Fairplay ZX - User Manual

Questions and Answers

C
Christian JenkinsAug 7, 2025
How to fix a Fairplay ZX parking brake that is hard to latch?
- R
  Richard FordAug 7, 2025
  If the parking brake on your Fairplay Golf Car is too hard to latch, there are a few potential causes. The pedal free play might not be correct; adjust the pedal free travel at the spherical nut and verify that the wheel brake actuators are fully returning. A sticky or dragging cable can also make the brake hard to latch; check for brake pedal return and ensure that the brake levers return at an equal rate, as uneven movement indicates a dragging cable. Lastly, glazed brake shoes can contribute to this issue; roughen up the glazed surface by sanding the shoes with emery cloth, ensuring that at least 0.06" (1.5 mm) of material remains.
J
Jon NortonAug 10, 2025
What to do if one wheel locks and the other keeps rotating on my Fairplay Golf Cars?
- A
  Amber MurphyAug 10, 2025
  If you're experiencing unequal braking on your Fairplay Golf Car, where only one wheel locks while the other continues to rotate, it could be due to a couple of reasons. The wheel that continues to rotate might not be adjusting properly, so check its brake operation when the brake is applied. Alternatively, a sticky or dragging cable could be the culprit. Check for brake pedal return and ensure that the brake cables return at an equal rate, which would indicate a dragging cable.
G
greenyeseniaAug 15, 2025
Why doesn't the parking brake lock on my Fairplay ZX Golf Cars?
- B
  Barbara MeyersAug 15, 2025
  If the park brake on your Fairplay Golf Car fails to lock when latched, the compensator spring adjustment might not be correct; return it to the factory specification. Alternatively, the brake pedal free travel could be excessive; adjust it as per the manual.
S
Shannon ClarkAug 19, 2025
Why are the brakes on my Fairplay ZX too sensitive?
- D
  davisstephenAug 19, 2025
  If the brakes on your Fairplay Golf Car are grabbing or feel oversensitive, it could be due to rust on the drums. To resolve this, drive the vehicle at maximum level ground speed while applying moderate force to the brake pedal. Repeat if necessary. Another possible cause is a binding brake pivot; check and replace parts as needed.
C
Catherine BassAug 25, 2025
How to troubleshoot wheels that do not lock on Fairplay Golf Cars?
- C
  Christine HoldenAug 25, 2025
  If the wheels on your Fairplay Golf Car do not lock when the brakes are applied, it could be that the brake system requires a complete adjustment; adjust the entire system. Another possibility is that the brake pedal is not returning properly; check the brake pedal linkage and the brake pedal free travel.
P
Peggy DavidsonAug 28, 2025
Why won't the parking brake stay latched on my Fairplay Golf Cars?
- V
  vbakerAug 28, 2025
  If the parking brake on your Fairplay Golf Car will not stay latched, it could be due to excessive wear. Check for a worn latch mechanism and replace it if needed; this part can be flipped for extended use.
S
Stephanie BryanNov 1, 2025
Why is the stopping distance too long on my Fairplay Golf Car?
- M
  Michael ElliottNov 2, 2025
  If the stopping distance of your Fairplay Golf Car exceeds acceptable limits, several factors could be responsible. It might be due to severely worn or damaged brake parts, which would require replacement. The brake pedal linkage, free travel, cables, automatic adjusters or pedal pivot could be faulty. Wet brake shoes can also increase stopping distance; check again when they are dry. Damaged or sticky brake cables should be inspected and replaced if necessary. Severely worn brake shoes should also be replaced, and glazed brake shoes need to be roughened up with emery cloth, ensuring at least 0.06" (1.5 mm) of material remains. The braking system's adjustment should be checked and corrected according to the manual. Also, inspect and repair any loose brake cables from anchor brackets, and r...

Summary

Foreword

Safety

Notes, Cautions and Warnings

Definitions of safety terms used throughout the manual.

General Information & Routine Maintenance

Serial Number Plate Location

Location and importance of serial number plates for parts identification.

Towing

Safe procedures and precautions for towing the vehicle.

Servicing the Vehicle

Essential safety and preparation steps before servicing.

Routine Maintenance

Schedule and procedures for regular vehicle upkeep.

Rear Axle Maintenance

Maintenance tasks specific to the rear axle.

Replacing the Lubricant

Step-by-step guide for replacing rear axle lubricant.

