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Club Car Cafe Express Maintenance And Service Manual
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2018
Café
Express
Maintenance
and
Service
Manual
Gasoline
V
ehicle
with
Subaru
EX40
Engine
Manual
Number
105344222
Edition
Code
0617A00000
2
Table of Contents
Table of Contents
5
SECTION 1 - Safety
13
Safety Details
13
Personal Safety
13
Machine Safety
13
Information
13
General Warnings
13
Disabling the Vehicle
15
Disconnecting the Battery-Gasoline Vehicles
15
Connecting the Battery-Gasoline Vehicles
15
Recycling Lead-Acid Batteries
16
International Safety Symbols on Batteries
17
SECTION 2 - Vehicle Specifications
20
Vehicle Specifications
20
SECTION 3 - General Information
21
Model Identification
21
Storage
22
Preparing the Gasoline Vehicle for Extended Storage
23
Returning the Stored Gasoline Vehicle to Service
23
SECTION 4 - Body and Trim
25
Cleaning the Vehicle
25
Seat Cleaning
25
Front Body Repair
26
Light Scratches
26
Abrasions and Haze
26
Large Scratches and Abrasions
26
Touch-Up Paint Color Chart
26
Front Body
27
Heavy Duty Bumper Removal
27
Heavy Duty Bumper Installation
27
Cowl Removal
29
Cowl Installation
29
Grille Removal
30
Grille Installation
31
Front Bumper and Side Fender Removal
33
Front Bumper and Side Fender Installation
33
Instrument Panel Removal
34
Instrument Panel Installation
34
Dash Removal
35
Dash Installation
35
Tilt Bed
37
Tilt Bed Removal
37
Tilt Bed Installation
37
Bed Latch Assembly Removal
39
Bed Latch Assembly Installation
39
Rear Fenders and Tailskirt
41
Rear Fender and Tailskirt Removal
41
Rear Fender and Tailskirt Installation
41
Electric Bed Lift
43
Electric Bed Lift Removal
44
Electric Bed Lift Installation
44
Floor Mat
45
Floor Mat Removal
45
Floor Mat Installation
45
SECTION 5 - Accelerator and Brake Pedal Group
47
Brake Pedal and Park Brake
47
Brake Pedal Removal (Gas and Electric Vehicles)
47
Brake Pedal Installation (Gas and Electric Vehicles)
47
Park Brake Removal
50
Park Brake Installation
50
Accelerator Pedal
51
Accelerator Pedal Removal - Gasoline Vehicles
51
Accelerator Pedal Installation - Gasoline Vehicles
52
Pedal Group Adjustment
53
SECTION 6 - Wheel Brake Assemblies
59
General Information
59
Brake Shoe Removal
59
Brake Assembly Cleaning
61
Brake Shoe Installation
63
Brake Adjustment
64
Brake Cluster Adjustment
64
Brake Cable Equalization
67
Final Brake Cluster Adjustment
68
Test Drive Vehicle
68
Brake Cluster Removal and Installation
69
Front Brake Cluster Removal
69
Front Brake Cluster Installation
69
Rear Brake Cluster Removal
71
Rear Brake Cluster Installation
71
Front Brake Cables
72
Front Brake Cable Removal
73
Front Brake Cable Installation
73
Rear Brake Cables
74
Rear Brake Cable Removal
74
Rear Brake Cable Installation
74
SECTION 7 - Steering and Front Suspension
77
General Information
77
Steering Wheel
77
Steering Wheel Removal
77
Steering Wheel Installation
78
Steering Column
79
Steering Column Removal
80
Steering Column Disassembly
80
Steering Column Assembly
80
Steering Column Installation
81
Steering Adjustment
82
Rack and Pinion
83
Rack and Pinion Inspection
83
Rack and Pinion Removal - Maintenance-Free Ball Joints
83
Rack and Pinion Disassembly
84
Rack and Pinion Assembly
86
Rack and Pinion Installation - Maintenance-Free Ball Joints
89
Tie Rod and Drag Link
90
Tie Rod and Drag Link Removal - Maintenance-Free Ball Joints
90
Tie Rod and Drag Link Installation - Maintenance-Free Ball Joints
90
Front Suspension
91
Lubrication
91
Wheel Alignment
91
Front Suspension Components
93
Leaf Spring Removal
93
Leaf Spring Installation
93
Kingpin and Steering Spindle Removal - Maintenance-Free Ball Joints
93
Kingpin and Steering Spindle Installation - Maintenance-Free Ball Joints
96
Delta A-Plate Removal
96
Delta A-Plate Installation
96
Shock Absorber Removal
96
Shock Absorber Installation
96
Front Wheel Bearings and Hubs
97
Front Wheel Free Play Inspection
97
Front Hub and Wheel Bearings Removal
97
Front Hub and Wheel Bearings Installation
98
SECTION 8 - Wheels and Tires
99
General Information
99
Wheels
99
Wheel Removal
99
Wheel Installation
99
Tires
100
Tire Removal
100
Tire Repair
100
Tire Installation
101
SECTION 9 - Rear Suspension
103
General Information
103
Shock Absorbers
103
Shock Absorber Inspection and Removal
103
Shock Absorber Installation
103
Multi-Leaf Springs
104
Multi-Leaf Spring Removal
104
Multi-Leaf Spring Installation
105
SECTION 10 - Periodic Maintenance
107
General Information
107
Pre-Operation and Daily Safety Checklist
107
Performance Inspection
108
Maintenance
108
Periodic Service Schedule
109
Periodic Lubrication Schedule
111
SECTION 11 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle
113
General Information
113
Accessories
113
Low Oil Warning Light
113
Ground Locations
113
Features of the Electronic Fuel Injection (EFI) System
114
Troubleshooting Guide
114
ECU Error Codes (Displayed by the Low Oil Warning Light)
114
Gasoline Powertrain
116
Wiring Diagrams
120
Electrical System
125
Test Procedures
126
Testing Basics
126
SECTION 12 - Electrical Components: Pedal-Start Gas Vehicle
157
Starter/Generator
157
Starter/Generator Removal
157
Disassembly of the Starter/Generator to Service the Brushes
157
Brush Inspection and Replacement
158
Brush Spring Inspection and Replacement
158
Starter/Generator Assembly
159
Disassembly of the Starter/Generator to Service the Armature/Commutator
160
Bearing Cleaning and Inspection
161
Bearing Removal
162
Field Coil Assembly
162
Visual Inspection of Armature
162
Commutator Cleaning and Inspection
163
Armature Ground Test
164
Visual Inspection of Field Coils
165
Starter/Generator Rework
165
Starter/Generator Assembly
165
Starter/Generator Installation
168
Belt Tension Adjustment for EFI Engines
169
Voltage Regulator
171
Voltage Regulator Removal
171
Voltage Regulator Installation
172
Engine Control Unit (ECU)
173
Engine Control Unit Removal
173
Engine Control Unit Installation
173
Key Switch
174
Key Switch Removal
174
Key Switch Installation
174
Maintenance/Operate Switch
175
Maintenance/Operate Switch Removal
175
Maintenance/Operate Switch Installation
175
Neutral Lockout Limit Switch
175
Neutral Lockout Limit Switch Removal
175
Neutral Lockout Limit Switch Installation
175
Solenoid
176
Solenoid Removal
176
Solenoid Installation
176
Fuse
176
Fuse Removal
177
Fuse Installation
177
Kill Limit Switch
178
Kill Limit Switch Removal
178
Kill Limit Switch Installation
178
Reverse Warning Buzzer
179
Reverse Warning Buzzer Removal
179
Reverse Warning Buzzer Installation
179
Reverse Buzzer Limit Switch
181
Reverse Buzzer Limit Switch Removal
181
Reverse Buzzer Limit Switch Installation
181
Low Oil Warning Light
183
Low Oil Warning Light Removal
183
Low Oil Warning Light Installation
183
Fuel Gauge/Hour Meter
183
General Information
183
Fuel Gauge/Hour Meter Removal
183
Fuel Gauge/Hour Meter Installation
184
Fuel Level Sending Unit
184
Oil Level Sensor
184
Oil Level Sensor Removal
184
Oil Level Sensor Installation
184
Voltage Limiter
184
Voltage Limiter Removal
185
Voltage Limiter Installation
185
Headlight Switch
186
Headlight Switch Removal
186
Headlight Switch Installation
186
Headlights
186
Headlight Bezel Removal
186
Headlight Bezel Installation
186
Headlight Bulb Removal (Halogen)
187
Headlight Bulb Installation (Halogen)
187
Headlight Bulb Removal (LED)
187
Headlight Bulb Installation (LED)
187
Battery
189
General Information
189
Testing the Battery
189
Preventive Maintenance
189
Self-Discharge
190
Vibration Damage
190
Battery Removal
191
Charging the Battery
191
Battery Installation
191
Battery Storage
192
Charging a Dead Battery
192
Ground Cables
