Install the neutral lockout limit switch 5 with two washers 6 and two nuts 2 Figure 12 18 Page 12 17 Tighten to 5 in Ib 0 6 N m Place the Forward Reverse handle in REVERSE to make sure that both switches actuate See following CAUTION CAUTION Do not overtighten the retaining nuts If the nuts are overtigh
140. damage Tighten the ball joints to 60 ft Ib 81 N m Tap a flange into the notch on the rack Figure 7 11 Page 7 9 Place a few drops of Loctite 222 to the threads of the screw 14 Figure 7 5 Page 7 6 Install the rack guide 16 pressure spring 15 and screw 13 The screw should be threaded in until it bottoms out and then backed out 1 4 turn Figure 7 5 Page 7 6 Insert a 3 8 inch 1 4 drive deep well socket into the steering column end of the universal joint 2 and tighten the bolts 1 to 15 ft Ib 20 3 N m Figure 7 13 Page 7 9 Use a torque wrench connected to the 3 8 inch deep well socket to measure the resistance of the rack and pinion Rotational resistance should measure 7 to 15 in Ib 0 8 to 1 7 N m If measured resistance is not 7 to 15 in Ib 8 to 1 7 N m adjust the screw 13 until correct setting is achieved Tighten the nut 14 to 28 ft Ib 38 N m Figure 7 12 Page 7 9 NOTE When tightening the nut 14 make sure the screw 13 does not change adjustment Figure 7 12 14 15 16 Page 7 9 Install the two dust seal bellows 9 Figure 7 5 Page 7 6 Install new bellows clamps wire ties 10 and 21 Install the tie rod ends 12 to each end of rack 18 Tighten the tie rod end jam nuts 11 to 20 ft Ib 27 N m Figure 7 5 Page 7 6 Page 7 8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION RACK AND PINION INSTALLATION Rack an
141. dispose of properly FUEL PUMP DISASSEMBLY NOTE A fuel pump rebuild kit is available from Club Car CCI P N 1014524 This kit includes all gaskets diaphragms and valves 1 Remove four screws 24 and lock washers 25 from front of the fuel pump Figure 14 9 Page 14 16 2 Remove the front cover of the fuel pump while holding the rest of the pump intact 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 15 FUEL SYSTEM Fuel Pump Fuel Pump Disassembly Continued 3 Note the orientations of the impulse gasket 27 the diaphragm 28 and the gasket 29 then remove them from the pump See following CAUTION A 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 If the impulse gasket 27 and the diaphragm 28 come off with the front cover note their orientations and remove them Figure 14 9 Page 14 16 Remove the pumping chamber 30 Remove the back cover 36 the fuel diaphragm 34 and gasket 35 Figure 14 9 Page 14 16 FUEL PUMP CLEANING AND INSPECTION 1 Using a nonflammable solvent clean the front cover pumping chamber and back cover Be sure the vent on the front cover is clean both inside and out Inspect the valve assemblies 31 32 and 33 and all gaskets and diaphragms fo
142. dividual Owner Golf Course Superintendent Club Car Associate Representative Other In order to help us better serve you please rate this publication in the following catgories Poor Fair Average Good Excellent 1 Ease of Understanding 2 Ease of Finding Information LJ LJ LJ L LJ 3 Clarity of Illustrations 4 Index Usability 5 Troubleshooting Chart Usability Comments Suggestions Please fax a copy of this page to 706 228 2662 Thank You Club Car Technical Publication Department 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Ciub Car NOTES Ciub Car NOTES Club Car Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl 1 706 863 3000 Fax 1 706 863 5808
143. drums and single brake pedal with automatic release park brake BODY CHASSIS Frame Chassis Aluminum and composite Front and rear body Dupont Surlyn Reflections Body finish High gloss molded in color Tires 18 x 8 5 8 tubeless 4 ply rated DIMENSIONS WEIGHT Overall length 32 om a es in Overall width 200 n ont 5 Overall height with canopy E M TA en Overall height at steering wheel be EE Weier 168 m 168 om Ground clearance GE ard Front wheel tread een coer i Rear wheel tread SE GE Weight standard electric vehicle with canopy with batteries Weight standard gasoline vehicle with canopy with battery without fuel ss Vi da Vi Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter VE SC pos an Standard seating capacity 2 4 Vehicle Specifications continued on next page 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 2 1 VEHICLE SPECIFICATIONS SPECIFICATIONS Two Passenger Gasoline Vehicle Four Passenger Gasoline Vehicle LIQUID CAPACITIES 0 83 0 96 bars Engine crankcase without filter oe iter ae iter Engine crankcase with filter a aB fiters a e fiters T 27 oz 27 Oz Unitized transaxle 0 8 liter 0 8 liter 6 7 gallons 25 4 6 7 gallons 25 4 Fuel tank liters liters TIRE PRESSURE Front and rear 12 14 psi 12 14 psi 0 83 0 96 bars
144. ds 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 1 Install the spark plug by threading it in until finger tight then tighten the spark plug to 20 ft Ib 27 N m CYLINDER HEAD See General Warnings Section 1 Page 1 1 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 Engines and Drivetrain Components Repair and Rebuild Manual 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 separa
145. e Finger tighten the two lock nuts Before tightening the cable housing lock nuts make sure the engine RPM adjustment is correct See Engine RPM Adjustment on page 14 9 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 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 2 Loosen the carburetor idle screw so that it is not touching the throttle lever Figure 14 4 Page 14 8 Slowly tighten the idle screw until it lightly touches the throttle lever then tighten it an additional 3 4 turn Figure 14 4 Idle Screw Page 14 8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FUEL SYSTEM Choke and Air Intake System ENGINE RPM ADJUSTMENT A DANGER Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 1 If the governor is adjusted proceed to step 2 otherwise adjust the governor See Governor Cable Installation and Adjustment on page 14 6 2 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Fi
146. e 1 1 1 2 Install the wheels See Wheel Installation Section 8 Page 8 1 Two passenger vehicles Install the leaf springs See Leaf Spring Installation Two Passenger Vehi cles Section 9 Page 9 4 Four passenger vehicles Install the leaf springs See Leaf Spring Installation Four Passenger Vehicles Section 9 Page 9 6 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 36 Page 16 16 Install the remaining four mounting bolts four flat washers and four nuts one bolt and nut at each corner of the mounting plate finger tight Tighten the four corner nuts with bolts to 23 ft Ib 31 2 N m Tighten the two center nuts on the engine block studs to 17 ft Ib 23 1 N m Figure 16 36 Page 16 16 Install the accelerator cable bracket on transaxle case Tighten the mounting screws to 134 in lb 15 1 N m Figure 16 37 Page 16 16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 15 UNITIZED TRANSAXLE N ex d S el HNZ D S amp STUDS TRANSAXLE MOUNTING PE MOUNTING NUT SS TYPICAL 2 PLACES bei Figure 16 36 Transaxle Mounting Unitized Transaxle Installation Figure 16 37 Accelerator Cable Bracket Page 16 16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual UNITIZED TRANSAXLE Unitized Transaxle Installation 16 Unitized Trans
147. e 16 8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 7 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal Continued 4 3 4 4 4 5 4 6 Page 16 8 VENT TUBE Figure 16 9 Fuel Vent Tube Figure 16 10 Air Intake Hose Disconnect impulse line from fuel pump Figure 16 11 Page 16 8 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 12 Page 16 8 IMPULSE LINE Figure 16 11 Impulse Line Figure 16 12 Fuel Line Disconnect the throttle cable from the pedal group See Pedal Group Removal Section 5 Page 5 1 Loosen the cable mounting nuts 1 and ensure the cable can move freely through the hole in the frame Figure 16 13 Page 16 9 Remove retaining nut and disconnect the engine ground wire from the oil filler tube mounting bracket Figure 16 14 Page 16 9 2005 Precedent Gasoline Golf Car Maintenance and Service Manual UNITIZED TRANSAXLE Unitized Transaxle Removal 16 ENGINE GROUND RETAINING NUT ACCELERATOR CABLE Figure 16 13 Throttle Cable Mounting Figure 16 14 Engine Ground Wire 4 7 Use a screwdriver or flat blade to snap the shifter cable rod end from the shifter arm on the unitized transaxle Compress the retaining clips on the cable boot and push the cable through the shifter bracket Figure 16 15 Page
148. e FOR WARD 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 All Club Car vehicles operate at reduced speed in reverse 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 SCHEDULE See General Warnings Section 1 Page 1 1 A WARNING Service repairs and adjustments must be made per instructions in this maintenance and service manual NOTE If the vehicle is constantly subjected to heavy use or severe operating conditions the preventive main tenance procedures should be performed more often than recommended in the periodic service and lubrication schedules Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep the vehicle in optimum operating condition Page 10 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual PERIODIC MAINTENANCE Periodic Service Schedule ETA PERIODIC SERVICE SCHEDULE REGULAR INTERVAL Monthly service by owner or trained technician SERVICE Engine Check engine oil level change if necessary Properly dispose of used oil See Periodic Lubrication Schedule on page 10 4 Check engine cooling air intake clean if necessary Visually inspect the unshrouded area around engine exhaust for gra
149. e Governor Cable Installation and Adjustment Section 14 Page 14 6 Unitized Transaxle Service The unitized transaxle is extremely durable and should require very little service under normal operating con ditions The only service required is to maintain proper lubricant level See Periodic Lubrication Schedule Section 10 Page 10 4 Lubricant should be level with bottom of level indicator hole w SHIFTER ARM SHIFTER LEVER Figure 16 1 Shifter Positions Figure 16 2 Lubricant Level Tools Required For This Section Hydraulic floor jack or chain hoist 12 to 18 in straight edge Jack stands 2 one ton capacity Small ball peen hammer 10 oz Hydraulic press Plastic or rubber mallet Bench vise Ratchet wrench 3 8 in drive Standard slip joint pliers Torque wrench 3 8 in drive External snap ring pliers 070 in tip 3 8 in Socket 3 8 in drive External snap ring pliers 047 in tip 7 16 in Socket 3 8 in drive 90 Internal snap ring pliers 090 in tip 10 mm Combination wrench Feeler gauge 1 2 in Socket 3 8 in drive 16 in rolling head prybar 9 16 in Socket 3 8 in drive Small punch or scratch awl 5 8 in Socket 3 8 in drive 1 4 in diameter drift or metal rod 12 mm Socket 3 8 in drive Bearing puller wedge attachment Axle seal tool CCI P N 1012812 CCI P N 1014162 Internal snap ring pliers CCI P N 10 mm socket 3 8 in drive 1012560 13 mm combina
150. e bolts 6 attaching the fan housing as shown Figure 12 27 Page 12 26 9 Remove the remaining four bolts 10 attaching the fan housing as shown Figure 12 27 Page 12 26 then while opening the housing detach the spark plug wire grommet 4 from the housing Figure 12 29 Page 12 27 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 25 ELECTRICAL COMPONENTS Ignition Coil Ignition Coil Removal Continued 10 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 26 Figure 12 27 Fan Housing and Shroud Installation Figure 12 28 Coil Removal Ignition Coil Installation NOTE If a new ignition coil is being installed the spark plug cap gasket protector tube and grommet 3 must be removed from the old coil and installed on the new coil See steps 1 through 8 for pro cedures to remove and install these existing parts If the existing ignition coil will be remounted proceed to step 9 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 27 Remove the cap 2 from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire 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
151. e placed on the wrong side of the vehicle they will not follow the vehicle s profile 1 2 Align the holes in the lower portion of each front support 7 and 10 with the corresponding holes in the vehicle Insert two bolts 11 through each front support into the threaded holes in the vehicle The bolts are color coded with gold thread lock Only finger tighten the bolts at this time 1 3 Slide the covers 12 and 13 over the front supports The covers are marked DRIVER and PASS to identify them as going on the driver side or passenger side respectively Do not install the screws 14 yet 2 Insert the two rear canopy supports 3 into the openings on the top of the Structural Accessory Module SAM 3 Fromthe inside of the basket insert two bolts 6 through the basket wall and into each support The bolts are color coded with blue thread lock Finger tighten the bolts to avoid cross threading the threads in the supports See following CAUTION CAUTION Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support This could result in damage to the components 4 Position the canopy on top of the front and rear supports Ensure that the front supports are properly positioned between the molded tabs on the underside of the canopy and that the molded protrusions at the rear of the canopy extend into the top of the rear supports 5 Secure the canopy to the front supports with fou
152. e shoes are under pressure and can release suddenly when brake shoe retainers are removed 10 Grasp both brake shoes and pull them together with the springs out of the brake assembly as shown Figure 6 6 Page 6 4 Figure 6 5 Remove Shoe Retainer Clip Figure 6 6 Remove Brake Shoes 11 Remove adjuster wheel 1 with two washers 2 and 3 from the backing plate Figure 6 7 Page 6 4 4 Jpn d dA YN Figure 6 7 Remove Adjuster Wheel Figure 6 8 Lubricate Slide and Slide Plate Page 6 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning E BRAKE ASSEMBLY CLEANING See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 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 Lubricate the slide 1 and slide plate 2 with dry moly lubricant CCI P N 1012151 on both sides of the backing plate Figure 6 8 Page 6 4 After lubricating work the slide back and forth to ensure that it slides smoothly and easily Reinstall rubber boot onto backing plate A 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 pers
153. ecure a bearing puller CCI 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 Discard the bearings 3 Slide the bearing retainer 32 off of the output end of the shaft Figure 12 7 Page 12 5 m GE A ATTACHMENT LUAM Da PRESS RAMI TOOL Y wies Dee socket or pipe Support inner race of bearing Press on armature ATTACHMENT TOOL BEARING IS SECTIONED FOR CLARITY Figure 12 9 Bearing Removal Field Coil Removal 1 Remove the retaining nut from each field coil terminal and slide the insulator out of the slots in the hous ing Remove the four pole piece screws from the housing Remove the four pole pieces from inside the housing Remove the field coils from the inside of the housing Figure 12 10 Page 12 7 See following NOTE NOTE Do not remove the insulators or the field coils unless an electrical test indicates that it is necessary Figure 12 10 Page 12 7 See Test Procedure 8 Section 11 Page 11 20 Visual Inspection of Armature Obvious defects can be seen by examining the armature If an armature has frayed or charred insulation bro ken wires or thrown solder it is obvious without testing that it should be replaced Faults seen during the
154. ed If air filter housing is extremely dirty clean thoroughly Use only Club Car replacement air filters CCI P N 102558201 or equivalent The use of other air filters could result in engine damage If the air filter is too small 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 Figure 14 7 AirFilter Page 14 12 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Ki Choke and Air Intake System FUEL SYSTEM W 7 O x E KE D Oo O ER 8 Fuel and Vent Lines Figure 14 Page 14 13 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FUEL SYSTEM Fuel Filter FUEL FILTER See General Warnings Section 1 Page 1 1 GENERAL INFORMATION Fuel is supplied to the fuel pump and carburetor through flexible lines An in line filter is installed between the fuel tank and the fuel pump Figure 14 8 Page 14 13 The filter fuel lines and the fuel tank vent should be inspected periodically for leaks The fuel filter should be replaced when necessary but under no circumstance should the period of time between filter changes exceed two years or 200 hours FUEL FILTER 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