Daily Brake Test

Daily procedure to ensure brake system functionality.

Vehicle Control System

How the vehicle's control systems operate.

Care and Cleaning of the Vehicle

Proper techniques for cleaning and maintaining the vehicle's appearance.

Trailering

Instructions and safety measures for trailering the vehicle.

Torque Specifications

Specific torque values for fasteners during maintenance.

Periodic Service Schedule

A schedule outlining regular maintenance intervals and tasks.

Safety (Section B)

General Safety Practices

Broad safety recommendations for golf car operations.

Maintenance Procedures

Detailed steps for safe maintenance execution.

Operating Safety Rules and Practices

Rules and practices for safe vehicle operation.

Operator Qualifications

Requirements for individuals authorized to operate golf cars.

Driving Golf Cars

Guidelines for safe operation of the golf car.

Maintenance Practices

General guidelines and best practices for vehicle maintenance.

Important Safety Warning

Critical safety warnings for vehicle service and repair.

Before Servicing the Vehicle

Essential safety precautions before performing any maintenance.

Battery Removal & Installation

Step-by-step guide for safely removing and installing batteries.

Lifting the Vehicle

Safe procedures for raising the vehicle for maintenance.

Front Suspension and Steering

Front Shock Absorber Replacement

Procedure for replacing front shock absorbers.

Front Axle Replacement

Step-by-step guide for replacing the front axle assembly.

Front Axle Alignment

Process for ensuring correct front axle alignment.

Front Spring Replacement

Procedures for replacing the front suspension springs.

Tie Rod, Wheel Bearing, King Pin Inspection

Inspection of steering linkage and wheel bearings.

Tie Rod Replacement

Steps for replacing the tie rod.

Steering Wheel Replacement

Procedure for replacing the steering wheel.

Universal Joint Replacement

Guide for replacing the universal joint in the steering system.

Steering Shaft Replacement

Steps involved in replacing the steering shaft.

Steering Gear Case Assembly Replacement

Procedure for replacing the steering gear case assembly.

Wheel Bearing Inspection;Lubrication

How to inspect and lubricate wheel bearings.

Bearing Adjustment

Process for adjusting wheel bearings.

King Pin Bush Replacement

Procedure for replacing king pin bushes.

Wheel Alignment

Critical steps for proper wheel alignment.

Rear Suspension

Shock Absorber Removal

Steps for removing rear shock absorbers.

Shock Absorber Installation

Procedures for installing rear shock absorbers.

Rear Leaf Spring Removal

Steps for removing rear leaf springs.

Rear Axle Assembly Removal

Safe procedures for removing the rear axle assembly.

Rear Axle

Axle Shaft Removal and Disassembly

Steps for removing and disassembling the rear axle shaft.

Rear Axle Shaft Replacement

Procedure for replacing the rear axle shaft.

Mechanical Brakes

Brake System Overview

General description of the vehicle's brake system.

How the Service Brake Works

Explanation of the service brake mechanism and operation.

Automatic Adjuster Mechanism

How the automatic brake adjuster functions to compensate for wear.

How the Parking Brake Works

Explanation of the parking brake's operational mechanism.

Troubleshooting Table

A guide to diagnosing and solving common brake problems.

Brake Pedal and Linkage Inspection

Procedures for inspecting the brake pedal and its associated linkage.

Check the Brake Pedal Free Travel

Method for checking and adjusting brake pedal free travel.

Periodic Brake Performance Test (PBPT)

Standardized test for evaluating overall brake system performance.

Wheel Brake Inspection

Detailed inspection of individual wheel brake components.

Maintenance and Repairs

Comprehensive section on brake system maintenance and part replacement.

Adjusting Brake Pedal Free Travel

Detailed steps for adjusting brake pedal free travel.

Backing Plate;Wheel Brake Assembly Service

Procedures for removing and installing wheel brake assemblies.

Brake Cable and Equalizer Assembly Service

Steps for replacing brake cables and equalizer components.

Compensator Assembly Service

Procedure for removing and installing the brake compensator assembly.

Brake Pedal Service

Steps for removing and installing the brake pedal.

Parking Brake Pedal Service

Procedure for removing and installing the parking brake pedal.

Parking Brake Linkage and Kick-Off Cam Service

Replacing parking brake release linkage and kick-off cam.

Wheels and Tires

Wheel and Tire Service

General service procedures for wheels and tires.

