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2009-2011 Club Car Gasoline Precedent Maintenance And Service Manual

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SKU: 103472702 Category:

Description

This Official 2009-2011 Club Car Gasoline Precedent Maintenance And Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2009, 2010, 2011 Club Car Gasoline Precedent Golf Cars.

 2009-2011 Club Car Gasoline Precedent Maintenance And Service Manual Table of Contents

SECTION 1 – SAFETY
General Warnings
Disabling the Vehicle
Disconnecting the Battery – Gasoline Vehicles
Connecting the Battery – Gasoline Vehicles
Recycling Lead-Acid Batteries
International safety symbols on batteries

SECTION 2 – VEHICLE SPECIFICATIONS

SECTION 3 – GENERAL INFORMATION
Serial Number Identification
Safety Committee
Storage – Gasoline Vehicle
Preparing the Gasoline Vehicle for Extended Storage
Returning the Stored Gasoline Vehicle to Service

SECTION 4 – BODY AND TRIM
Cleaning the Vehicle
Seat
Front and Rear Body Repair
Stress Lines or Streaks
Minor Impact Damage/Deformations
Minor Scratches and Surface Blemishes
Gouges, Punctures, Tears, Large Scratches, and Abrasions
Front Body
Front Body Removal
Front Body Installation
Front Bumper
Instrument Panel
Instrument Panel Removal
Instrument Panel Installation
Floor Mat and Retainers
Floor Mat Retainer Removal
Floor Mat Retainer Installation
Kick Plate and Choke Button Bezel
Kick Plate and Choke Button Removal
Kick Plate and Choke Button Installation
Rear Body – Two-Passenger Vehicles
Universal Accessory Mounting
Backrest and Structural Accessory Module (SAM)
Rear Body Components (Two-Passenger)
Rear Body – Four-Passenger Vehicles
Seat Backs
Seat Support
Foot Deck
Rear Body Components (Four-Passenger)
Canopy – Two-Passenger
Two-Passenger Canopy Removal
Two-Passenger Canopy Installation
Canopy – Four-Passenger
Four-Passenger Canopy Removal
Four-Passenger Canopy Installation
Canopy (Monsoon Version) – Four-Passenger
Monsoon Canopy Removal
Monsoon Canopy Installation

SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Pedal Group – Gen I
Pedal Group Removal
GCOR
Debris Shields
Brake Return Spring
Pawl Assembly
Accelerator Return Spring
Pedal Group Installation
Pedal Group – Gen II
Pedal Group Removal
Throttle Position Sensor
Debris Shields
Accelerator Pedal Removal
Accelerator Pedal Installation
Brake Pedal Removal
Brake Pedal Installation
Pedal Group Installation

SECTION 6 – WHEEL BRAKE ASSEMBLIES
General Information
Brake Shoe Removal
Brake Assembly Cleaning
Brake Shoe Installation
Brake Cable Equalizer Adjustment
Brake Cluster Removal and Installation
Brake Cluster Removal
Brake Cluster Installation
Brake Cable Removal and Installation
Brake Cable Removal
Brake Cable Installation

SECTION 7 – STEERING AND FRONT SUSPENSION
General Information
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Installation
Rack and Pinion
Rack and Pinion Inspection
Rack and Pinion Removal
Rack and Pinion Disassembly
Rack and Pinion Assembly
Rack and Pinion Installation
Front Suspension
Lubrication
Wheel Alignment
Front Suspension Components
Tie Rod End Removal
Tie Rod Installation
Leaf Spring Removal
Leaf Spring Installation
Kingpin and Steering Spindle Removal
Kingpin and Steering Spindle Installation
Control Arm Removal
Control Arm Installation
Shock Absorber Removal
Shock Absorber Installation
Front Wheel Bearings and Hubs
Front Wheel Free Play Inspection
Front Flub Removal
Flub Installation
SECTION 8 – WHEELS AND TIRES
General Information
Wheels
Wheel Removal
Wheel Installation
Tires
Tire Removal
Tire Repair
Tire Installation

