Club Car 2009 Electric Precedent Maintenance And Service Manual

Club Car

Golf Cars


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Table of Contents
  • General Warnings

    13
  • Serial Number Identification

    19
  • Safety Committee

    20
  • Preparing the Electric Vehicle for Extended Off-Season Storage

    21
  • Cleaning the Vehicle

    23
  • Front and Rear Body Repair

    24
  • Minor Scratches and Surface Blemishes

    25
  • Front Bumper

    27
  • Instrument Panel

    28
  • Floor Mat and Retainers

    29
  • Kick Plate and Charger Receptacle Bezel

    30
  • Universal Accessory Mounting

    31
  • Rear Body Components (Two-Passenger)

    33
  • Seat Backs

    35
  • Foot Deck

    36
  • Rear Body Components (Four-Passenger)

    37
  • Two-Passenger Canopy Removal

    38
  • Two-Passenger Canopy Installation

    40
  • Four-Passenger Canopy Removal

    42
  • Pedal Group

    43
  • Throttle Position Sensor

    45
  • Brake pedal removal

    47
  • Section 6 โ€” wheel brake assemblies

    49
  • Brake assembly cleaning

    53
  • Brake shoe installation

    55
  • Brake cable equalizer adjustment

    58
  • Brake cluster removal and installation

    59
  • Brake cable removal and installation

    61
  • Brake cable installation

    62
  • Steering wheel

    65
  • Steering wheel installation

    66
  • Steering column installation

    67
  • Rack and pinion

    68
  • Rack and pinion disassembly

    69
  • Rack and pinion assembly

    71
  • Rack and pinion installation

    72
  • Front suspension

    74
  • Front suspension components

    76
  • Leaf spring removal

    77
  • Control arm removal

    78
  • Front wheel bearings and hubs

    81
  • Section 8 โ€” wheels and tires

    83
  • Tire repair

    84
  • Tire installation

    85
  • Shock absorbers

    87
  • Leaf springs (two-passenger vehicles)

    88
  • Leaf spring installation (two-passenger vehicles)

    89
  • Leaf springs (four-passenger vehicles)

    90
  • Leaf spring installation (four-passenger vehicles)

    91
  • General warning

    93
  • Periodic service schedule

    95
  • Periodic lubrication schedule

    98
  • Section 11 โ€” iq system troubleshooting

    99
  • Wiring diagrams

    100
  • Troubleshooting

    105
  • Troubleshooting guide

    106
  • Test procedures

    111
  • Cdm troubleshooting guide

    135
  • Section 12 โ€” excel system troubleshooting

    137
  • Batt voltage

    179
  • Open armature

    186
  • Batt aux voltage

    201
  • Brake volts in

    202
  • Main cont driver

    203
  • Main coil open

    207
  • Main dropout (1 or)

    208
  • Key switch

    219
  • Battery warning light

    220
  • Battery warning light installation

    221
  • Forward/reverse rocker switch installation

    222
  • Electronics module cover

    223
  • Tow/run switch

    224
  • Testing the throttle position sensor

    225
  • Reverse buzzer

    226
  • Electronics module

    227
  • Speed controller

    230
  • Testing the solenoid

    231
  • Onboard computer (obc)

    232
  • Charger receptacle

    233
  • Charger receptacle installation

    234
  • Ferrite beads โ€“ ce mark vehicles

    236
  • Section 16 โ€” batteries

    237
  • Battery troubleshooting chart

    238
  • Battery testing โ€“ 12 volt

    239
  • Discharge test

    242
  • Battery troubleshooting examples

    244
  • Battery testing โ€“ 8 volt

    245
  • Battery replacement

    251
  • Battery care

    252
  • Battery care โ€“ vehicles without the single-point watering system

    253
  • Electrolyte level

    254
  • Battery charger

    255
  • Charging batteries

    256
  • Plug and receptacle

    257
  • Early excessive discharging

    258
  • Initial maintenance of the spws

    259
  • Battery storage

    261
  • Section 17 โ€” battery charger

    263
  • Motor identification

    265
  • Motor removal

    267
  • Motor disassembly

    268
  • Motor component testing and inspection

    271
  • Motor frame and field windings inspection

    273
  • Reconditioning the motor

    276
  • Motor installation

    278
  • Axle bearing and shaft

    281
  • Axle bearing

    284
  • Transaxle removal

    285
  • Transaxle disassembly, inspection, and assembly

    288
  • Transaxle assembly

    290
  • Transaxle installation

    291
  • Slow pedal up

    296

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