Tire Repair

Methods for repairing flat tires.

Wheel Installation

Procedures for mounting wheels onto the vehicle hub.

Motor

Removing Motor

Safe procedures for removing the electric motor.

Disassembling Motor

Detailed steps for disassembling the motor.

Replacing Bearing

Procedure for replacing motor bearings.

Replacing Brush

Steps for replacing worn motor brushes.

Brush Wear

How to inspect and measure motor brush wear.

Assembling Motor

Procedures for reassembling the motor after service.

Motor Test

Methods for testing the motor's performance.

Installing Motor

Steps for installing the motor onto the vehicle.

Electronic Speed Control (Non-PDS)

General (ESC)

Overview of the electronic speed control system components.

Pedal Box

Description of the pedal box components.

Controller

Description of the speed controller unit and its function.

General Troubleshooting (ESC)

Common troubleshooting steps for the ESC system.

Testing Battery Voltage

Verifying battery voltage as a diagnostic step for ESC.

Continuity Check

Method for checking electrical continuity in circuits.

Testing a Switch for Continuity

How to test switches using a multimeter.

Testing a Solenoid for Continuity

How to test solenoids for continuity.

Controller Parameters Setup Specification

Guide for configuring controller parameters and settings.

Test to Controller Fault

Procedure for identifying and diagnosing controller faults.

Controller Fault Code Retrieval and Solutions

Detailed reference for controller fault codes and their solutions.

Accelerator Testing and Replacement

Procedures for testing and replacing the accelerator system.

Controller Replacement

Steps for replacing the electronic speed controller.

Solenoid Replacement

Procedure for replacing the speed control solenoid.

Battery and Charger

Battery Care and Maintenance

Essential practices for maintaining battery health and longevity.

Electrolyte Level and Water Level

Procedures for checking and maintaining battery electrolyte levels.

Cleaning the Battery

Steps for safely cleaning battery terminals and surfaces.

Battery Replacement

Safe procedures for removing and installing vehicle batteries.

Prolonged Storage

Recommendations for storing batteries for extended periods.

Charging Battery

Important precautions and steps for charging the vehicle's batteries.

Troubleshooting (Charger)

Guide for diagnosing and resolving issues with the battery charger.

Understanding Charger

Explanation of how the battery charger operates and its features.

Battery Charger Maintenance

Routine maintenance procedures for the battery charger.

Continuity Check

Method for testing electrical continuity in charger circuits.

Diode Test Procedure

How to test diodes within the charger.

Charger Troubleshooting Procedures

A flowchart to guide troubleshooting of charger malfunctions.

Body

Body Component Replacement

General procedures for replacing body panels and components.

Accessory Wirings

DVOM Usage

Explanation and use of the Digital Volt-Ohm Meter for diagnostics.

Wiring Troubleshooting

General approach and logic for diagnosing wiring problems.

Power Supply Checks

Steps to verify power supply to the accessory circuits.

Accessory Wiring Checks

Procedures for checking wiring integrity and connections for accessories.

Paint

Minor Scratches Repair

Procedure for repairing minor paint damage on the vehicle body.

Larger Scratches Repair

Method for repairing larger paint scratches on the vehicle body.

Complete Panel Repair

Guidance on panel replacement versus touch-up painting.

Troubleshooting

Electrical System Troubleshooting

Troubleshooting common electrical system issues.

Front Suspension and Steering Troubleshooting

Troubleshooting common problems related to suspension and steering.

General Specifications

Vehicle Parameters (4 P)

Key technical specifications for the 4-passenger model.

Electrical System (2 P)

Specifications for the 2-passenger model's electrical system.

Electrical System (6 P)

Specifications for the 6-passenger model's electrical system.

Speed Control Specifications

Information regarding the vehicle's speed control system.

Vehicle Dimensions (2 P)

Physical dimensions of the 2-passenger model.

Incline & Turning Clearance (2 P)

Performance specifications like grade capability and turning radius.

Vehicle Dimensions (6 P)

Physical dimensions of the 6-passenger model.

General Safety Warnings

General safety warnings for vehicle operation.

Pre-Service Safety Precautions

Critical safety precautions before performing any maintenance.

Fairplay ZX Specifications

General

Motor	48V AC
Battery	8 x 6V
Forward Speed	15 mph
Top Speed	19 mph
Charger	Onboard
Frame	Steel
Suspension	Independent

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