Name: Club Car Precedent
Brand: Club Car
Rating: 4 (1 reviews)

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2020Precedent,

Villager2and4

Maintenanceand

ServiceManual

ElectricVehiclewithERICChargingSystem

GasolineVehiclewithKohlerECH440Engine

ManualNumber86753090004

EditionCodeB

Table of Contents7
SECTION 1 - Safety19
- Safety Details19
- General Warnings20
SECTION 2 - Vehicle Specifications25
- Electric - Vehicle Specifications25
- Gasoline - Vehicle Specifications27
SECTION 3 - Extended Storage31
- Electric Vehicle Extended Storage31
  - Extended Storage Preparation - Electric31
  - Return to Service from Extended Storage - Electric32
- Gasoline Vehicle Extended Storage34
  - Extended Storage Preparation - Gasoline34
  - Return to Service from Extended Storage - Gasoline35
SECTION 4 - Body and Trim37
- Cleaning the Windshield37
- Cleaning the Vehicle Exterior37
- Cleaning the Vehicle Interior38
- Body Repair38
- Seat Hinge40
  - Seat Hinge Removal40
  - Seat Hinge Installation40
- Hip Restraint41
  - Hip Restraint Removal41
  - Hip Restraint Installation41
- Front Body41
  - Front Body Removal41
- Front Body Installation42
Front Bumper44
Headlight Adjustment45
- Aiming the Headlight Beam45
Instrument Panel46
- Instrument Panel Removal46
- Instrument Panel Installation46
Dash Assembly47
- Dash Assembly Removal47
- Dash Assembly Installation47
Floor Mat and Retainers48
- Floor Mat Removal48
- Floor Mat Installation48
- Floor Mat Retainer Removal48
- Floor Mat Retainer Installation48
Kick Plate and Charger Receptacle Bezel - Electric Vehicles50
- Kick Plate and Charger Receptacle Bezel Removal50
- Kick Plate and Charger Receptacle Bezel Installation51
Kick Plate - Gasoline Vehicles52
- Kick Plate Removal52
- Kick Plate Installation52
Access Panel53
- Access Panel Removal53
- Access Panel Installation53
Visage Display Unit Overhead Baskets54
- Overhead Basket Removal54
- Overhead Basket Installation54
- Overhead Speaker Basket Removal55
- Overhead Speaker Basket Installation55
Two-Passenger - Canopy56
- Two-Passenger Canopy Removal56
- Two-Passenger Canopy Installation57
- Two-Passenger Canopy with Visage Display Unit Removal57
- Two-Passenger Canopy with Visage Display Unit Installation59
- Two-Passenger Front Canopy Strut Removal61
- Two-Passenger Front Canopy Strut Installation62
- Two-Passenger Rear Canopy Support Removal63
- Two-Passenger Rear Canopy Support Installation64
Two-Passenger - Rear Body64
- Universal Accessory Mounting64
- Structural Accessory Module (SAM)65
- Seat Back66
- Bag Rack Assembly67
- Bag Strap68
- Sweater Basket69
- Rear Beauty Panel70
- Rear Underbody71
- Rear Crossmember72
Villager 4 - Monsoon Canopy73
- Monsoon Canopy Removal73
- Monsoon Canopy Installation74
- 2+2 Front Canopy Strut Removal75
- 2+2 Front Canopy Strut Installation76
- 2+2 Rear Canopy Support Removal77
- 2+2 Rear Canopy Support Installation78
Villager 4 - Rear Body79
- Seat Backs79
- Fixed Rear Seat81
- Fold-Down Rear Seat84
- Seat Support88
- Foot Deck - 2+289
- Rear Beauty Panel (2+2 Vehicles)93
- Rear Underbody94
SECTION 5 - Accelerator and Brake Pedal Group95
- Pedal Group - Electric Vehicle95
- Pedal Group - Gasoline Vehicle98
- Debris Shields100
- Accelerator Pedal Removal100
- Accelerator Pedal Installation100
- Brake Pedal Removal101
- Brake Pedal Installation101
SECTION 6 - Wheel Brake Assemblies103
- General Information103
- Brake Shoe Removal105
- Brake Assembly Cleaning107
- Brake Shoe Installation110
- Brake Cable Equalizer Adjustment114
- Brake Cluster115
  - Brake Cluster Removal115
  - Brake Cluster Installation117
- Brake Cable119
  - Brake Cable Removal119
  - Brake Cable Installation122
SECTION 7 - Steering and Front Suspension125
- General Information125
- Steering Wheel125
  - Steering Wheel Removal125
  - Steering Wheel Installation126
- Steering Column128
  - Steering Column Removal128
  - Steering Column Installation129
- Rack and Pinion130
- Front Suspension133
  - Lubrication133
  - Wheel Alignment133
- Front Suspension Components136
- Front Wheel Hubs146
SECTION 8 - Wheels and Tires149
- General Information149
- Wheels149
  - Wheel Removal149
  - Wheel Installation149
- Tires150
SECTION 9 - Rear Suspension153
- General Information153
- Shock Absorbers153
- Panhard and Bracket156
  - Panhard and Bracket Removal156
  - Panhard and Bracket Installation156
- Leaf Springs (Two-Passenger)157
  - Leaf Spring Removal (Two-Passenger)157
  - Leaf Spring Installation (Two-Passenger)159
- Leaf Springs (Four-Passenger)160
  - Leaf Spring Removal (Four-Passenger)160
  - Leaf Spring Installation (Four-Passenger)162
- Leaf Springs (Four-Passenger - Heavy Duty with Panhard)163
  - Leaf Spring Removal (Four-Passenger - Heavy Duty with Panhard)163
  - Leaf Spring Installation (Four-Passenger - Heavy Duty with Panhard)165
SECTION 10 - Periodic Maintenance167
- General Information167
- Pre-Operation and Daily Safety Checklist167
  - Performance Inspection168
- Maintenance169
- Periodic Service Schedules170
- Periodic Lubrication Schedules174
- Air Filter176
  - Air Filter Removal176
  - Air Filter Installation176
- Engine Oil176
SECTION 11 - Controller Diagnostic Tool (CDT)183
- General Information184
  - Features184
- Plugging the CDT into the Vehicle185
  - Introductory Display185
- Quick Reference Guide - Excel with ERIC Charging System186
- System Info187
- Parameters188
- