Club Car Cafe Express Maintenance And Service Manual

Club Car Cafe Express

284 pages

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2018CaféExpress

MaintenanceandService

Manual

GasolineVehiclewithSubaruEX40Engine

ManualNumber105344222

EditionCode0617A00000

Table of Contents

Table of Contents5
SECTION 1 - Safety13
- Safety Details13
- General Warnings13
SECTION 2 - Vehicle Specifications20
- Vehicle Specifications20
SECTION 3 - General Information21
- Model Identification21
- Storage22
  - Preparing the Gasoline Vehicle for Extended Storage23
  - Returning the Stored Gasoline Vehicle to Service23
SECTION 4 - Body and Trim25
- Cleaning the Vehicle25
  - Seat Cleaning25
- Front Body Repair26
- Front Body27
- Tilt Bed37
- Rear Fenders and Tailskirt41
  - Rear Fender and Tailskirt Removal41
  - Rear Fender and Tailskirt Installation41
- Electric Bed Lift43
  - Electric Bed Lift Removal44
  - Electric Bed Lift Installation44
- Floor Mat45
  - Floor Mat Removal45
  - Floor Mat Installation45
SECTION 5 - Accelerator and Brake Pedal Group47
- Brake Pedal and Park Brake47
- Accelerator Pedal51
  - Accelerator Pedal Removal - Gasoline Vehicles51
  - Accelerator Pedal Installation - Gasoline Vehicles52
- Pedal Group Adjustment53
SECTION 6 - Wheel Brake Assemblies59
- General Information59
- Brake Shoe Removal59
- Brake Assembly Cleaning61
- Brake Shoe Installation63
- Brake Adjustment64
- Brake Cluster Removal and Installation69
- Front Brake Cables72
  - Front Brake Cable Removal73
  - Front Brake Cable Installation73
- Rear Brake Cables74
  - Rear Brake Cable Removal74
  - Rear Brake Cable Installation74
SECTION 7 - Steering and Front Suspension77
- General Information77
- Steering Wheel77
  - Steering Wheel Removal77
  - Steering Wheel Installation78
- Steering Column79
- Steering Adjustment82
- Rack and Pinion83
- Tie Rod and Drag Link90
  - Tie Rod and Drag Link Removal - Maintenance-Free Ball Joints90
  - Tie Rod and Drag Link Installation - Maintenance-Free Ball Joints90
- Front Suspension91
  - Lubrication91
  - Wheel Alignment91
- Front Suspension Components93
- Front Wheel Bearings and Hubs97
SECTION 8 - Wheels and Tires99
- General Information99
- Wheels99
  - Wheel Removal99
  - Wheel Installation99
- Tires100
SECTION 9 - Rear Suspension103
- General Information103
- Shock Absorbers103
  - Shock Absorber Inspection and Removal103
  - Shock Absorber Installation103
- Multi-Leaf Springs104
  - Multi-Leaf Spring Removal104
  - Multi-Leaf Spring Installation105
SECTION 10 - Periodic Maintenance107
- General Information107
- Pre-Operation and Daily Safety Checklist107
  - Performance Inspection108
- Maintenance108
- Periodic Service Schedule109
- Periodic Lubrication Schedule111
SECTION 11 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle113
- General Information113
- Troubleshooting Guide114
  - ECU Error Codes (Displayed by the Low Oil Warning Light)114
  - Gasoline Powertrain116
- Wiring Diagrams120
- Electrical System125
- Test Procedures126
  - Testing Basics126
SECTION 12 - Electrical Components: Pedal-Start Gas Vehicle157
- Starter/Generator157
- Bearing Removal162
- Field Coil Assembly162
- Visual Inspection of Armature162
- Commutator Cleaning and Inspection163
- Armature Ground Test164
- Visual Inspection of Field Coils165
- Starter/Generator Rework165
- Starter/Generator Assembly165
- Starter/Generator Installation168
- Belt Tension Adjustment for EFI Engines169
Voltage Regulator171