155. ed or melted elec trodes 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 A 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 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 Page 13 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FE290 ENGINE Cylinder Head E Spark Plug Installation NOTE Before installing the plug check the condition of the threa
156. edent Gasoline Golf Car Maintenance and Service Manual Page 17 1 TORQUE CONVERTER Drive Belt Troubleshooting Continued 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 7 Page 17 6 TORQUE CONVERTER TOOL KIT CCI P N 1014510 DRIVEN CLUTCH CAM PRESS TOOL CCI P N 101809101 H t i i DRIVE CLUTCH HUB PULLER ui IN Ce M y b CCI P N 1014497 C DRIVEN CLUTCH PULLER PLUG CCI P N 1014507 DRIVEN CLUTCH CAM PULLER CCI P N 1014508 DRIVE CLUTCH HOLDER TOOL CCI P N 1015524 DRIVE CLUTCH PULLER CCI P N 1014496 Figure 17 1 Torque Converter Tool Kit DRIVE BELT See General Warnings Section 1 Page 1 1 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 DRIVE BELT REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in Gener
157. el 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 Ib 1 9 N m Position the sensor and bracket on inside of crankcase and install two mounting screws Connect sensor wire 2 to cord connector 1 Figure 13 5 Page 13 6 Install screw 3 through wire clamp and into crankcase cover Tighten to 30 in Ib 3 4 N m 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 Clean the gasket surfaces on the crankcase cover to fit a new gasket during installation and inspect the oil seal for wear and damage Install crankcase cover Using HANDS ONLY seat cover completely against the crankcase If the cover will not seat the camshaft is not installed correctly Install and finger tighten evenly the eight cover mounting bolts Figure 13 6 Page 13 7 Tighten the cover mounting bolts in two steps First in the sequence shown tighten all eight bolts to approximately 130 in Ib 14 N m Then repeating the sequence tighten them to 250 in Ib 28 2 N m Figure 13 6 Page 13 7 Connect the yellow jumper wire 11 to the cord connector 12 Figure 13 3 Page 13 5 Page 13 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FE
158. elines Light Soiling A solution of 1096 liquid dish soap and warm water applied with a soft damp cloth is rec ommended 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 pud dle on affected area for approximately 30 minutes Rinse with a water dampened cloth to remove any remaining bleach concentration 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 1 BODY AND TRIM Front and Rear Body Repair 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 See General Warnings Section 1 Page 1 1 STRESS LINES OR STREAKS Repeatedly flexing the Surlyn 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
159. enger Vehicles 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 13 BODY AND TRIM Rear Body Four Passenger Vehicles TYPICAL 10 PLACES 6 PLACES 2 PLACES Or 4 PLACES Figure 4 10 Foot Deck Four Passenger Vehicles FOOT DECK Foot Deck Removal 3 Remove screws 8 and 11 securing the rear hip restraints 6 and remove the hip restraints from the vehicle Figure 4 9 Page 4 13 4 Remove the four bolts 2 securing the foot deck 1 to the vehicle frame Figure 4 10 Page 4 14 Foot Deck Installation 1 Install foot rest in reverse order of removal 2 Tighten bolts 2 to 71 in Ib 8 N m Figure 4 10 Page 4 14 Page 4 14 2005 Precedent Gasoline Golf Car Maintenance and Service Manual BODY AND TRIM TYPICAL 2 PLACES TYPICAL 2 PLACES M Ji m E AS d PI e Figure 4 11 Seats Four Passenger Vehicles REAR BODY COMPONENTS FOUR PASSENGER Rear Beauty Panel Removal 1 Remove seat support See Seat Support Removal on page 4 13 Remove screw 15 and remove shift handle 14 from vehicle a 560m Lift rear beauty panel from vehicle Rear Body Four Passenger Vehicles TYPICAL 2 PLACES Remove four screws 13 attaching the rear beauty panel 12 to the fuel bucket Figure 4 8 Page 4 11 Remove two screws 17 to remove shift cover 16 from rear beauty panel 12 2005 Precedent Gasoline Golf Car Maintenan
160. ent Gasoline Vehicle Accessory Wiring Diagram Optional Page 11 8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM HEADLIGHT ASSEMBLY www 16 GREEN 16 ORANGE 16 BLACK gig 16 ORANGE 18 ORANGE 16 BLACK 16 ORANGE 16 BLACKWHT Wiring Diagrams 12 BLACK w 14 YELLOW VOLTAGE LIMITER 16 BROWNIWHT 16 GREEN LIGHT SWITCH 16 RED 16 BLUE WHITE 16 WHITE 12 ORANGE 12 BLUE 16 YELLOW 16 BROWNMHITE 18 BLUEWHT 18 BLUEWHT N LL DIODE 18 BLUE WHT BRAKE LIGHT RELAY Figure 11 4 Precedent Gasoline Vehicle Accessory Wiring Diagram Optional 2005 Precedent Gasoline Golf Car Maintenance and Service Manual 9 PIN CONNECTOR CONNECTS TO MAIN HARNESS SEE FIGURES 11 1 AND 11 2 Page 11 9 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams 18 ORANGE 18 WHITEBLK SONIC WELD x 9 POSITION CONNECTOR CONNECTS TO MAIN HARNESS SEE FIGURES 11 1 AND 11 2 BBLUE OIL LIGH E
161. er 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 to16 ohms If the reading is not within limits replace the solenoid 4 Remove the 10 gauge white wire crimped with a 16 gauge red wire from the large post of the solenoid Do not allow the wires to touch the frame or other components of the vehicle Figure 11 15 Page 11 19 10 GAUGE WHITE WIRE ASSEMBLY 16 GAUGE N RED WIRE ASSEMBLY Figure 11 15 Solenoid Wire Removal 5 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 16 Page 11 19 SOLENOID SOLENOID WAVETEK Figure 11 16 Solenoid Continuity Test Figure 11 17 Solenoid Ground Test 6 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m 7 Place the Forward Reverse handle in NEUTRAL and place the neutral lockout cam in the MAINTE NANCE 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 8 With the Forward Reverse handle still in NEUTRAL and the neutral lockout cam in the MAINTENANCE position
162. erclockwise three or four revolutions while gently pulling it off the wire Figure 11 28 Page 11 27 Using a multimeter set to 200 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 29 Page 11 28 If no continuity the cap has failed and must be replaced Proceed to the next step with the spark plug cap still removed Figure 11 29 Spark Plug Cap Test 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 30 Page 11 28 If the resistance is between 6 0k 11 0k ohms the secondary coil is within acceptable limits If the resistance is not between 6 0 k 11 0k ohms bench test the ignition coil See Test Procedure 15B Ignition Coil Bench Test on page 11 29 6 If the preceding procedures 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 Page 11 28 Figure 11 30 Secondary Coil Test without Cap 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures
163. ery Frozen batteries can explode Page 3 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual GENERAL INFORMATION CAUTION Batteries in a low state of charge will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED OFF SEASON 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 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 3 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 Battery should be clean and free of corrosion Wash top and terminals of battery with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of
164. ess panel on the vehicle 4 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 5 Push the starter generator down so it is at the lowest point of its adjustment travel With the starter gen erator 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 6 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 See following NOTE NOTE As an alternative to using a pry bar a belt tensioning tool is available from Club Car CCI P N 102570401 7 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 ft lb 101 7 N m or 45 ft lb 61 N m for an existing belt Figure 12 14 Page 12 11 8 While maintaining the tension tighten the adjustment nut 12 to 12 ft 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 A CAUTION Remove pry bar before starting engine 9 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1
165. evel 10 Install a new or cleaned spark plug gapped to 0 027 0 031 inch 0 686 0 787 mm and connect plug wire to plug 11 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 12 Adjust the engine RPM setting See Engine RPM Adjustment Section 14 Page 14 9 13 If initial checks indicate the engine is functional place the neutral lockout cam in OPERATE position 14 Test drive vehicle to ensure all systems are functional and correctly adjusted Page 13 10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FE290 ENGINE TORQUE SPECIFICATIONS Engine Installation ITEM SIZE LIMITS Oylinder head bolts M8 220 in Ib 24 N m Valve clearance adjustment nuts M5 90 in Ib 10 N m Connecting rod bolts coat threads with engine oil Mz 180 in Ib 20 N m Flywheel retaining nut M16 63 ft Ib 86 N m Crankcase cover to block bolts M8 250 in Ib 28 3 N m Starter Generator bracket to block bolts ME 00 nib 2S Nem Oil drain plug M14 20 ft lb 27 1 N m Fan housing screws M6 90 in Ib 10 N m Fan shroud screws M6 25 in Ib 2 8 N m Bolts marked with 4 e Sb n when used with nuts M5 30 in lb 3 4 N m ADJUSTMENTS AND SETTINGS ITEM Spark plug gap standard LIMITS 0 027 to 0 031 in 0 69 to 0 79
166. fler as a positioning guide for the clamp and bracket Install the hex nuts 10 and lock washers 11 Tighten the nuts fingertight Install the hex head cap screw 7 lock washer 8 and flat washer 9 Tighten the cap screw fingertight Tighten the hex nuts 10 to 11 ft Ib 14 9 N m Tighten the hex cap screw 7 to 14 ft Ib 18 9 N m Tighten the muffler clamp 6 to 40 in Ib 4 5 N m Noc o 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 15 1 EXHAUST SYSTEM Muffler Muffler Installation Continued TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 15 1 Exhaust System 8 Connect the spark plug wire 9 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 10 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAIN TENANCE position Start the engine and check for exhaust leaks and proper engine operation See fol lowing DANGER A DANGER Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 11 After checking the exhaust and engine for proper operation return the neutral lockout cam to the OPER ATE position Page 15 2 2005 Precedent Gasoline Golf Car Maintenance and Servi
167. from the fuse holder See Fuse Removal Section 12 Page 12 15 gw d Ze Ju Connect the probes of a multimeter set to 200 ohms to the fuse terminals The reading should be con tinuity If there is no continuity determine and repair the cause of the fuse failure Replace the fuse with a properly rated new one Figure 11 8 Fuse TEST PROCEDURE 3 GROUND CABLES See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Check the starter generator ground cable 2 1 Setthe 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 9 Page 11 16 The reading should be continuity If there is no continuity clean and tighten cable connections If the connections are good 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 10 Page 11 16 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 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 15 TROUBLESHOOTIN
168. fter cable rod end to the shifter arm Figure 16 48 Page 16 20 24 Attach the ground wire to the mounting screw on the oil filler tube mounting bracket and tighten to 50 in Ib b 7 N m Figure 16 49 Page 16 20 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 19 UNITIZED TRANSAXLE Unitized Transaxle Installation Figure 16 48 Connect Shifter Cable Figure 16 49 Engine Ground Wire 25 Insert the accelerator cable through the hole in the frame and connect the accelerator cable to the pedal group as described in GCOR Section 5 Page 5 3 Position the accelerator cable in the mounting brack ets in the vehicle base and adjust mounting nuts 1 to remove all slack in the wire portion of the cable Tighten mounting nuts to 23 in Ib 2 6 N m Figure 16 50 Page 16 20 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 20 Figure 16 50 Connect Cable Figure 16 51 Connect Fuel Line 27 Connectthe impulse line to the fuel pump and secure it with the hose clamp Figure 16 52 Page 16 21 28 Connect air intake hose to carburetor and secure hose clamp Figure 16 53 Page 16 21 Page 16 20 2005 Precedent Gasoline Golf Car Maintenance and Service Manual UNITIZED TRANSAXLE Unitized Transaxle Installation 16 IMPULSE LINE Figure 16 52 Impulse Line Figure 16 53 Air Intake Hose 29 Connect carburetor vent tube
169. g is incorrect replace the limit switch Figure 11 18 Page 11 20 LEVER UP LEVER PRESSED NEGATIVE NEGATIVE POSITIVE PROBE Ll E Tester light is Tester light is out gt on Meter reads Meter read 1 Le i approximately zero 737 ohms PN N Figure 11 18 Test Neutral Lockout Switch 4 Check to be sure the lobes on the cam are pressing the neutral lockout limit switch 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 snaps fully back into place If the cam lobes still do not activate the limit switch replace the cam TEST PROCEDURE 8 STARTER GENERATOR STARTER FUNCTION See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Ensure that wires are connected correctly and are tight If they are not rewire or tighten as necessary Page 11 20 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 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 paint to ensure a good ground While holding the black
170. 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 apply ing 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 Page 12 26 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Ignition Coil 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 Ib 3 4 N m Figure 12 30 Page 12 27 9 5 SZ 0 012 Inch 0 304 mm Figure 12 29 Coil Installation Figure 12 30 Set Air Gap 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
171. gener eege ri Rear Body Components Four Passenger sssesssssssssseeeeeeeeeeee nennen nennen nnns Canopy Two Passenger eene nnns entres en nnns nnn RR RR nn ra en rnn rene nn entren nennen Two Passenger Canopy Removal eene nennen nennen nennen nnns enne Two Passenger Canopy Installation sssssssseseeen enne enne nnne nnns Canopy Four Passenger enne nen entere RR Ran RR nnn etn rns entres nnns entren rennen Four Passenger Canopy Removal sse eene nnne enne nennen nennen nnne nnns Four Passenger Canopy Installation sess nennen nnns SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP Debris Shields A eege E e eek Qe EE BER ates Brake Return Spring EE Pawl ASsembly i ttti utum Accelerator Return Spring sessir iradia eee iiaa nc Pedal Group Installation 45 cet ooi gear ene rtt Gi i lali SECTION 6 WHEEL BRAKE ASSEMBLIES General InfOrtratiOnt lt A eae ad eda e Brake Shoe Removal NN Brake Assembly Cleaning cccooocccnnncccnooccnononnncnncncnnnanannnn crac cra nennen nnne nn nr en nnne ennt ennt eennn senes Brake Shoe Installation i35 6r e Ea SEEN EE en RE dea praua ilo eda eh vend Brake Cable Equalizer Adjustment sssssssssssseeeeeeenenen nennen nennen nnne nnns nnne Brake Cluster Removal and Installation ooonoocccccnoooccccccnonannnconannncnononnnnnnn conan nnnnnnnnnnnn ccoo nn nnnnnnnns Brake ClusteriInstallatio
172. gine 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 See Hydrometer Test on page 11 12 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 Section 12 Page 12 12 VOLTAGE REGULATOR BATTERY NH SOLENOID Figure 11 21 Voltage Regulator Test TEST PROCEDURE 12 DISCONNECTED KILL WIRE See General Warnings Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 23 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 12 Disconnected Kill Wire Continued 2 Disconnect the engine kill white black wire at the bullet connector located next to the RPM limiter Figure 11 22 Page 11 24 3 With the neutral lockout cam in the MAINTENANCE position turn the key switch to the ON position In a well ventilated area depress the accelerator to start the engine 4 f the engine begins to run test the engine kill circuit for a shorted wire or other failed components in the