192
SECTION 13 - Engine (Subaru EX40)
193
General Information
193
Before Servicing
193
Engine Rotation
193
Torque Specifications
194
Adjustments and Settings
194
Engine Oil - Gasoline Vehicle
194
Spark Plug
197
Breather
198
Valve Clearance Check and Adjustment
199
Engine Removal
200
Engine Installation
202
Flywheel
202
Flywheel Removal
203
Flywheel Installation
204
Oil Level Sensor
204
Testing the Oil Level Sensor
204
Oil Level Sensor Removal
204
Oil Level Sensor Installation
205
Ignition Coil
206
Testing the Ignition Coil
206
Ignition Coil Removal
206
Ignition Coil Installation
206
Snubber
207
Snubber Removal
207
Snubber Installation
207
SECTION 14 - Fuel System: Gasoline Vehicles
209
General Information
209
EFI System Features/Specifications
209
Relieving Fuel Pressure
210
To Relieve Fuel Pressure
210
Throttle Body
211
Throttle Body Removal
211
Throttle Body Installation
212
Engine Control Linkages
214
General Information
214
Ground Speed
215
Accelerator Rod
215
Governor Cable
217
Accelerator Cable
219
Closed Throttle or Idle Adjustment - Pedal-Start Vehicles
220
How to Measure Ground Speed
221
Engine RPM Adjustment
221
Air Intake System
222
Air Filter
223
Air Cleaner Removal
223
Air Cleaner Installation
223
Fuel Line
224
Fuel Line Removal
224
Fuel Line Installation
225
Fuel Pump Module
226
General Information
226
Fuel Pump Module Removal
226
Fuel Pump Module Installation
226
Fuel Tank
229
General Information
229
Fuel Tank Removal
229
Fuel Tank Disposal
230
Fuel Tank Storage
230
Fuel Tank Installation
230
Fuel Filter
231
General Information
231
Fuel Filter Removal
231
Fuel Filter Installation
232
Fueling Instructions - Gasoline Vehicle
232
SECTION 15 - Exhaust System: Gasoline Vehicles
235
Muffler
235
Muffler Removal
235
Muffler Installation
235
SECTION 16 - Clutches: Gasoline Vehicles
237
General Information
237
Troubleshooting
238
Drive Belt
239
Drive Belt Removal
239
Drive Belt Installation
239
Drive Clutch
240
Drive Clutch Removal
241
Drive Clutch Cleaning and Inspection
242
Drive Clutch Disassembly
243
Inspection of Drive Clutch Parts
245
Drive Clutch Assembly
246
Drive Clutch Installation
247
Driven Clutch
248
Driven Clutch Removal
249
Driven Clutch Disassembly
249
Driven Clutch Inspection
250
Driven Clutch Assembly
250
Driven Clutch Installation
252
SECTION 17 - Transaxle (ED65): Gasoline Vehicles
253
General Information
253
Shifter Lever
253
Neutral Lockout
253
Governor System
254
Transaxle Service
254
Lubrication
254
Tools Required for this Section
255
Rear Hubs
256
Rear Hub Removal
256
Rear Hub Installation
256
Axle Tubes, Axle Shafts and Wheel Bearings
258
Axle Tube and Axle Shaft Removal
258
Axle Tube and Axle Shaft Installation
259
Rear Wheel Bearing Removal
259
Rear Wheel Bearing Installation
259
Axle Shaft Oil Seal Removal
259
Axle Shaft Oil Seal Installation
260
Transaxle Removal
261
Transaxle Installation
265
Shifter Cable
265
Shifter Cable Removal
265
Shifter Cable Installation
266
Shifter Cable Adjustment
266
SECTION 18 - Refreshment Unit
267
General Information
267
Refreshment Center Compartments
267
Cleaning
267
Interior Aluminum Surfaces
267
Exterior Aluminum Surfaces
267
Drains
268
Refreshment Center Doors
268
Canopy Cover
268
Windshield
268
Canopy
268
Canopy Removal
269
Canopy Installation
270
Canopy Frame Removal
270
Canopy Frame Installation
270
Unit Maintenance and Repairs
271
Trash Drawer
271
Slide Doors
272
Coffee Doors
273
Containers
274
Cup Holder
274
Index
275
Other manuals for Club Car Cafe Express
Owner's Manual
56 pages
Owner's Manual Supplement
20 pages
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Club Car Cafe Express Specifications
General
Model
Cafe Express
Seating Capacity
2
Power Source
Electric
Top Speed
15 mph
Charging Time
8-10 hours
Frame Material
Aluminum
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