- Voltage Regulator Removal171
- Voltage Regulator Installation172
Engine Control Unit (ECU)173
- Engine Control Unit Removal173
- Engine Control Unit Installation173
Key Switch174
- Key Switch Removal174
- Key Switch Installation174
Maintenance/Operate Switch175
- Maintenance/Operate Switch Removal175
- Maintenance/Operate Switch Installation175
Neutral Lockout Limit Switch175
- Neutral Lockout Limit Switch Removal175
- Neutral Lockout Limit Switch Installation175
Solenoid176
- Solenoid Removal176
- Solenoid Installation176
Fuse176
- Fuse Removal177
- Fuse Installation177
Kill Limit Switch178
- Kill Limit Switch Removal178
- Kill Limit Switch Installation178
Reverse Warning Buzzer179
- Reverse Warning Buzzer Removal179
- Reverse Warning Buzzer Installation179
Reverse Buzzer Limit Switch181
- Reverse Buzzer Limit Switch Removal181
- Reverse Buzzer Limit Switch Installation181
Low Oil Warning Light183
- Low Oil Warning Light Removal183
- Low Oil Warning Light Installation183
Fuel Gauge/Hour Meter183
- General Information183
- Fuel Gauge/Hour Meter Removal183
- Fuel Gauge/Hour Meter Installation184
Fuel Level Sending Unit184
Oil Level Sensor184
- Oil Level Sensor Removal184
- Oil Level Sensor Installation184
Voltage Limiter184
- Voltage Limiter Removal185
- Voltage Limiter Installation185
Headlight Switch186
- Headlight Switch Removal186
- Headlight Switch Installation186
Headlights186
- Headlight Bezel Removal186
- Headlight Bezel Installation186
- Headlight Bulb Removal (Halogen)187
- Headlight Bulb Installation (Halogen)187
- Headlight Bulb Removal (LED)187
- Headlight Bulb Installation (LED)187
- Battery189
- Ground Cables192
SECTION 13 - Engine (Subaru EX40)193
- General Information193
- Engine Removal200
- Engine Installation202
- Flywheel202
  - Flywheel Removal203
  - Flywheel Installation204
- Oil Level Sensor204
- Ignition Coil206
- Snubber207
  - Snubber Removal207
  - Snubber Installation207
SECTION 14 - Fuel System: Gasoline Vehicles209
- General Information209
  - EFI System Features/Specifications209
- Relieving Fuel Pressure210
  - To Relieve Fuel Pressure210
- Throttle Body211
  - Throttle Body Removal211
  - Throttle Body Installation212
- Engine Control Linkages214
- Air Intake System222
- Fuel Line224
  - Fuel Line Removal224
  - Fuel Line Installation225
- Fuel Pump Module226
- Fuel Tank229
- Fuel Filter231
- Fueling Instructions - Gasoline Vehicle232
SECTION 15 - Exhaust System: Gasoline Vehicles235
- Muffler235
  - Muffler Removal235
  - Muffler Installation235
SECTION 16 - Clutches: Gasoline Vehicles237
- General Information237
- Troubleshooting238
- Drive Belt239
  - Drive Belt Removal239
  - Drive Belt Installation239
- Drive Clutch240
- Driven Clutch248
SECTION 17 - Transaxle (ED65): Gasoline Vehicles253
- General Information253
- Rear Hubs256
  - Rear Hub Removal256
  - Rear Hub Installation256
- Axle Tubes, Axle Shafts and Wheel Bearings258
- Transaxle Removal261
- Transaxle Installation265
- Shifter Cable265
SECTION 18 - Refreshment Unit267
- General Information267
  - Refreshment Center Compartments267
- Cleaning267
- Canopy268
- Unit Maintenance and Repairs271
Index275

Other manuals for Club Car Cafe Express

Owner's Manual56 pages

Owner's Manual Supplement20 pages

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Club Car Cafe Express Specifications

General

Brand	Club Car
Model	Cafe Express
Category	Golf Cars
Language	English

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