173. gure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 3 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and place the neutral lockout cam in the MAINTENANCE position 4 Connect a tachometer CCI 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 2950 30 RPM 6 To reduce RPM adjust the two lock nuts 12 to move the cable housing toward the rear of the vehicle until the specified RPM is reached Figure 14 3 Page 14 7 To increase RPM adjust the two lock nuts 12 to move the cable housing forward until the specified RPM is reached 7 Be sure both lock nuts are locked against the bracket 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 pre vent proper RPM adjustment Check them for excessive wear See Section 17 Torque Converter CHOKE AND AIR INTAKE SYSTEM See General Warnings Section 1 Page 1 1 GENERAL INFORMATION The choke and air intake system is a simple mechanism requiring very little or no maintenance The system consists of a
174. hanging a 12 volt battery in any Club Car gasoline powered vehicle the same size battery with adequate amperage ratings should be used as a replacement Club Car recommends a group 70 side post battery CCI 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 The group 70 clas sification 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 5cm D x 18 4 cm H It is important to use the proper size to ensure that the battery clamp will fit correctly Page 12 28 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Battery Testing the Battery See Test Procedure 1 Section 11 Page 11 12 Preventive Maintenance To keep the battery in good operating condition follow these steps on a regular basis 1 Any corrosion build up on or around the battery should be removed immediately Post connections should be clean and tight Any frayed or worn wires should be replaced After all cables have been con nected and properly tightened to 20 ft Ib 27 1 N m coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to prevent future corrosion 2 The battery should be kept clean and dry to minimize 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
175. he dust cap 12 using a rubber mallet and tapping lightly around the edge of the cap Repeat the procedure for the opposite wheel Install wheels and finger tighten lug nuts Lower the vehicle and finish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 N m Figure 7 20 Front Wheel Hub Page 7 18 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SECTION 8 WHEELS AND TIRES A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care e Keep tires properly inflated See Section 2 Vehicle Specifications Keep lug nuts properly tightened Keep the front end aligned and adjusted A WARNING Tires affect vehicle handling When selecting a replacement tire use only original equipment or comparable tires WHEELS See General Warnings Section 1 Page 1 1 WHEEL REMOVAL 1 Slightly loosen the lug nuts on the wheel to be removed 2 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 Section 1 Page 1 1 3 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 n
176. he frame crossmember forward of the spring mounting tabs Lower the vehi cle to let the jack stands support the vehicle Figure 9 2 Page 9 3 See following WARNING 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 9 1 Leaf Springs Two Passenger Vehicles 9 REAR SUSPENSION BRAKE CABLE HANGER MOUNTING TYPICAL ON EACH SIDE OF VEHICLE C j DA V A PN A emi MN uo eT D 7 A E v 3 YOO Figure 9 1 Rear Suspension Assembly and Mounting Two Passenger Vehicles 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 9 2 REAR SUSPENSION Leaf Springs Two Passenger Vehicles TEN Leaf Spring Removal Two Passenger Vehicles Continued A WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 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 2 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 3 Remove the tire and wheel assembly on the side from wh
177. hicle 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 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 1 1 EN SAFETY General Warnings A WARNING Only trained technicians should service or repair the vehicle 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 Prior to leaving the vehicle unattended or servicing the vehicle turn the key switch OFF remove the key and place the Forward Reverse handle in the NEUTRAL position Chock the wheels when servicing the vehicle To avoid unintentionally starting the vehicle Disconnect battery cables negative cable first Figure 1 1 Page 1 3 Disconnect the spark plug wire from the spark plug 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 Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Use
178. ich the spring is to be removed 4 Remove the bow tie locking pin 1 and the clevis pin 2 at the brake lever and brake cable connection and remove cable end 3 from the brake lever Figure 9 3 Page 9 3 Detach the brake cable from the shock mount bracket 4 5 Remove the nut 5 cup washer 9 and rubber bushings 10 from the lower mounting stem of the shock absorber Figure 9 1 Page 9 2 6 Remove the nuts 13 and the U bolt 11 securing the spring to the transaxle Remove the shock mount bracket 15 and the U bolt 7 Remove the bolt 17 and nut 2 attaching the rear of the spring to the shackle 1 8 Remove the nut 2 and bolt 17 attaching the front of the spring to the vehicle frame and remove the spring 9 Inspect the bushings 4 and sleeves 3 in the spring eyes and replace them if they are worn or dam aged AS SEEN FROM DRIVER SIDE OF VEHICLE REAR OF VEHICLE Figure 9 2 Support Vehicle on Jack Stands Figure 9 3 Disconnect Brake Cable 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 9 3 EN REAR SUSPENSION Leaf Springs Four Passenger Vehicles LEAF SPRING INSTALLATION TWO PASSENGER VEHICLES 1 To install the springs reverse the removal procedure See following CAUTION A 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
179. igure 4 8 Page 4 11 Wheel Liner Installation 1 Position liners 8 and 9 on vehicle and secure with bolts 10 Bolts 10 thread into J clips 11 attached to the inner frame rail Tighten bolts to 4 4 ft Ib 6 N m REAR BODY FOUR PASSENGER VEHICLES See General Warnings Section 1 Page 1 1 SEAT BACKS Seat Back Removal Remove screws 9 or 13 securing seat back 8 or 11 to seat support and remove the seat back Figure 4 11 Page 4 15 Page 4 12 2005 Precedent Gasoline Golf Car Maintenance and Service Manual BODY AND TRIM Rear Body Four Passenger Vehicles Seat Back Installation Secure seat back 8 or 11 to seat support with screws 9 or 13 Tighten screws to 71 in Ib 8 N m Figure 4 11 Page 4 15 SEAT SUPPORT Seat Support Removal 1 Remove screws 8 and 11 securing the rear hip restraints 6 and remove the hip restraints from the vehicle Figure 4 9 Page 4 13 2 Remove the screws 5 and bolts 4 from the seat support 3 and remove the seat support from the vehi cle Seat Support Installation 1 Install in the reverse order of removal 2 Tighten bolts 4 to 53 in Ib 6 N m Tighten screws 5 to 44 in Ib 5 N m Tighten bolts 8 and 11 to 124 in Ib 14 N m Figure 4 9 Page 4 13 TYPICAL 10 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Ro Figure 4 9 Seat Supports Four Pass
180. ine Golf Car Maintenance and Service Manual FUEL SYSTEM Fuel Pump FUEL PUMP See General Warnings Section 1 Page 1 1 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 filter is not clogged To clean the air vent the fuel pump must be disassembled FUEL PUMP 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 2 Access the engine compartment 3 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 4 Turn fuel shut off valve on top of the fuel tank to the closed OFF position Figure 14 12 Page 14 21 5 Remove hardware 11 attaching the fuel pump 8 and lift the fuel pump out of the engine compartment Figure 14 8 Page 14 13 6 Remove the clamp 6 and impulse line 12 from fuel pump 7 Disconnect the fuel lines 10 and 13 from the pump and plug them to prevent fuel leakage See follow ing WARNING A WARNING Carefully drain any fuel remaining in the pump into an approved container Add drained fuel back into fuel tank or
181. ine Golf Car Maintenance and Service Manual Page 14 17 FUEL SYSTEM Fuel Tank FUEL TANK See General Warnings Section 1 Page 1 1 GENERAL INFORMATION The vehicle is equipped with a high impact plastic 6 7 gallon 25 4 liter fuel tank A WARNING f 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 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAIN TENANCE position Turn fuel shut off valve to the closed OFF position and run the engine until fuel remaining in the car buretor fuel pump and fuel lines is used up and the engine stalls Figure 14 12 Page 14 21 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 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Return the neutral lockout cam to the OPERATE position Loosen but do not remove the carburetor drain screw 11 and drain fuel remaining in the carburetor bowl into an approved container Figure 14 2 Page 14 4 Retighten carburetor drain screw Using a siphon with a suction device siphon all fuel out of the tank and into an approved con
182. ings Section 1 Page 1 1 STEERING WHEEL REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 If scorecard holder is secured to steering wheel with screws remove the two mounting screws 8 Figure 7 3 Page 7 3 Remove the scorecard holder plate 1 Match mark the steering wheel 7 and steering column shaft 9 so when the steering wheel is removed it can be placed back in exactly the same position on steering column shaft Loosen the steering wheel bolt 6 and back it off approximately 1 4 inch 6 mm Do not remove the bolt If it is difficult to remove the steering wheel use the steering wheel puller CCI P N 102061201 to remove steering wheel 6 1 Place the puller anvil 4 through the top opening of the steering wheel Figure 7 1 Page 7 2 6 2 Insert the anvil feet through the two slots in the base plate marked B 5 as shown Figure 7 1 Page 7 2 6 3 Rotate the anvil screw 6 clockwise until the base plate contacts the bottom of the steering wheel where it attaches to the steering column Figure 7 2 Page 7 2 6 4 Using a 1 2 inch drive air impact wrench tighten the anvil screw 6 until the steering wheel breaks free from the steering shaft 6 5 Remove the steering wheel puller 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7 1 7 STEERING AND FRONT SUSPENSION Steering Co
183. ith experience repairing Surlyn bodies Page 4 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual BODY AND TRIM Front and Rear Body Repair o TYPICAL 4 PLACES 5 PLACES TYPICAL 5 PLACES Figure 4 1 Front Body 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 3 BODY AND TRIM Front Body FRONT BODY See General Warnings Section 1 Page 1 1 FRONT BODY REMOVAL 1 Remove the four screws 2 and pull the brow cap 1 from the brow and fascia assembly 4 Figure 4 1 Page 4 3 Pullthe front beauty panel 3 up and away from the brow and fascia assembly 4 disengaging the snap tabs Ifthe vehicle is equipped with a canopy loosen the canopy support cover then loosen but do not remove the front canopy support bolts If there is no canopy remove the non canopy cover Remove the five screws 8 and lift the brow and fascia assembly 4 from the front underbody 5 Remove the five screws 7 to separate the front fascia 6 from the brow 5 FRONT BODY INSTALLATION Install fascia 6 to brow 5 with five screws 7 Tighten screws to 3 3 ft Ib 4 5 N m Install brow and fascia assembly 4 to front underbody with five screws 8 Tighten screws to 1 8 ft Ib 2 5 N m Install front beauty panel 3 over brow 5 Tabs on the forward edge of the front beauty panel should fit into slots between the fascia and the brow Position br
184. k marker This should be written in a loca tion that will be visible when the carburetor is installed on the engine Install the carburetor on the engine Figure 14 1 Page 14 3 12 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 3 12 2 Install the intake pipe gasket 16 check for proper orientation and intake pipe 17 12 3 Install the carburetor retaining nuts 19 and tighten them to 50 in Ib 5 7 N m Connect fuel supply line 26 and tighten screw clamp to 9 in Ib 1 0 N m if equipped Figure 14 1 Page 14 3 Install carburetor vent line 14 and clamp 13 Install the governor cable Install the governor guard 5 flat washer and nylon lock nut Tighten to 30 in Ib 3 4 N m Install the intake hose 23 and secure with hose clamp NOTE Make sure the intake hose is not twisted during installation 18 19 20 Turn fuel shut off valve on top of fuel tank to the ON position Figure 14 13 Page 14 22 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Test drive the vehicle 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 5 FUEL SYSTEM Engine Control Linkage ENGINE C
185. kcase 13 STARTER i 4 GENERATOR Figure 13 3 Oil Level Sensor Wire Figure 13 4 Crankcase Cover CRANKCASE COVER REMOVAL 1 Remove yellow jumper wire 11 from cord connector 12 Figure 13 3 Page 13 5 2 Remove nuts and clamps at two ended bolts 1 and 2 Figure 13 4 Page 13 5 3 Remove eight bolts 3 and remove the crankcase cover 4 Figure 13 4 Page 13 5 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 4 Page 13 5 4 Remove the crankcase cover gasket completely It may stick to the flanged surface of the crankcase OIL LEVEL SENSOR Testing the Oil Level Sensor See Test Procedure 21 Section 11 Page 11 32 Oil Level Sensor Removal If not already removed remove crankcase cover See Crankcase Cover Removal on page 13 5 Disconnect the oil level sensor wire 2 from the cord connector 1 Figure 13 5 Page 13 6 Remove the screw 3 from the wire clamp 4 Zo m Remove the two mounting screws from the inside of the crankcase cover and remove the oil level sensor and bracket 5 f necessary remove the three screws 7 that hold the sensor to the bracket 5 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 13 5 FE290 ENGINE Crankcase TYPICAL 3 Figure 13 5 Oil Level Sensor Cil Level Sensor Installation 1 If the oil lev
186. l Gauge Voltage Test 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 35 SECTION 12 ELECTRICAL COMPONENTS A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 STARTER GENERATOR See General Warnings Section 1 Page 1 1 Testing the Starter Generator See Test Procedure 8 Starter Generator Starter Function on page 11 20 and Test Procedure 10 Starter Generator Generator Function on page 11 22 Starter Generator Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Disconnect spark plug wire from the spark plug See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 3 Remove the access panel on the vehicle TO Figure 12 1 Starter Generator Mounting 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 1 ELECTRICAL COMPONENTS Starter Generator Starter Generator Removal Continued 4 Mark and disconnect the wires from the starter generator 1 Loosen the two pivot nuts 7 and bolts 5 Figure 12 1 Page 12 1 5 Remove the mounting adjustment nut 12 washer 9 and bolt 11 Lower the starter generator and remove the belt 4 from the pulley 10 6 Support the starter generator so that when the pivot bolts are removed the starter generator will
187. le in position Figure 5 9 Page 5 7 9 Adjust engine RPM See Engine RPM Adjustment Section 14 Page 14 9 10 Place floor cover plate 7 over the floor opening Figure 5 2 Page 5 2 11 Reinstall the floor mat 2 over the pedal group Make sure tabs on floor mat sides are beneath the sill 3 Tighten screws 1 to 53 in Ib 6 N m Figure 5 1 Page 5 1 SY LA KEN ACCELERATOR CABLE ee 2 N A Ee Figure 5 9 Accelerator Cable Adjustments 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 5 7 SECTION 6 WHEEL BRAKE ASSEMBLIES A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 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 Precedent Golf Cars are equipped with self adjusting mechanically expanding shoe drum brakes on each rear wheel BRAKE SHOE REMOVAL See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 1 Disconnect