SECTION 9 – REAR SUSPENSION
General Information
Shock Absorbers
Shock Absorber Removal and Inspection
Shock Absorber Installation
Leaf Springs (Two-Passenger Vehicles)
Leaf Spring Removal (Two-Passenger Vehicles)
Leaf Spring Installation (Two-Passenger Vehicles)
Leaf Springs (Four-Passenger Vehicles)
Leaf Spring Removal (Four-Passenger Vehicles)
Leaf Spring Installation (Four-Passenger Vehicles)

SECTION 10 – PERIODIC MAINTENANCE
General Information
Periodic Service Schedules
Periodic Lubrication Schedules
Engine Oil
Engine Oil Level Check
Engine Oil And Filter Change
Battery – Gasoline Vehicles

SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM – GCOR
General Information
Troubleshooting Guide
Wiring Diagrams – GCOR
Electrical System
Test Procedures

SECTION 12 – TROUBLESHOOTING AND ELECTRICAL SYSTEM – TPS
General Information
Troubleshooting Guide
Wiring Diagrams – Throttle Position Sensor
Electrical System
Test Procedures

SECTION 13 – ELECTRICAL COMPONENTS
Starter/Generator (Model G425419)
Testing the Starter/Generator
Starter/Generator Removal
Disassembly of the Starter/Generator to Service the Brushes
Brush Inspection and Replacement
Brush Spring Inspection and Replacement
Starter/Generator Assembly
Disassembly of the Starter/Generator to Service the Armature/Commutator
Bearing Cleaning and Inspection
Bearing Removal
Field Coil Removal
Visual Inspection of Armature
Commutator Cleaning and Inspection
Armature Ground Test
Visual Inspection of Field Coils
Starter/Generator Rework
Starter/Generator Assembly
Starter/Generator Installation
Belt Tension Adjustment
Starter/Generator (Model 114-01-4005B)
Testing the Starter/Generator
Starter/Generator Removal
Disassembly of the Starter/Generator to Service the Brushes
Brush Inspection and Replacement
Brush Spring Inspection and Replacement
Starter/Generator Assembly
Disassembly of the Starter/Generator to Service the Armature/Commutator
Bearing Cleaning and Inspection
Bearing Removal
Field Coil Assembly
Visual Inspection of Armature
Commutator Cleaning and Inspection
Armature Ground Test
Visual Inspection of Field Coils
Starter/Generator Rework
Starter/Generator Assembly
Starter/Generator Installation
Belt Tension Adjustment
Voltage Regulator
Testing the Voltage Regulator
Voltage Regulator Removal
Voltage Regulator Installation
Key Switch
Testing the Key Switch
Key Switch Removal
Key Switch Installation
Solenoid
Testing the Solenoid
Solenoid Removal
Solenoid Installation
Fuse
Testing the Fuse
Fuse Removal
Fuse Installation
Limit Switches
Accelerator Pedal Limit Switch
Kill Limit Switch
Neutral Lockout Limit Switch
Neutral Lockout Cam
Testing the Neutral Lockout Cam
Neutral Lockout Cam Removal
Neutral Lockout Cam Installation
Reverse Warning Buzzer
Testing the Reverse Warning Buzzer
Reverse Warning Buzzer Removal
Reverse Warning Buzzer Installation
Reverse Buzzer Limit Switch
Testing the Reverse Buzzer Limit Switch
Reverse Buzzer Limit Switch Removal
Reverse Buzzer Limit Switch Installation
Low Oil Warning Light
Testing the Low Oil Warning Light
Low Oil Warning Light Removal
Low Oil Warning Light Installation
Fuel Gauge
Testing the Fuel Gauge
Fuel Gauge Removal
Fuel Gauge Installation
Fuel Level Sending Unit
Testing the Fuel Level Sending Unit
Hour Meter
Testing the Hour Meter
Hour Meter Removal
Hour Meter Installation
RPM Limiter
Testing the RPM Limiter
RPM Limiter Removal
RPM Limiter Installation
Ignition Coil
Testing Ignition Coil
Ignition Coil Removal
Ignition Coil Installation
Oil Level Sensor
Testing the Oil Level Sensor
Oil Level Sensor Removal
Oil Level Sensor Installation
Battery
General Information
Preventive Maintenance
Self-Discharge
Water Level
Vibration Damage
Mineral Content
Battery Removal
Charging the Battery
Battery Installation
Battery Storage
Charging a Dead Battery
Ground Cables
Testing the Ground Cables

SECTION 14 – AS11 FE 350 ENGINE
General Information
Before Servicing
Engine Rotation
Spark Plug
Cylinder Head
General Information
Breather Valve (Reed Valve)
Crankcase
Engine Removal
Crankcase Cover Removal
Oil Level Sensor
Crankcase Cover Installation
Ignition Coil and Flywheel
Ignition Coil and Flywheel Removal
Flywheel Installation
Ignition Coil Inspection and Repair
Ignition Coil Installation
Crankcase Cover Installation
Engine Installation
Torque Specifications
Adjustments and Settings
General Information
Before Servicing
Engine Rotation
Spark Plug
Cylinder Head

SECTION 15 – AS26 FE 350 ENGINE
General Information
Breather Valve (Reed Valve)
Valve Clearance Check and Adjustment
Crankcase
Engine Removal
Crankcase Cover Removal
Oil Level Sensor
Crankcase Cover Installation
Ignition Coil and Flywheel
Ignition Coil and Flywheel Removal
Flywheel Installation
Ignition Coil Installation
Crankcase Cover Installation
Engine Installation
Torque Specifications
Adjustments and Settings

SECTION 16 – FUEL SYSTEM
General Information
Carburetor
Main Jet Elevation/Size Chart
Changing the Main Jet
Engine Control Linkage
General Information
Governor Cable
Accelerator Cable
Closed Throttle or Idle Adjustment
Engine RPM Adjustment
Choke and Air Intake System
General Information
Choke Button
Air Intake Components Removal
Air Intake Components Installation
Air Filter
Fuel Filter
General Information
Fuel Filter Removal
Fuel Filter Installation
Fuel Pump
General Information
Fuel Pump Removal
Fuel Pump Disassembly (Metal Pump Only)
Fuel Pump Cleaning and Inspection (Metal Pump Only)
Fuel Pump Assembly (Metal Pump Only)
Fuel Pump Installation
Fuel Tank
General Information
Fuel Tank Removal
Fuel Tank Disposal
Fuel Tank Storage
Fuel Tank Installation
Fuel Lines
Fuel Shut-Off Valve
Fully Open Position
Carbon Canister (If Equipped)
Carbon Canister Removal

SECTION 17 – EXHAUST SYSTEM
Muffler
Muffler Removal
Muffler Installation

SECTION 18 – UNITIZED TRANSAXLE
General Information
Shifter Lever
Neutral Lockout
Governor System
Unitized Transaxle Service
Tools Required For This Section
Lubrication
Axle Shaft
Axle Shaft and Oil Seal Removal
Axle Bearing
Axle Shaft Installation
Unitized Transaxle Removal
Unitized Transaxle Installation
Forward/Reverse Shifter Cable
Forward/Reverse Shifter Cable Removal
Forward/Reverse Shifter Cable Installation
Forward/Reverse Shifter Cable Adjustment

SECTION 19-TORQUE CONVERTER: GASOLINE VEHICLE
General Information
Troubleshooting
Drive Belt
Drive Belt Removal
Drive Belt Installation
Drive Clutch
Drive Clutch Removal
Drive Clutch Cleaning and Inspection
Drive Clutch Disassembly
Inspection of Drive Clutch Parts
Drive Clutch Assembly
Drive Clutch Installation
Driven Clutch
Driven Clutch Removal
Driven Clutch Disassembly
Driven Clutch Inspection
Driven Clutch Assembly
Driven Clutch Installation

SECTION i – INDEX

Additional information

Weight 2 lbs
Dimensions 10 × 7.5 × 0.7 in