188. lenoid failed Test Procedure 6 Solenoid on page 11 18 GCOR failed Test Procedure 5A Accelerator Pedal Limit Switch on page 11 17 Key switch failed Test Procedure 4 Key Switch Starter Circuit on page 11 17 Troubleshooting Guide continued on next page 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 11 3 EB TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM Starter fails to operate continued POSSIBLE CAUSES Neutral lockout limit switch failed Loose or broken wire in starter generator circuit REFER TO Test Procedure 7 Neutral Lockout Limit Switch on page 11 20 Starter Generator Section 12 Page 12 1 Cylinder and or crankcase flooded with fuel Section 14 Fuel System Starter Generator does not charge battery Transmission does not engage or disengage smoothly Loose or broken wire in starter generator circuit Test Procedure 10 Starter Generator Generator Function on page 11 22 Generator field coil is shorted Test Procedure 10 Starter Generator Generator Function on page 11 22 Brushes are worn or commutator is dirty Starter Generator Section 12 Page 12 1 Starter generator belt is loose or slipping Belt Tension Adjustment Section 12 Page 12 11 Voltage regulator failed Test Procedure 11 Voltage Regulator on page 11 23
189. llatiOon n eee toe c tee ee eet SE toe o e eo ea epe edes ee eo Mate Euel EIness Peter APRS EE E F el Sh t Off MalVe niet eere ose bt to ede eb esee tee tle to tee deed Ae ed SECTION 15 EXHAUST SYSTEM General Information e i Muffler MoitlerRerteoval CERES EE UTILE Muffler InstallatiOri EE Page viii 2005 Precedent Gasoline Golf Car Maintenance and Service Manual 15 1 15 1 15 1 15 1 SECTION 16 UNITIZED TRANSAXLE General Information ne etd p m d enp OPEP Qu E ees 16 1 E ubriCatior s oda da SoS LL Le E 16 3 Axle Sliaft i niai a 16 3 Axle Shaft and Oil Seal Removal sse ennt nennen nennen 16 3 Axle Bearing red epa tete i epi ed nd e TO eee iota 16 4 Axle Shatt Installation gt o rie ettet ibd b cis ven itte ie dee td 16 6 Unitized Transaxle Removal sse eene enne nnne nnns nn nnn nennt nnne nnns 16 7 Unitized Transaxle Installation sesssseeeeeneeneennnnneennem menn nnne nenne nennen 16 15 Forward Reverse Shifter Cable AAA 16 22 Forward Reverse Shifter Cable Removal sse nnne nnne 16 22 Forward Reverse Shifter Cable Installation sesssssseseeeeeeenneenen eene 16 22 Forward Reverse Shifter Cable Adjustment sessssssssssssseeeeeeeen nennen nennen 16 24 SECTION 17 TORQUE CONVERTER General Informatiol 1 2 Eee ate ER ee Comte ce D ete rette 17 1 DOUE ed As 17 1 Drive Belica a A
190. llowing WARNING A 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 See General Warnings Section 1 Page 1 1 Also see DANGER on page 12 28 1 Charge the battery using an automotive type 12 volt battery charger Follow all warnings and procedures supplied by the battery charger manufacturer Page 12 30 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Battery 2 Attach the positive charger cable to the positive battery post 3 Attach the negative charger cable to the negative battery post 4 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 A 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 DC leads
191. ltage Regulator on page 11 23 If the voltage does not rise a tear down inspection of the starter generator will be necessary See Starter Generator Removal Section 12 Page 12 1 5 Connect the yellow wire to the DF terminal on the starter generator Page 11 22 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 11 VOLTAGE REGULATOR See General Warnings Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Ensure that the wires are connected correctly and are tight If they are not rewire or tighten as necessary 3 Check the engine RPM setting to ensure that it is correctly adjusted See Engine RPM Adjustment Section 14 Page 14 9 4 With the battery in good condition and fully charged run the engine for several minutes to bring the volt age regulator to operating temperature 5 Turn the key switch to OFF 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 and white wires crimped together from the voltage regulator attached Place the black probe on the negative GC battery post Figure 11 21 Page 11 23 Turn the key switch to the ON position Press the accelerator to start the en
192. lumn Steering Wheel Removal Continued 7 Remove the steering wheel bolt 6 and the steering wheel 7 from the steering column 9 Figure 7 3 Page 7 3 SCORECARD HOLDER MAY BE DIFFERENT THAN THAT SHOWN Figure 7 1 Steering Wheel Puller 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 before installing the steering wheel 1 Install the steering wheel 7 on the steering column shaft 9 Be sure to align the match marks placed on the wheel and steering column in step 4 above Figure 7 3 Page 7 3 2 Install the steering wheel bolt 6 and tighten to 13 ft Ib 17 6 N m 3 Install the scorecard plate 1 4 If required install the plate mounting screws 8 Tighten screws to 16 in Ib 1 8 N m STEERING COLUMN See General Warnings Section 1 Page 1 1 STEERING COLUMN REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the steering wheel as previously instructed 3 Remove the dash insert instrument panel dash assembly and front bumper See Section 4 Body and Trim Page 7 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Steering Column STEERING AND FRONT SUSPENSION APPEARANCE OF SCORECARD HOLDER MAY BE D
193. mit switch is located on the Forward Reverse shifter red white and orange wires are connected to it 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 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 Ifthe 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 the limit switch See Reverse Buzzer Limit Switch Removal Section 12 Page 12 19 TEST PROCEDURE 20 REVERSE BUZZER See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 Remove the instrument panel See Key Switch Removal Section 12 Page 12 13 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 Diagrams on page 11 6 If the buzzer will not function when properly wired replace the buzzer See Reverse Warning Buzzer
194. mm Ignition coil air gap standard 0 012 in 0 304 mm Oil pressure min at fast idle speed 45 5 psi 314 kPa Oil filter bypass valve opening pressure 11 4 to 17 0 psi 78 to 118 kPa Compression pressure min Crankcase vacuum min at governed speed 156 psi 1076 kPa 1 18 in 30 mmHg Oylinder head gasket surface flatness max 0 002 in 0 05 mm Valve clearance exhaust intake when engine is cold 0 005 in 0 127 mm Engine RPM 2950 30 RPM 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 13 11 SECTION 14 FUEL SYSTEM A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 GENERAL INFORMATION The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment The car buretor atomizes the fuel mixes it with air and feeds the combustible mixture into the cylinder CARBURETOR See General Warnings Section 1 Page 1 1 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 Cleaning Inspection and Repair Section 13 Page 13 2 Air filter element See Air Filter on page 14 11 Fuel filter See Fuel Filter on page 14 14 Choke and air intake system f
195. mp 15 should be used at the carburetor FUEL SHUT OFF VALVE See General Warnings Section 1 Page 1 1 The fuel shut off valve is located on top of the fuel tank The fuel shut off valve should always be turned to the closed OFF position during vehicle storage towing or trailering Figure 14 12 Page 14 21 Unless the engine will be run as part of a procedure the fuel shut off valve should also be closed OFF before perform ing maintenance or service procedures CLOSED OFF POSITION SELECTOR IS ALIGNED WITH OFF MARKINGS ON THE SIDES OF VALVE VIEWED FROM SELECTOR SIDE OF VALVE Figure 14 12 Closed Fuel Shut off Valve Position Fully Open Position The valve s open position differs from standard valve configurations For the valve to be fully open it must be turned approximately 120 from the closed OFF position until it cannot be turned any further Figure 14 13 Page 14 22 If the valve becomes partially closed Figure 14 14 Page 14 22 the engine will not run properly due to fuel starvation 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 21 FUEL SYSTEM Fuel Shut Off Valve PARTIALLY CLOSED FULL OPEN ON POSITION POSITION VIEWED FROM SELECTOR SIDE OF VALVE VIEWED FROM SELECTOR SIDE OF VALVE Figure 14 13 Open Fuel Shut off Valve Position Figure 14 14 Incorrect Fuel Shut off Valve Position Page 14 22 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SECTION
196. mper cables GROUND CABLES See General Warnings Section 1 Page 1 1 Testing the Ground Cables See Test Procedure 3 Section 11 Page 11 15 Page 12 32 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SECTION 13 FE290 ENGINE A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 GENERAL INFORMATION See General Warnings Section 1 Page 1 1 All Club Car gasoline vehicles are powered by 4 cycle overhead valve single cylinder air cooled engines 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 compo nent 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 FE290 engine For complete instruction on engine disassembly repair rebuilding and reassembly see the Engines and Drivetrain Components Repair and Rebuild Manual CCI P N 102396501 BEFORE SERVICING Carefully read the applicable information and instructions before beginning engine service Diagrams DAN GER WARNING CAUTION and NOTE statements and detailed descriptions have been included wherever necessary Anyone attempting engine service should ha
197. n 3 2 ica ida e de ct e dida di nda eno geg Se Brake Cable Removal and Installation esses nnne enne SECTION 7 STEERING AND FRONT SUSPENSION General Information EE Page iv 2005 Precedent Gasoline Golf Car Maintenance and Service Manual 5 1 5 1 5 3 5 3 Steering Wheel eee te pt e ER e b ek eicit be i pe bn EE eee x 7 1 Steering Wheel Removal A 7 1 Steering Wheel Installation sseesssesseseseseseeseeeennenen nnne nnne nnn enne en nnns nennt rns 7 2 Steering Column sse RARA RR narrar 7 2 Steering Column REMOVAL A 7 2 Steering Column Installation ssssssssssesssseeseeeeeneeen nennen nnne nnne nnns nnns nennen nnns 7 4 Racksand PIONERA Ee EU 7 4 Rack and Pinion Removal 2 cente teet tiara 7 4 Rack and Pinion Disassembly kk 7 5 Rack and PinionrAssernibly ascii tit teo p a aee tot tenue ht eg dev adhe eite dE e 7 8 Rack and Pinion Installation 7 9 Front SUSPENSION EE 7 10 Biet el 7 10 Wheel Alignment EE 7 10 Front Suspension Components kk 7 12 Tie Rod End Removal cool iodo TE e IR I E T ir acorde 7 12 Tie Rod Installation etta det eet ee Lori eoe ee teet aa 7 12 Leaf Spring Removal s ne n NRI AS Edu i one T de dns 7 13 Reie A UE EE 7 13 Kingpin and Steering Spindle Removal sssssssessseeeeeeneeeeeneen ennemi 7 13 Kingpin and Steering Spindle Installation 7 13 Control Arm Removal ooooocccccnnocccccnno
198. n place with four screws 13 Tighten screws to 3 7 ft Ib 5 N m Figure 4 8 Page 4 11 2 Position the shift cover 16 on the front of beauty panel 12 and secure with two screws 17 Tighten screws to 22 in lb 2 5 N m 3 Position handle 14 on shift mechanism Secure handle in place with screw 15 Tighten screw to 14 in Ib 1 6 N m 4 Position canopy support brackets 1 and 2 on vehicle and secure each with one screw 3 Tighten screws to 53 in Ib 6 N m Access Panel Access panel 6 is secured to the rear underbody 4 with two expanding screws 7 Figure 4 8 Page 4 11 When replacing the panel tighten screws 7 enough to hold the panel in place Rear Underbody Removal 1 Remove four screws 5 attaching the rear underbody 4 to vehicle Figure 4 8 Page 4 11 2 Remove two screws 18 and washers 23 that attach the underbogy to the two liners 8 and 9 3 Liftthe rear edge of the rear underbody 4 until the front portion slides out from beneath the front under body Remove the rear underbody from the vehicle Rear Underbody Installation 1 Install rear underbody 4 on the vehicle Figure 4 8 Page 4 11 Install two washers 23 and screws 18 to secure the underbody to the two wheel liners 8 and 9 and install four screws 5 to secure the underbody to the vehicle Tighten screws 5 and 18 to 3 7 ft Ib 5 N m Wheel Liner Removal 1 Remove bolts 10 to release liners 8 and 9 from vehicle F
199. n to finger tight Figure 12 13 Page 12 11 Install the belt 3 then tighten the mounting bolts See Belt Tension Adjustment on page 12 11 Connect the yellow wire from main harness to the DF terminal on the starter generator Install a flat washer lock washer and nut onto the terminal Tighten the nut to 31 in Ib 3 5 N m Install the white wire from the solenoid to the F2 terminal on the starter generator Install the 10 gauge black wire from the main harness to the A2 terminal on the starter generator Install a flat washer lock washer and nut onto each terminal and tighten the nut to 48 in Ib 5 4 N m Adjust belt tension See Belt Tension Adjustment on page 12 11 Page 12 10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Starter Generator TYPICAL 2 PLACES Figure 12 13 Starter Generator Installation Figure 12 14 Belt Tension Gauge Belt Tension Adjustment Belt tension should be checked periodically If the belt slips when starter generator motor operates adjust belt to correct tension 1 If not already disconnected disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 If not already disconnected disconnect spark plug wire from the spark plug See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 3 Remove the acc
200. nce on the the brake system is complete lower the vehicle onto the floor With the brake pedal in the full up or at rest position adjust the turnbuckle until the proper brake tension is achieved The turnbuckle is properly adjusted when the distance from the top of the equalizer to the upper flange sur face is 2 inches 1 16 inch 51 mm x 1 6 mm 2 Ensure that both threaded rods are visible in the witness holes of the turnbuckle before the jam nuts are tightened Figure 6 18 Page 6 10 3 Tighten the rear jam nut first labeled 1 of 2 to 13 ft Ib 17 5 N m Figure 6 18 Page 6 10 then tighten the front jam nut to 13 ft Ib 17 5 N m See following WARNING For optimal performance drive the vehicle and apply the brakes approximately 20 times to burnish the shoes center the clusters and adjust the brake mechanism A WARNING Reduced braking force could result if the jam nuts are not tightened in the proper sequence 4 Once steps 2 and 3 are complete recheck the 2 inch specification listed in step 1 If the measurement has not changed the adjustment is complete If the measurement has changed perform steps 1 through 3 again 5 Replace access panel and floor mat 5 1 Place floor cover plate 7 over the floor opening See Figure 5 2 Section 5 Page 5 2 5 2 Reinstall the floor mat 2 over the pedal group Make sure tabs on floor mat sides are beneath the sill 3 Tighten screws 1 to 53 in Ib 6 N m See Figure 5 1 Secti
201. nch 2 54 cm 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 Off Season Storage Section 3 Page 3 3 Page 10 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual PERIODIC MAINTENANCE Battery 1 Turn the key switch to the OFF position 2 Lift and remove seat bottom 3 The fuel tank is located on the driver side of the vehicle Figure 10 2 Page 10 5 Remove fuel cap and fill the fuel tank with fresh unleaded fuel only See preceding CAUTION and NOTE 4 Replace fuel cap on tank Make sure cap is tightened securely 5 Replace seat bottom BATTERY For periodic battery maintenance see Battery Section 12 Page 12 28 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 10 7 SECTION 11 TROUBLESHOOTING AND ELECTRICAL SYSTEM A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 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
202. nd clean it with a nonflammable solvent Figure 14 2 Page 14 4 See following NOTE Page 14 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FUEL SYSTEM Carburetor NOTE Make sure the fuel bowl gasket 9 remains properly seated in the carburetor body when the fuel bowl is removed Figure 14 2 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 TYPICAL 2 PLACES Figure 14 1 Carburetor Installation 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 3 FUEL SYSTEM Carburetor Changing the Main Jet Continued 6 Remove the main jet 8 from the carburetor body and discard it Figure 14 2 Page 14 4 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 2 Page 14 4 STEPS 2 AND 3 Drain carburetor over a catch basin by turning bowl drain screw 11 counterclockwise 2 to 3 turns Jud SE ys AA IN zi NE Mark carburetor RO and corresponding position of fuel bowl CAUTION DO NOT REMOVE VALVE SPRING FROM FLOAT TO DO SO WILL DAMAGE SPRING If spring looks like this holding float firmly and rotating valve counterclockwise to seat spring in seat of float bowl
203. nd place the black probe on the vehicle frame Figure 11 12 Page 11 16 The read ing should be continuity If there is no continuity clean and tighten all cable connections If the connections are good repair or replace the cable RED 4 PROBE EY x INLINE CONNECTOR TO FRAME GROUND BLACK PROBE Figure 11 11 Battery Ground Cable Test Figure 11 12 Fuel Tank Ground Page 11 16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 4 KEY SWITCH STARTER CIRCUIT See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Remove the instrument panel assembly See Key Switch Removal Section 12 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 switch to ON Place the red probe of the multimeter on the No 2 terminal and the black probe on the No 1 terminal of the key switch The reading should be continuity If the reading is incorrect replace the key switch Figure 11 13 Page 11 17 KEY SWITCH STARTER CIRCUIT Figure 11 13 Test Key Switch Engine Starter Circuit TEST PROCEDURE 5 GCOR See General Warnings Section 1 Page 1 1
204. ng 71 the ring must be in place on the axle before a new bearing and collar are pressed on Page 16 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual UNITIZED TRANSAXLE DER 3 Qe e as de Axle Shaft Figure 16 6 Differential Gear Case Axle Tubes 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 5 E UNITIZED TRANSAXLE Axle Shaft Axle Bearing Installation 1 2 3 Ensure that the retaining ring 70 is loosely placed on the axle shaft See preceding NOTE Install a new axle bearing 71 on axle 67 or 68 Push bearing onto axle until bearing is flush against axle shoulder Figure 16 6 Page 16 5 Apply two drops of Loctite 2719 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 Place a new sealed bearing 71 on shaft 67 or 68 Figure 16 6 Page 16 5 5 Install collar 73 onto axle shaft Place axle assembly on bearing puller wedge attachment and press col lar onto axle Place the bearing puller wedge attachment against collar and press b
205. ng Installation Four Passenger Vehicles SECTION 10 PERIODIC MAINTENANCE General Information Pre Operation and Daily Safety Checklist AA Performance Inspection Periodic Service Schedule Periodic Lubrication Schedule Periodic Lubrication Schedule cccccccncnccccccccnnoncccnonononaranonnnnnononcnnnnn conan cnnnno non na rca nn conan iens nnn dala Engine Dll EE Engine Oil Level Check Oil VISCOSITY ici oo aa Fueling Instructions Battery SECTION 11 TROUBLESHOOTING AND ELECTRICAL SYSTEM General Information Troubleshooting Guide Wiririg DIagraltfis ire tte e re timet te nct Eee dee educ deo E t nde muss Electrical System sesssssssssssssessseeseenen nennen nnne nnns en nnns enter r tnn Test leiere IEN Index of Test Procedures 9 1 9 1 9 1 9 1 9 1 9 1 9 4 9 4 9 4 9 6 SECTION 12 ELECTRICAL COMPONENTS Staiter Gener ator eege ENEE e edd dE ee des Voltage EU TEE Key Switch el OMG EE Page vi 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Neutral Lockout Can ME 12 18 Reverse Warning BUZZGr 5 acte eoe eee lie Hen Ue e Rabe etnia 12 18 Reverse Buzzer Limit Switch oooooocccconncccccncnnooonnnnonononcnnnnnnnnnnnnonnonnn eene ener nennen nennen nnns 12 19 Low Oil Warning Eight creen e det 12 20 RI Reie E 12 21 Fuel Level Sending Unit A 12 23 Hour Meta IM 12 23 RPM Limite rivera ge T Ee E da a ee 12 24 Ignition Coil i he mem aiiud ean 12
206. ng so the clips on the housing ends secure the housing in the hole 2 Hold the bolt 5 and the equalizer bracket 4 in the upright position and slip the cable head through the hole on top of the bracket Pivot the equalizer to the horizontal position to capture the cable heads in the equalizer 3 Insert the rear cable housing into the shock mount bracket 4 Figure 6 20 Page 6 11 Push the cable housing end into the bracket to ensure the clips on the housing end secure the cable in position 4 Atthe rear wheel brake connect the cable to the brake actuator arm using new clevis pin 2 and new bow tie locking pin 1 Figure 6 20 Page 6 11 5 Place tab 3 on cable housing over the forward leaf spring mounting bolt 2 Figure 6 21 Page 6 11 Install nut 1 Tighten nut to 18 4 ft Ib 25 N m 6 Adjust the brakes See Brake Cable Equalizer Adjustment on page 6 8 Page 6 12 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SECTION 7 STEERING AND FRONT SUSPENSION A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 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 See General Warn
207. nings Section 1 Page 1 1 RACK AND PINION REMOVAL 1 Remove the front bumper as instructed See Section 4 Body and Trim 2 Remove the retaining pins 1 and tie rod end retaining nuts 2 Figure 7 4 Page 7 5 3 Remove the tie rod ends 3 from the spindle assemblies Page 7 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7 4 Rack and Pinion Removal 4 Remove the three bolts 5 from the steering rack and pinion assembly mounting bracket 5 Remove the bolt 6 from the universal joint then remove the rack and pinion assembly and universal joint from the vehicle RACK AND PINION DISASSEMBLY 1 Remove the two tie rod ends 12 and inspect for excessive wear Figure 7 5 Page 7 6 2 Remove clamps 10 and 21 from bellows 9 Figure 7 5 Page 7 6 NOTE If the dust seal bellows are secured with a metal clamp remove the clamp Do not reuse the clamp when the rack and pinion is reassembled Use a plastic wire tie to secure the dust seal bellows 3 Remove the two hex nuts 11 and slide off both of the dust seal bellows 9 from ball joints 8 4 Remove rack screw nut 14 rack guide screw 13 rack guide pressure spring 15 and the rack guide 16 5 Remove the universal joint assembly from the pinion 5 by removing the bolt and then sliding off the uni versal joint 6 Remove the dust seal Figure 7 6 Page 7 7 7 Remove
208. normal methods perform step 7 of Brake Shoe Hemoval on page 6 2 then continue with this procedure Although step 7 below allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes 7 Remove the axle 7 1 Using 90 snap ring pliers CCI P N 1012560 remove the axle retaining ring 1 Figure 6 3 Page 6 2 7 2 Pull the axle shaft 2 from the axle tube Figure 6 3 Page 6 2 8 Remove bow tie locking pin 13 and clevis pin 12 from brake cable Figure 6 4 Page 6 3 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 6 9 e WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation Brake Cluster Removal Continued 9 Remove four bolts 11 and lock nuts 10 that mount the brake assembly to the transaxle Figure 6 4 Page 6 3 10 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 A CAUTION Before installing axle shaft clean any residual oil from the exposed end of the axle tube and from the oil seal area Be sure bolts 11 CCI P N 1014153 and new lock nuts 10 CCI P N 1013924 are used to mount the brake assembly Figure 6 4 Page 6 3 3 Tighten bolts to 30 ft Ib 40 6 N m 4 Install the rear axle onto the transaxle 5 Place a 1 4 to 3 8 inch 6 10 mm diameter rod against the retaining ring and tap ligh
209. not fall to the ground Remove the two pivot nuts 7 and bolts 5 from the mounting bracket 7 Remove the starter generator Disassembly of the Starter Generator to Service the Brushes 1 Remove the two bolts 20 and pull commutator end cover 23 free of starter generator housing 24 Figure 12 2 Page 12 2 See following NOTE NOTE lf 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 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 2 Remove brush covers 29 and 30 screws 25 and lock washers 26 brush springs 28 and brushes 27 Figure 12 3 Page 12 2 See following NOTE NOTE To clean and inspect the armature commutator and the bearings See Disassembly of the Starter Generator to Service the Armature Commutator on page 12 4 TYPICAL 4 PLACES TYPICAL 2 PLACES 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 wear line on the side of the brush If the end of the brush is within 1 16 inch 1 6 mm of the wear line replace all four brushes
210. 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 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 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 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 Section 1 Page 1 1 5 Remove the rear wheel and brake drum 6 Use 90 internal snap ring pliers 0 090 tip to remove internal retaining ring 1 from axle tube Figure 16 3 Page 16 3 Figure 16 3 Retaining Ring Figure 16 4 Rolling Head Prybar 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 3 UNITIZED TRANSAXLE Axle Shaft Axle Shaft and Oil Seal Removal Continued 7 Carefully pull the axle shaft 2 straight out of the axle tube Figure 16 3 Page 16 3 8 Position a 16 inch 40 cm rolling head prybar Figure 16
211. o gain access to the pedal group hardware 4 Lift off cover plate 7 Figure 5 2 Page 5 2 5 Loosen jam nuts 4 and 5 on each side of turnbuckle 6 6 Nut 4 has a left hand thread te m Figure 5 1 Pedal Group Access 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 5 1 EN ACCELERATOR AND BRAKE PEDAL GROUP TYPICAL 2 PLACES TYPICAL 2 PLACES ACCELERATOR CABLE ATTACHMENT REMOVAL Figure 5 2 Pedal Group Page 5 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Pedal Group ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group 8 Pedal Group Removal Continued 7 Loosen turnbuckle 6 until the threaded rod from the pedal group is free of the turnbuckle 8 Loosen two nuts 8 and 9 on the accelerator cable and lift the cable from its mounting bracket 9 Remove two screws 2 on the driver side of the pedal group and two screws 1 on the passenger side of the pedal group 10 Slightly lift pedal group from the vehicle to gain access to the connections 11 and 12 to the GCOR on the passenger side of the pedal group 11 Disconnect the electrical connector at the GCOR 12 Release the end of the accelerator cable 10 from the pedal group 13 Remove two screws 1 to separate the GCOR from the pedal group Figure 5 3 Page 5 3 Figure 5 3 GCOR Removal GCOR The pedal group for the Precedent gasoline vehicle includes a Gasoline Controller Output Regulator GCOR
212. ompressing each take up spring install a drive button over the rib and take up spring as shown Figure 17 10 Page 17 8 15 Install a no 10 24 button retaining machine screw with flat washer through each button and into the rib Tighten the three screws to 34 in Ib 3 8 N m Figure 17 10 Page 17 8 16 Install the thrust washer 11 onto the moveable face assembly Figure 17 7 Page 17 6 17 Install the hub assembly 1 on the moveable face assembly and align the match marks made before dis assembling the clutch Press the hub assembly on by hand 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 17 11 TORQUE CONVERTER Drive Clutch DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED Figure 17 17 Correct Orientation of Drive Button Take up Spring DRIVE CLUTCH INSTALLATION 1 Place the drive clutch assembly on the crankshaft taper Position the mounting washer with the green side facing out on the bolt 17 and start the bolt into the crankshaft Figure 17 7 Page 17 6 See fol lowing NOTE NOTE The drive clutch mounting bolt has left hand threads 2 Tighten the drive clutch retaining bolt 17 to 25 ft Ib 33 9 N m Figure 17 7 Page 17 6 3 Install the starter generator belt and adjust belt tension as instructed See Belt Tension Adjustment Section 12 Page 12 11 Tighten the starter generator mounting hardware to 23 ft Ib 31 2 N m and the adjusting hardware to 13 ft Ib 17 6 N m 4 Lower
213. on 5 Page 5 1 Page 6 8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation e JAM NUT 1 OF 2 f i I w Ka EQUALIZER TURNBUCKLE Figure 6 18 Brake Equalizer Adjustment BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 Brake Cluster Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 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 Gen eral Warnings Section 1 Page 1 1 3 Gain access to the pedal group by removing the floor mat and access panel See Pedal Group Removal Section 5 Page 5 1 4 Loosen the two jam nuts 1 and 3 on either side of turnbuckle 2 Figure 6 1 Page 6 2 Note that the forward jam nut 1 is a left hand thread Thread each nut approximately 1 2 inch 12 7 mm away from the turnbuckle 5 Loosen turnbuckle 2 to release tension on the equalizer bracket 4 that pulls on the heads of the brake cables 6 Remove lug nuts and rear wheels and then the brake drums NOTE When servicing vehicles with self adjusting brakes with badly worn brake shoes and when the drums cannot be removed by
214. on and or significant change in specifications or proce dures will be forwarded to all Club Car dealers and will when applicable appear in future editions of this manual Club Car Inc 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 Inc P O Box 204658 Augusta Georgia 30917 4658 USA Attention Warranty Department Page ii 2005 Precedent Gasoline Golf Car Maintenance and Service Manual CONTENTS SECTION 1 SAFETY General WarningS EE 1 1 SECTION 2 VEHICLE SPECIFICATIONS SECTION 3 GENERAL INFORMATION Serial Number Identification essessssssssssssseses esent nennen nnne nnns enne nnne 3 1 Safety eu CT 3 2 elle CEET 3 2 Preparing the Gasoline Vehicle for Extended Off Season Storage ssssssssss 3 3 Returning the Stored Gasoline Vehicle to Service sssssssssseeeene 3 4 SECTION 4 BODY AND TRIM Cleaning the Vehicle Ee RE toilette Ce rd eti Lo eia Sch 4 1 EE 4 1 Front and Rear Body Repair sssssssssssseeeeeeen nennen nennen nennen nnns nnne nnne nennen 4 2 Stress Lines or Streaks ae erect ate er E Pa a nde tt le epe i b ie ctu HE oet a 4 2 Minor Impact Damage Deformations ss
215. on and they must be replaced Inspect the pins on the primary weights 2 There should be no measurable wear Replace them if they are worn scratched or damaged 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 7 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 nstall 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 7 Page 17 6 Install the primary weights on the mounting pins Figure 17 12 Page 17 9 Page 17 10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TORQUE CONVERTER Drive Clutch 8 Install a wave washer on
216. onal injury 4 Use a small brush to carefully apply a light coat of white lithium NLGI 42 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 5 Use a small brush to carefully apply a light coat of white lithium NLGI 42 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 BOSSES Figure 6 9 Apply Grease On Bosses Figure 6 10 Apply Grease To Brake Shoes and Slots 6 Use a small brush to carefully apply a light coat of white lithium NLGI 42 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 6 See preceding WARNING 7 Install the adjuster wheel 1 and two washers 2 and 3 into the adjuster assembly Figure 6 7 Page 6 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 6 5 EN WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Figure 6 11 Apply Grease To Brake Adjuster Figure 6 12 Install Adjuster Wheel Trailing Shoe BRAKE SHOE INSTALLATION See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 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 adjuste
217. onto the fixed face assembly Figure 17 23 Page 17 17 5 1 3 Install the retaining ring 2 Figure 17 22 Page 17 15 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 CCI 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 Page 17 16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TORQUE CONVERTER Driven Clutch CAUTION Do not use a metal hammer to tap the fixed face hub A metal hammer will damage the shaft CAM PRESS TOOL Zz Figure 17 23 Cam Press Tool Figure 17 24 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 CCI 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 sur face Figure 17 24 Page 17 17 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 thr
218. oonnnnnnononnnnnnonononnnnnnnnnnrnn nono E nnns sene r rn rn nennen nene nennen ener nnns 7 14 Control Arm Installation WEE 7 17 Shock Absorber Removal A 7 17 Shock Absorber Installation oooooonnccnnnnicinncicinnncnnncccnnnnccnnnrrcannnrr cnn cnn nennen nnne nnne nnne nnne nnn nnns 7 17 Front Wheel Bearings and Hubs sssessssseseseeeeneeen emen nennen nnne nennen nennt nnne nnns 7 17 Front Wheel Free Play Inspection 7 17 Front Hub le E 7 17 Hub Installation osito iaa 7 18 SECTION 8 WHEELS AND TIRES General InfOrmati ri 3 eir rein dues Fees ete laeta cene ed ua aee rev E nguy rena aee reete een Ee geet 8 1 O onibus att ctetu iioi Mose ee ee eege e ees 8 1 Wheel Removal c u 8 1 Wheel Installatiori ET 8 1 MIOS este eee A E E eidem Inn ena DI MEUS 8 2 TIE REMOVAl ii iaa 8 2 TS Repara EE 8 3 Tir installation EE 8 3 SECTION 9 REAR SUSPENSION CAN nennen enne nnn nnn rns entres nnn res entres entres entres entr rennen nn SHOCK ADSORDCMS teo Dn a Shock Absorber Removal and Inspection sse nnne Shock Absorber Installation ecc etii ira Leaf Springs Two Passenger Vehicles sss eene nnne nnne Leaf Spring Removal Two Passenger Vehicles Leaf Spring Installation Two Passenger Vehicles Leaf Springs Four Passenger Vehicles sssssssssssssesseseeeeeeenenen nne Leaf Spring Removal Four Passenger Vehicles Leaf Spri
219. or restriction of air flow See Choke and Air Intake System on page 14 9 Fuel pump See Fuel Pump on page 14 15 Fuel lines from fuel tank to filter to pump to carburetor See Fuel Lines on page 14 21 Exhaust system for restrictions See Section 15 Exhaust System 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 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 1 FUEL SYSTEM MAIN JET ELEVATION SIZE CHART FE290 ENGINE CALLE MAIN JET SIZE 0 3000 ft 0 914 4 m Be 3000 5000 ft a 914 4 1524 m 5000 8000 ft a 1524 2438 4 m 8000 10 000 ft Ss 2438 4 3048 m 10 000 ft and over 72 3048 m and over Carburetor CHANGING THE MAIN JET 1 Remove the carburetor 1 1 1 2 1 3 1 4 1 5 1 6 1 7 NOTE Turn fuel shut off valve on fuel tank to the closed OFF position Figure 14 12 Page 14 21 Loosen the intake air hose clamp 22 and disconnect the intake air hose 23 at the ca
220. osition the shift lever of the transaxle will also be in the NEUTRAL position Figure 16 56 Page 16 24 Retighten nuts at the Forward Reverse assembly to 43 in Ib 4 9 N m ESA UE TOP VIEW c c fos SHIFTER ARM SHIFTER LEVER Figure 16 56 Forward Reverse Positions Page 16 24 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SECTION 17 TORQUE CONVERTER A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 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 for
221. oth bearing and collar onto shaft See following CAUTION CAUTION 7 e 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 Use external snap ring pliers 0 047 inch tip to install collar retaining ring 74 Figure 16 6 Page 16 5 AXLE SHAFT INSTALLATION 1 2 Clean bearing and seal seats in axle tube 75 or 76 Figure 16 6 Page 16 5 Place a new oil seal 72 in axle tube with seal lip facing inside of the axle tube Figure 16 6 Page 16 5 Use an axle seal tool CCI P N 1014162 to press it in until it seats firmly in position Figure 16 8 Page 16 7 See following NOTE NOTE The new seal can be installed by tapping the axle seal tool with a mallet CAUTION 3 Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft 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 Install the bearing retaining ring 70 in the axle tube Figure 16 6 Page
222. ough the clutch body 5 until the threaded bolt washers bearing and hub guide are against the fixed face hub Figure 17 24 Page 17 17 5 2 4 Hold the clutch assembly and cam installation tool together and place the fixed face down on spaced blocks Figure 17 23 Page 17 17 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 CCI P N 1014080 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 17 17 TORQUE CONVERTER Driven Clutch 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 22 Page 17 15 Secure with a new bolt 11 See following NOTE NOTE The bolt 11 must be replaced with a new bolt CCI P N 102242101 containing a locking
223. oup Qv Lubricant First change 100 hours additional change e m a 400 Change engine oil and oil filter 32 oz 0 95 liter without filter 38 oz rounds for golf cars or dispose of properly O 1 12 liters with filter annually whichever comes first Page 10 4 Figure 11 Lubrication Points 2005 Precedent Gasoline Golf Car Maintenance and Service Manual PERIODIC MAINTENANCE Engine Oil EJ ENGINE OIL See General Warnings Section 1 Page 1 1 Even though the low oil warning light on the dash should illuminate if the engine oil level becomes low the engine oil level should be checked monthly The vehicle should be on a level surface when checking oil ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil from the stick Figure 10 1 See fol lowing CAUTION A CAUTION Do not remove dipstick while engine is running 2 Check oil level by fully inserting the dipstick into the oil filler tube and immediately removing it 3 Ifthe 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 4 Reinsert dipstick into the oil filler tube NOTE Properly recycle or dispose of used oil in accordance with local state and federal regulations
224. ove bolt then rotate shackle up and away from spring mm Figure 17 5 Shock Absorbers Figure 17 6 Rear Shackle 5 Raise the rear of the vehicle enough to allow the centerline of the drive clutch to drop below the frame rails for access to the bolt securing the drive clutch Place jack stands beneath the frame rails just forward of the spring mounts See following WARNING A WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 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 6 Remove the drive clutch retaining bolt 17 and mounting washer 19 Figure 17 7 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 7 Lubricate the threaded portion of the clutch puller tool with a light oil and thread the clutch puller tool into the clutch retaining bolt hole 8 Using a 1 2 inch drive air wrench tighten the clutch puller tool The drive clutch will come free of the crankshaft Figure 17 4 Page 17 4 9 Suppor
225. ow cap 1 to cover the edge of both the brow 5 and the front beauty panel 3 Secure brow cap 1 with four screws 2 Tighten screws to 3 3 ft Ib 4 5 N m FRONT BUMPER The underbody bracket 1 connects the front suspension to the front underbody Figure 4 2 Page 4 5 Each bracket is secured in place by two taptite screws 2 tightened to 13 ft Ib 17 6 N m The front bumper 3 is attached to the vehicle frame rails by nuts 5 and bolts 4 The nuts 5 need to go on top of the bumper attaching brackets always insert the bolts 4 through the bottom The nuts are tightened to 13 3 ft Ib 18 N m INSTRUMENT PANEL See General Warnings Section 1 Page 1 1 INSTRUMENT PANEL REMOVAL 1 Remove two screws 5 at sides and one screw 4 on top of instrument panel 3 Figure 4 3 Page 4 5 2 Tilt instrument panel up to release it from the dash assembly 1 Disconnect the electrical connector on the passenger side of the instrument panel 3 and remove the panel Remove two barrel fasteners 7 to release dash tray 6 Remove three screws 2 and remove dash assembly 1 from vehicle Page 4 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual BODY AND TRIM Instrument Panel SUSPENSION TYPICAL 2 PLACES TYPICAL TYPICAL 2 PLACES Figure 4 3 Instrument Panel 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 5 BODY AND TRIM Floor Mat and Retainers
226. parts and replace them as necessary Install the kingpin 7 over the leaf spring eye Insert the bolt 8 Figure 7 19 Page 7 16 Tighten the bolt to 17 ft Ib 23 N m 3 Install the wave washer 6 on the kingpin Install the steering spindle on the kingpin Place upper clevis over the kingpin threads and install conical washer 2 and nut 1 Tighten the nut to 50 ft Ib 68 N m 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7 13 STEERING AND FRONT SUSPENSION Front Suspension Components Kingpin and Steering Spindle Installation Continued 5 Attach the tie rod ends 12 to the spindle tabs then install and tighten the nuts 14 to 70 ft Ib 95 N m 6 Install the retaining pins 15 Figure 7 18 Page 7 15 Install front hub and wheel See Hub Installation on page 7 18 CONTROL ARM REMOVAL 1 o aR ON Loosen lug nuts on both front wheels and raise front of the vehicle with a chain hoist or floor jack Place jack stands under the front aluminum rails of the vehicle frame and lower the vehicle onto the jack stands Remove wheel Remove bolts 17 and move rack and pinion to allow clearance for bolt 19 Figure 7 18 Page 7 15 Remove bolts 11 and 19 Remove the control arm 6 Inspect the bushings 7 and sleeves 8 and 9 in the control arm and replace them if necessary Page 7 14 2005 Precedent Gasoline Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION
227. r 23 free of the starter generator housing 24 Figure 12 2 Page 12 2 To separate armature 33 from output end cover 36 remove nut 41 lock washer 40 pulley 39 shaft key 34 spacer 37 and bearing retainer screws 43 Figure 12 7 Page 12 5 Page 12 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Starter Generator TYPICAL 3 PLACES 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 5 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 Bear ings 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 Figure 12 8 Bearing Play Inspection 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 5 ELECTRICAL COMPONENTS Starter Generator Bearing Removal 1 Place the wedge attachment tool CCI 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 s
228. r Spray CCI P N 1014305 to minimize corrosion DAMPER RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL ___ WHITE BLACK FEMALE BULLET KILL CIRCUIT WIRE TERMINAL Figure 12 24 RPM Limiter Assembly BROWN WIRE BLACK WIRE Page 12 24 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Ignition Coil IGNITION COIL See General Warnings Section 1 Page 1 1 Testing Ignition Coil See Section 11 Test Procedure 13 Page 11 24 Test Procedure 14 Page 11 26 and Test Procedure 15 Page 11 26 Ignition Coil Removal 1 ov c Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Access engine compartment Disconnect spark plug wire from the spark plug See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Remove the governor guard 1 Figure 12 25 Page 12 25 Remove the muffler See Muffler Removal Section 15 Page 15 1 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 25 Figure 12 25 Governor Guard Removal Figure 12 26 Stiffener Removal 7 Remove the pan head bolts 5 securing the fan shroud 8 to the fan housing 9 Figure 12 27 Page 12 26 8 Loosen but do not remove the thre
229. r assembly Figure 6 12 Page 6 6 See following NOTE NOTE The trailing shoe has 17T stamped into the tip of the shoe flange Figure 6 12 Page 6 6 The leading shoe is stamped 17L When installing the shoes the stamping on both shoes should be ori ented 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 ariver 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 Figure 6 13 Page 6 6 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 BRONZE SPRING SPRING COILS SILVER SPRING Note that the silver spring is mounted with the coils to the side of the adjustment lever spring A Figure 6 13 Install Trailing Shoe Retainer Clip Figure 6 14 Attach Springs Page 6 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Shoe Installation E 4 While maintaining spring attachment on both shoes position tips of leading shoe in the mounting slots and then push shoe in
230. r bolts 8 and lock nuts 9 Use two bolts on each sup port inserting the bolts from the inside Tighten the lock nuts to 50 in Ib 5 6 N m 6 Secure the canopy to the rear supports with two bolts 4 and locknuts 5 Tighten the lock nuts to 50 in Ib 5 6 N m 7 Atthe rear supports 3 tighten the four bolts 6 to 31 in Ib 3 5 N m 8 Atthe front supports 7 and 10 tighten the four bolts 11 to 18 4 ft Ib 25 N m 9 Position each cover 12 and 13 over its respective support A hole in each cover should be aligned with a corresponding hole in the support Secure the cover to the support with a screw 14 Tighten the screws 14 to 31 in Ib 4 6 N m Page 4 18 2005 Precedent Gasoline Golf Car Maintenance and Service Manual BODY AND TRIM Canopy Two Passenger L CL TYPICAL an 4 PLACES TYPICAL 4 PLACES 16 TEN EI Tea 2 PLACES 2 PLACES TYPICAL 2 PLACES SEATS REMOVED FOR CLARITY TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 4 13 Precedent Four Passenger Canopy 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 19 BODY AND TRIM Canopy Four Passenger CANOPY FOUR PASSENGER See General Warnings Section 1 Page 1 1 CAUTION To prevent damage to the canopy do not remove the canopy supports 1 and 6 from the vehicle without first removing the canopy 9 Figure 4 13 Page 4 19 FOUR PASSENGER CANOPY REMOVAL
231. r damage Figure 14 9 Page 14 16 If a valve assembly is damaged the rubber retaining plug 33 and valve assembly must be replaced PUMPING FUEL INLET CHAMBER ae NY i QUO f FUEL SES C5 VALVE 2 ASSEMBLY S S DIRECTION OF FUEL IMPULSE FLOW LINE ER ON Figure 14 9 Fuel Pump Figure 14 10 Fuel Pump Orientation Page 14 16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FUEL SYSTEM Fuel Pump FUEL PUMP ASSEMBLY 1 Install the fuel gasket 35 and diaphragm 34 on the back cover 36 Figure 14 9 Page 14 16 2 Install the valve assembly in the pumping chamber 30 See following CAUTION CAUTION f the valve assembly is not installed exactly as shown Figure 14 9 Page 14 16 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 and the fuel out let align with the arrows on the front of the front cover Figure 14 9 Page 14 16 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 and then the lock washers 25 and four screws 24 on the assembly Be sure the arrows on the front cover point from the fuel inlet to the fuel outlet Figure 14 10 Page 14 16 Tighten the screws to 26 in Ib 3 0 N m FUEL PUMP INSTALLATION 1 Connect to the fuel pump the fuel line
232. rburetor end only Figure 14 1 Page 14 3 Remove the governor guard 5 Release the governor cable from the carburetor Disconnect the carburetor vent line 14 Disconnect the fuel supply line 26 at the carburetor end only Temporarily plug the end of the fuel line to prevent fuel leakage Remove the carburetor retaining nuts 19 intake pipe 17 and carburetor 12 See following 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 3 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 2 Position the carburetor with the drain screw 11 over a catch basin Figure 14 2 Page 14 4 3 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 Ib 1 1 N m Return fuel to the fuel tank or dispose of properly 4 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 2 Page 14 4 5 Remove the carburetor fuel bowl retaining screw and washer 12 then remove the fuel bowl 10 a
233. re 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 A 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 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 8 3 EN WHEELS AND TIRES Tires Tire Installation Continued 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 Figure 8 2 Inflate Tire Page 8 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SECTION 9 REAR SUSPENSION A DANGER See General Warnings Section 1 Page
234. re in place and are easy to read Do not leave children unattended on vehicle Page 1 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SAFETY General Warnings Remove negative ut JL eme his DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE Figure 1 1 Battery Cable Removal 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 1 3 SECTION 2 VEHICLE SPECIFICATIONS SPECIFICATIONS Two Passenger Gasoline Vehicle Four Passenger Gasoline Vehicle POWER SOURCE Engine 4 cycle OHV 286 cc 9 0 hp rated 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 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 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 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
235. recedent Gasoline Golf Car Maintenance and Service Manual Page 7 7 STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY 1 Apply a liberal amount of EP grease to the teeth of the rack 18 then slide the rack through the bushing 7 and housing 17 Figure 7 5 Page 7 6 CAUTION n step 2 do not press against the outer race of the bearing If the pinion bearing 4 was removed grease a new bearing before installation Press new bearing onto pinion shaft exerting all pressure on the inner race Then install the C type stop ring 3 See previous CAUTION Install pinion 5 and bearing 4 assembly into the housing 17 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 pin ion bearing assembly with a rubber mallet See following CAUTION CAUTION 11 12 13 Do not force the pinion bearing assembly into the housing The gear teeth or the small bearing could be damaged Install the large snap ring 2 Use a socket to apply pressure evenly and press in a new dust seal Figure 7 10 Page 7 9 Apply a small amount of grease to the rack guide 16 where it comes into contact with the rack 18 Figure 7 5 Page 7 6 Install the ball joints 8 onto the rack 18 by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from
236. ro Install urethane bushings 15 and steel sleeves 14 into leaf spring eyes Figure 7 19 Page 7 16 Install leaf spring 13 bottom spring plate 16 and four bolts 17 Using a crisscross pattern sequence tighten bolts to 23 ft lb 31 N m Install spring in kingpins 7 with bolts 8 Tighten to 17 ft lb 23 N m Install the wheels and finger tighten the lug nuts Lower the vehicle and finish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 N m Adjust camber and toe in See Wheel Alignment on page 7 10 KINGPIN AND STEERING SPINDLE REMOVAL o 9 o N Remove the front hub See Front Hub Removal on page 7 17 Remove retaining pins 15 and nuts 14 then remove tie rod ends 12 from the tabs on the spindles Figure 7 18 Page 7 15 Remove the nut 1 and conical washer 2 from the top of the kingpin 7 Figure 7 19 Page 7 16 Raise the upper clevis from the kingpin Slide the spindle 3 off the kingpin 7 Remove the wave washer 6 and inspect it If the washer is broken or has a wave bottom to wave crest height dimension of less than 0 040 inch 1 mm it must be replaced Remove bolt 8 from bottom of kingpin 7 and remove kingpin 8 Inspect the kingpin and spindle If either is worn or damaged it must be replaced 9 Inspect the bushings 4 If the bushings are worn or damaged remove them and press in new ones KINGPIN AND STEERING SPINDLE INSTALLATION Inspect all
237. screen is partially blocked or plugged Section 14 Fuel System Section 18 FE290 Engine Governor is improperly adjusted Section 14 Fuel System Carburetor is too lean check main jet size Excessive carbon deposits on piston head or in combustion chamber Section 14 Fuel System Section 13 FE290 Engine Spark plug heat range is incorrect Section 13 FE290 Engine Unsuitable or contaminated fuel Section 14 Fuel System Loss of engine power Exhaust valve is restricted with carbon deposit Section 13 FE290 Engine Muffler or exhaust pipe restricted with carbon or other substance Section 15 Exhaust System Ignition coil failed Section 11 Troubleshooting and Electrical System Test Procedures 13 14 and 15 Troubleshooting Guide continued on next page Page 11 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide Eg TROUBLESHOOTING GUIDE SYMPTOM Loss of engine power continued POSSIBLE CAUSES Air filter is dirty or clogged REFER TO Section 14 Fuel System Governor is improperly adjusted Section 14 Fuel System Throttle linkage out of adjustment Section 14 Fuel System Low cylinder compression Section 18 FE290 Engine Spark plug failed Section 13 FE290 Engine Restricted fuel flow
238. semblies must be replaced if surfaces are worn more than 0 060 inch 1 5 mm 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 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 a A C N 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 Ib 0 9 N m Figure 17 22 Page 17 15 Slide the moveable face assembly 7 onto the fixed face shaft 8 Place the end of the spring 5 into the hole in the moveable face assembly Install the key 3 into the keyway of the fixed face assembly 8 shaft 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 5 1 1 Place the clutch assembly in a press and position the cam press tool CCI P N 101809101 on the cam as shown Figure 17 23 Page 17 17 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
239. ss and debris and clean if necessary Tires Check air pressure and adjust if necessary See Section 2 Vehicle Specifications General vehicle Wash engine compartment and underside of vehicle Do not wash engine when hot Semiannual service by trained technician only every 50 hours of operation or every 100 rounds of golf Battery Clean terminals and wash dirt from casing Apply Battery Terminal Protector Spray CCI P N 1014305 to battery terminals Check electrolyte level See Section 12 Battery Front wheel alignment and camber Electrical wiring and connections Check and adjust if necessary See Section 7 Steering and Front Suspension Check for tightness and damage replace if necessary Brake system Check brake shoes replace if necessary See Section 6 Wheel Brake Assemblies Lubricate brake slides per lubrication Schedule See Section 6 Wheel Brake Assemblies Check brake cables for damage replace if necessary Annual service by trained technician only every 100 hours of operation or every 200 rounds of golf Engine Check for leaks around gaskets fill plugs etc Inspect clean and gap spark plug replace if necessary Engine air intake system Check air filter element replace if necessary Check clamps for tightness check hose for cracks Pedal group Lubricate all rotating joints See Periodic Lubrication Schedule on p
240. sssssssesseeeseeeenene eene 4 2 Minor Scratches and Surface Blemishes A 4 2 Gouges Punctures Tears Large Scratches and AbraSiONns oooccconoocccnconononcncnonannnnnconannnnnconnnnno 4 2 Front Body um epo ode aei usan em eeu 4 4 Front ele Viele VC 4 4 Front Body Installation uet oie ette iet er etg rito eor ett e ue tei nde D dee Dn in Pep E EE eds 4 4 Belg lu 4 4 Instrument Panel licita cen EE eb dee IR RR o be tn De ees 4 4 Instrument Panel Removal Ask 4 4 Instrument Panel Installation 4 6 Floor Mat and Retainers AAA 4 6 Floor Mat Retainer Removal A 4 7 Floor Mat Retainer Installation ssseeeeeeeeenenennnenenm enn enne nnne nnne 4 7 Kick Plate and Choke Button ssssssssssssseseeseeeenene nennen enne nnne rra nr 4 7 Kick Plate and Choke Button Removal nennen nnne 4 7 Kick Plate and Choke Button Installation sssssseeeeeeeeeeeeenneennee nnne 4 7 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page iii Rear Body Two Passenger Vehicles uk Universal Accessory Mounting occccononcccnonononcncnonanoncnnnnnnnnnonnnnnn cnn ro nan nr nr cnn rn cnn ARNA nnne nennen nnns Backrest and Structural Accessory Module SAM sse Rear Body Components Two Passenger sse nnne eene nnne nnne Rear Body Four Passenger Vehicles uk Seat Backs vic oce de d pr er Dr tu HR ru aie eee Se Va e Eee NEEN SEAL SUPP OM EpL pM FOOUDOCK ee
241. sting the Neutral Lockout Cam See Test Procedure 23 Section 11 Page 11 33 Neutral Lockout Cam Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the external snap ring 14 Figure 12 19 Page 12 17 3 Remove the plastic washer 12 and the spring 13 4 Remove the cam 11 Neutral Lockout Cam Installation 1 Install the cam 11 Figure 12 19 Page 12 17 2 Install the spring 13 and the plastic washer 12 3 Install the external snap ring 14 onto the shaft Be sure the snap ring is installed in the groove on the shaft 4 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion REVERSE WARNING BUZZER See General Warnings Section 1 Page 1 1 Testing the Reverse Warning Buzzer See Test Procedure 20 Section 11 Page 11 32 Reverse Warning Buzzer Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the instrument panel See Key Switch Removal on page 12 13 3 Disconnect the wires from the reverse warning buzzer 2 Figure 12 20 Page 12 19 4 Remove the two mounting screws 3 securing the buzzer to the instrument panel Page 12 18 200
242. t 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 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 17 5 TORQUE CONVERTER Z M 9 NS S AS d l Figure 17 7 Drive Clutch Assembly Page 17 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TORQUE CONVERTER Drive 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 7 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 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 Figure 17 8 Page 17 7 1 Make match marks on the
243. tainer See following DANGER and WARNING A 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 A 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 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 11 Page 14 19 Do not remove the lower nut on the center stud of the sending unit If vehicle is not equipped with a fuel level sending unit disconnect black ground wire See following WARNING Page 14 18 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FUEL SYSTEM Fuel Tank A WARNING Make sure the key switch is off before disconnecting wiring 9 Remove the vent tube 14 and fuel line 9 from the fuel tank Figure 14 8 Page 14 13 10 Remove two screws 3 holding the forward end of the fuel tank hold down 2 Lift up on the forward end of the hold down and release the rear end from the fuel bracket 11 Lift the fuel tank 1 out of the vehicle FUEL TANK DISPOSAL 1 Remove the cap from the tank Thoroughly rinse the cap 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 Ina well ventilated area
244. tenance and Service Manual Page vii E gine Control Linkage EE General Information GOVE Or Cable tt A a on Accelerator Cable acicate Closed Throttle or Idle Adjustment AAA Engine RPM Adjustment et ein d ta edel dunes eet ma ar eee Choke and Air Intake System essssssssssssssseesseeeee ener nennen nns n nenne nnns enne nennen nn General Information Choke Button EE ans 0 le a Uo de aede dee a d Air Intake Components Removal sssssssssseseeeeeeeneneenene enne nnenetnns nnne nennen nennen nnns Air Intake Components Installation sssssssssseseees eene nnne nnne nnne nnns AID AMON egene LE ARS cuu atu Mi Fuel Filter e rite tad ts Eed General Information reote eerie EE EE adn refte haa a Fuel Filter m nie f essentiel is din Fuel Filter Installation Fuel EH DDR ig catt et ada General Information ee Fuel Pump REMOVAL A Fuel Pump Disassembly intet eene eee mue eu eevee este chee sees a aevo nme Fuel Pump Cleaning and Inspection Fuel Pump Assembly icono Lo cui e Du Y ul td Po uda ceat Fuel Pump Installation ooooononnnncccnccnnnnncccnccnnnonanancncconnnnncnnnnnnnr nn nncnnnnnn cnn anna nn nn nnnnnnn nn rn sensn nennen nnns EUuel Tak ir A ta General Information imet EE ad dh Fuel Fank Remova l ege keete dia dns Fuel Tank Disposal tette dp to ee tees cena tle cero ded cea cbr a tags Fuel Tank Storage E Fuel Tank nsta
245. tened limit switches could be damaged FORWARD REVERSE ASSEMBLY FORWARD REVERSE ASSEMBLY El Oss E NS S d Figure 12 18 Neutral Lockout and Reverse Buzzer Figure 12 19 Neutral Lockout Cam Limit Switches NEUTRAL LOCKOUT REVERSE BUZZER LIMIT SWITCH LIMIT SWITCH Age Ro 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 Figure 12 18 Page 12 17 3 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 4 Place the Forward Reverse handle in NEUTRAL The neutral lockout cam should be in the OPERATE position 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 5 Test drive the vehicle in both forward and reverse for proper operation 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 12 17 ELECTRICAL COMPONENTS Neutral Lockout Cam NEUTRAL LOCKOUT CAM See General Warnings Section 1 Page 1 1 If the cam lobes have worn to the point where they will no longer activate the neutral lockout limit switch the cam must be replaced Te
246. tes from the air and drains back to the crankcase The air passes through a tube and vents to the intake manifold See Engines and Drivetrain Components Repair and Rebuild Man ual for inspection and repair CRANKCASE See General Warnings Section 1 Page 1 1 ENGINE REMOVAL To perform repairs on crankcase components remove engine from the vehicle See following CAUTION CAUTION Before removal and disassembly clean the engine 1 Remove the powertrain See Unitized Transaxle Removal Section 16 Page 16 7 See following NOTE 2 Remove starter generator See Starter Generator Removal Section 12 Page 12 1 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 13 3 FE290 ENGINE Crankcase 3 Remove drive clutch See Drive Clutch Removal Section 17 Page 17 4 and following NOTE NOTE The crankshaft has left hand threads at the clutch mounting hole Remove muffler See Muffler Removal Section 15 Page 15 1 Remove engine mounting hardware items 1 2 5 and 6 Figure 13 2 Page 13 4 Lift engine from the mounting plate Noo 0 E 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 TYPICAL r KI W i n 7 4 PLACES M MSS o TYPICAL TYPICAL 2 PLACES Figure 13 2 Engine Mounting Plate Page 13 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FE290 ENGINE Cran
247. the button actuates the choke A spring clip attaches the rod to the choke If the choke button requires service the kick plate must be removed See Kick Plate and Choke But ton Section 4 Page 4 7 AIR INTAKE COMPONENTS 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 2 Access the engine compartment 3 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 4 Hose 3 may be removed by removing the clamps 4 at the choke and the carburetor Figure 14 6 Page 14 10 5 The air intake assembly 1 is secured to the fuel bucket with four screws 2 Access to the screws requires that the kick plate be removed See Kick Plate and Choke Button Section 4 Page 4 7 AIR INTAKE COMPONENTS INSTALLATION A WARNING Intake hose is made from a special fire retardant neoprene material Use of any hose that does not meet CCI specifications could create a fire hazard 1 Position air intake assembly 1 inside the fuel bucket Figure 14 6 Page 14 10 Secure intake assem bly with four screws 2 Tighten screws to 2 7 ft lb 3 5 N m 2 Install hose 3 and secure one end to the air intake assembly 1 and one end to the carburetor Install clamps 4 to secure the hose in place 3 Install kick plate and choke button See Kick Plate and Choke But
248. tion The engine produces carbon monoxide which is an odorless deadly poison 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 Allow the engine to run for a few minutes to ensure that the fuel lines are full of fuel Inspect each fuel line for leaks 12 1 Check all of the fuel line clamps at the carburetor fuel filter fuel pump and fuel tank for leaks 12 2 Inspect each fuel line to ensure that the lines are not cracked cut or worn Page 14 20 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FUEL SYSTEM Fuel Lines FUEL LINES See General Warnings Section 1 Page 1 1 The fuel lines must be properly routed and all hose clamps must be tight The fuel lines should be kept clean See following WARNING A WARNING Make sure fuel lines are the correct length and are properly routed Failure to heed this warning could result in a fire due to damaged fuel lines Fuel line 9 runs directly from the fuel tank to the fuel filter 7 The fuel filter has an arrow indicating fuel flow direction Figure 14 8 Page 14 13 Fuel line 10 runs directly from the fuel filter to the fuel inlet of the fuel pump Fuel line 13 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 cla
249. tion wrench Page 16 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual 17 mm socket 3 8 in drive 7 16 in combination wrench 1 2 in combination wrench 9 16 in combination wrench 11 16 in combination wrench 2 17 mm combination wrench Small flat blade screwdriver Medium flat blade screwdrivers 2 No 2 phillips head screwdriver 1 4 in nut driver 5 16 in nut driver Small knife or wire snippers Governor gear shaft installation tool CCI P N 101933101 Brake cable removal tool CCI P N 1025555 UNITIZED TRANSAXLE Axle Shaft 16 LUBRICATION There are two oil port plugs located on the right driven clutch side of the unitized transaxle Figure 16 2 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 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 Tighten the plug to 20 ft lb 27 1 N m AXLE SHAFT See General Warnings Section 1 Page 1 1 Removal of the unitized transaxle is
250. tly at four or five locations to ensure it is properly seated See following WARNING A 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 6 Tighten lug nuts on rear wheels using a crisscross pattern to 55 ft Ib 74 6 N m See Wheel Installa tion Section 8 Page 8 1 7 Adjust the brakes See Brake Cable Equalizer Adjustment on page 6 8 BRAKE CABLE REMOVAL AND INSTALLATION See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 Brake Cable Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Place chocks at the front wheels Gain access to the pedal group by removing the floor mat and access panel See Pedal Group Removal Section 5 Page 5 1 Loosen the two jam nuts 1 and 3 on either side of turnbuckle 2 Figure 6 19 Page 6 11 Note that the forward jam nut 1 is a left hand thread Thread each nut approximately 1 2 inch 12 7 mm away from the turnbuckle Loosen turnbuckle 2 until the bolt 5 is free of the turnbuckle Page 6 10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation e
251. to carburetor and secure with hose clamp Figure 16 54 Page 16 21 Figure 16 54 Carburetor 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 Ib 28 5 N m 32 Ensure that all wiring is secured properly See following WARNING A 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 33 Connect the spark plug wire 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 21 E UNITIZED TRANSAXLE Forward Reverse Shifter Cable 34 35 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Adjust the engine RPM setting See Engine RPM Adjustment Section 14 Page 14 9 FORWARD REVERSE SHIFTER CABLE See General Warnings Section 1 Page 1 1 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
252. to identify them as going on the driver side or passenger side respectively Do not install the screws 5 yet Remove the two bolts that secure the hip restraint 15 to the seat supports 7 Align the rear canopy support 6 with the top of the seat supports 7 and secure with two bolts 8 as shown Tighten the hardware to 124 in Ib 14 N m Secure the front of the canopy 9 to the front supports 1 with four spacers 10 bolts 11 and cap nuts 12 Tighten the hardware to 10 ft Ib 13 6 N m Secure the rear of the canopy 9 to the rear canopy support 6 with four bolts 13 and cap nuts 14 Tighten the hardware to 10 ft lb 13 6 N m Tighten the four bolts 3 installed in step 1 2 to 18 ft Ib 25 N m Secure each front support cover 4 with one screw 5 Tighten the hardware to 53 in Ib 6 N m Page 4 20 2005 Precedent Gasoline Golf Car Maintenance and Service Manual SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 PEDAL GROUP See General Warnings Section 1 Page 1 1 PEDAL GROUP REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove screws 1 Pull floor mat retainer 3 away from the vehicle Figure 5 1 Page 5 1 3 Pull floor mat 2 over the pedal group t
253. to 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 LEADING SHOE TRAILING EN Figure 6 15 Install Leading Shoe Figure 6 16 Check Shoe Positions 6 Place a flatblade screwdriver under the adjusting arm and raise the arm off of the adjusting wheel While holding the arm up turn the wheel upward until it stops Figure 6 17 Page 6 7 Remove the screw driver _ ADJUSTING ADJUSTING WHEEL Figure 6 17 Set Adjusting Wheel 7 Install the rear axle onto the transaxle See following NOTE NOTE There is a LEFT and RIGHT side axle The splined portions on the axles that insert into the tran saxle 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 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 6 7 EN WHEEL BRAKE ASSEMBLIES Brake Cable Equalizer Adjustment
254. ton Section 4 Page 4 7 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 Access the engine compartment 2 Pullthe yellow tab 1 on the air filter cover 2 away from the air filter housing Figure 14 7 Page 14 12 3 Rotate the cover counterclockwise to approximately the 10 o clock position to release the internal locking tabs Remove the cover 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 11 FUEL SYSTEM Choke and Air Intake System Air Filter Replacement Continued 4 Remove the air filter 3 and dispose of properly 5 Using a clean cloth wipe away any dust or dirt from inside the air filter housing Remove all dirt build up around the inside lip of the housing or the cover will not seal properly 6 Install new air filter inserting the open end into the housing first 7 Placethe cover 2 overthe housing Press firmly to engage the seals and rotate the cover clockwise until the yellow tab is at the 11 o clock position 8 Press in the yellow tab 1 to lock the cover on the housing See following CAUTION CAUTION Engine damage will occur if the air filter cover is not properly secur
255. ure 16 26 Page 16 13 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 27 Page 16 13 15 Place blocks under the engine pan so they will completely support the engine and keep it level to the floor Figure 16 28 Page 16 13 See following NOTE 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 29 Page 16 13 Page 16 12 2005 Precedent Gasoline Golf Car Maintenance and Service Manual UNITIZED TRANSAXLE Unitized Transaxle Removal SNUBBER BRACKET Lift snubber out of bracket Roll entire powertrain out from under vehicle body y APPROX 6 INCH DRIVEN SS Sa m CLUTCH WOODEN BLOCKS DRIVE CLUTCH AN Figure 16 28 Position Powertrain Figure 16 29 Remove Drive Belt Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle Figure 16 30 Page 16 14 18 Loosen but do not remove the governor arm retaining bolt 1 Figure 16 31 Page 16 14 Remove the governor arm from the shaft Do not disconnect cables
256. uts using a crisscross pattern to 55 ft Ib 74 6 N m 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 8 1 EN WHEELS AND TIRES Tires TIRES See General Warnings Section 1 Page 1 1 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 atire 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 3 3 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 3 4 Once the lower bead is started over the rim flange the tire can be removed from the rim by hand TIRE TOOL UPPER TIRE TIRE BEADS POSITIONED IN RIM WELL RIM LOWE
257. ve 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 CCI P N 101881101 is designed to give maximum life and efficient combustion of fuel The spark gap is 0 027 0 031 inches 0 69 0 79 mm Spark Plug Removal See General Warnings Section 1 Page 1 1 CAUTION Before removal and disassembly clean the engine 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 13 1 FE290 ENGINE General Information 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 mix ture 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 burn
258. vehicle to the height required to position the leaf springs in the mounting shackles Install the mounting bolts and lock nuts Tighten lock nuts to 15 ft Ib 20 3 N m Figure 17 18 Page 17 13 5 Position shocks in the shock mounts and install cushions mounting washers and nuts Tighten nuts until cushions expand to be the same diameter as the mounting washers Figure 17 19 Page 17 13 Page 17 12 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TORQUE CONVERTER Driven Clutch Figure 17 18 Leaf Spring and Shackles Figure 17 19 Shock Absorbers Lower vehicle and remove the lifting device Install the drive belt as instructed See Drive Belt Installation on page 17 3 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Connect the spark plug wire to the plug Drive the vehicle and check for proper operation DRIVEN CLUTCH See General Warnings Section 1 Page 1 1 DRIVEN CLUTCH REMOVAL 1 Remove the drive belt as instructed See Drive Belt Removal on page 17 2 2 Remove the access panel on the rear of the vehicle 3 Remove the bolt 11 and mounting washer 12 from the clutch shaft Figure 17 22 Page 17 15 4 5 Grasp the driven clutch assembly and slide it off the shaft Leave the key
259. verse buzzer limit switch 4 Figure 12 18 Page 12 17 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Shift the Forward Reverse handle to the REVERSE position The buzzer should sound LOW OIL WARNING LIGHT See General Warnings Section 1 Page 1 1 Testing the Low Oil Warning Light See Test Procedure 22 Section 11 Page 11 33 Low Oil Warning Light Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Remove the instrument panel See Key Switch Removal on page 12 13 Disconnect the wires from the low oil warning light 11 Figure 12 21 Page 12 21 Press the retaining tabs and remove the low oil warning light from the instrument panel Page 12 20 2005 Precedent Gasoline Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Fuel Gauge YELLOW YELLOW WHITE Figure 12 21 Low Oil Warning Light Low Oil Warning Light Installation 1 Push a new unit into hole in instrument panel until plastic tabs engage Figure 12 21 Page 12 21 2 Connect yellow and yellow white wires from the wire harness to the low oil warning light 3 Install the instrument panel 3 1 Connect the electrical connector 3 Figure 12 16 Page 12 13 3
260. vis pin 2 at the brake lever and brake cable connection and remove cable end 3 from the brake lever Figure 9 3 Page 9 3 Detach the brake cable from the shock mount bracket 4 Remove the nut 5 cup washer 9 and rubber bushings 10 from the lower mounting stem of the shock absorber Figure 9 4 Page 9 5 Remove the nuts 13 and the U bolt 11 securing the spring and jounce bumper to the transaxle Remove the shock mount bracket 15 jounce bumper bracket 20 and the U bolt 11 Remove the bolt 17 and nut 2 attaching the rear of the spring to the shackle 1 8 Remove the nut 2 and bolt 17 attaching the front of the spring to the vehicle frame and remove the spring Inspect the bushings 4 and sleeves 3 in the spring eyes and replace them if they are worn or dam aged Page 9 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Leaf Springs Four Passenger Vehicles ES REAR SUSPENSION TS BRAKE CABLE HANGER MOUNTING REF SE Ba E bes E ON CE EACH SIDE gt OF VEHICLE Y gt s NX D d TYPICAL 2 PLACES Figure 9 4 Rear Suspension Assembly and Mounting Four Passenger Vehicles 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 9 5 EN REAR SUSPENSION Leaf Springs Four Passenger Vehicles LEAF SPRING INSTALLATION FOUR PASSENGER VEHICLES 1 To install the springs reverse the removal procedure
261. water Rinse solution off battery Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CCI P N 1014305 VENT4 SHUT OFF VALVE CLOSED OFF POSITION 4 SELECTOR IS ALIGNED PE WITH OFF MARKINGS ON THE SIDES OF VALVE VIEWED FROM SELECTOR SIDE OF VALVE Figure 3 2 Fuel Tank Figure 3 3 Fuel Shut Off Valve Closed Position Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in Gen eral Warnings Section 1 Page 1 2 To protect the engine remove the spark plug and pour 1 2 ounce 14 2 mL of SAE 10 weight oil into the engine through the spark plug hole Rotate the engine crankshaft by hand several times and then install the spark plug 6 Adjust tires to recommended tire pressure See Section 2 Vehicle Specifications 7 Perform semiannual periodic lubrication See Periodic Lubrication Schedule Section 10 Page 10 4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 3 3 Storage LET E GENERAL INFORMATION Storage Preparing the Gasoline Vehicle for Extended Off Season Storage Continued 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 the fuel systems to operation
262. weater Basket The sweater basket 11 is secured to the bag hoop assembly by three screws 12 Tabs on the upper edge of the basket align with holes in the bag hoop 6 for installation purposes Tighten screws 12 to 4 8 ft Ib 6 5 N m to secure the sweater basket Figure 4 7 Page 4 9 REAR BODY COMPONENTS TWO PASSENGER Rear Beauty Panel Removal 1 Remove SAM See SAM Removal on page 4 10 2 Remove one screw 3 from each canopy support bracket 1 and 2 Figure 4 8 Page 4 11 Remove canopy supports Remove four screws 13 attaching the rear beauty panel 12 to the fuel bucket Remove screw 15 and remove shift handle 14 from vehicle Remove two screws 17 to remove shift cover 16 from rear beauty panel 12 O oc bh CO Lift rear beauty panel from vehicle Page 4 10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual BODY AND TRIM Rear Body Two Passenger Vehicles TWO PASSENGER VEHICLES ONLY TYPICAL 4 PLACES TYPICAL 4 PLACES TWO PASSENGER VEHICLES ONLY d TWO PASSENGER VEHICLES ONLY Figure 4 8 Rear Body Components 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 11 BODY AND TRIM Rear Body Four Passenger Vehicles Rear Beauty Panel Installation 1 Install rear beauty panel 12 on vehicle Make sure body clips on the rear of the beauty panel engage the mating slot in the rear underbody 4 Secure beauty panel i
263. wheels Access the engine compartment Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 To prevent fuel drainage turn the fuel shut off valve 5 on the fuel tank 1 Figure 14 8 Page 14 13 to the closed OFF position Figure 14 12 Page 14 21 Remove the clamps 6 and fuel lines 9 and 10 from the filter 7 and plug the fuel lines Figure 14 8 Page 14 13 FUEL FILTER INSTALLATION CAUTION Fuel filter is marked with flow direction arrows Make sure that the filter is installed with arrows pointing in the direction of fuel flow from tank to the fuel pump Install the fuel filter 7 in the fuel line Use new clamps 6 Figure 14 8 Page 14 13 Turn the fuel shut off valve to the ON position Figure 14 13 Page 14 22 Connect battery cables positive cable first and tighten hardware to 12ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Place the Forward Reverse handle in the NEUTRAL position chock the wheels and place the neutral lockout cam in the MAINTENANCE position Start the engine and check for fuel leaks See following DANGER A DANGER 5 Repair all fuel leaks before operating the vehicle Place the neutral lockout cam in the OPERATE position Page 14 14 2005 Precedent Gasol
264. wide open throttle WOT position 4 While holding the arm and shaft in the fully counterclockwise position tighten the governor arm lever nut to 36 in Ib 4 0 N m 5 Check engine RPM adjustment See Engine RPM Adjustment on page 14 9 ACCELERATOR CABLE Accelerator Cable Removal 1 Access the engine compartment 2 Access the pedal group and remove accelerator cable from the pedal group See Pedal Group Removal Section 5 Page 5 1 3 Loosen the two lock nuts 12 that secure the accelerator cable to the vehicle Figure 14 3 Page 14 7 4 Release the accelerator cable housing from bracket 9 5 Release the end of accelerator cable from the governor lever arm and remove the cable from vehicle Page 14 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual FUEL SYSTEM Engine Control Linkage GOVERNOR Figure 14 3 Governor and Accelerator Cables 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 7 FUEL SYSTEM Engine Control Linkage Accelerator Cable Installation 1 Insert the accelerator cable through the hole in the frame and feed it towards the pedal group Connect the accelerator cable to the pedal group See GCOR Section 5 Page 5 3 Connect the end of the accelerator cable 7 to the governor lever arm Figure 14 3 Page 14 7 Press on the cable 7 to snap it in place in bracket 9 Adjust two lock nuts 12 to remove excess slack in the accelerator cabl
265. y charged in order to perform the following test procedures Battery maintenance procedures including watering information and allowable min eral content can be found in section 12 of this manual See Battery Section 12 Page 12 28 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and 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 CCI 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 7 Page 11 13 A 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 Page 11 12 2005 Precedent Gasoline Golf Car Maintenance and Service Manual TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 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 perform ing the hydrometer test Figure 11 6 Page 11
266. ystem ccccccccccccccnccanananananananancnnnnonona 16 2 governor cable installation and adjustment 14 6 removal susi o 14 6 ground straps eerren 12 32 Testirigus uie iden E ai e 11 15 H hour meter circuit cccccccccccnoonnnncnonnnnnnns 11 11 l ignition testing WEE 11 24 ignition coil Eet installation removal i ete e e etti ODI wes ae cn O Testirig deua EES EL inspection drive Clutch bus ecce etie drive clutch parts driven cl tch iii emet front wheel free play fuel pump pre operation and daily safety checklist 10 1 shock absorber spark plug starter generator armature A m hi bearing brush spring brushes isse ee commutator A skh tea instrument panel EE te e EE 4 6 removal ninia 4 4 K key switch engine kill circuit testing 11 31 installation oocccccccccnnnnnnanananonanananonnnnnnnnnos 12 14 removal e ice iia 12 13 starter Circuit tedere titi 11 11 kick plate removal i55 ETE TETEA 4 7 2005 Precedent Gasoline Golf Car Maintenance and Service Manual kick plate and choke button installation siig aa 4 7 kill circuit engine TESTING trar 11 18 11 23 11 31 L leaf spring see suspension front and suspension rear low oil warning light installation eei ee aet removal ue diese o eee testing cete

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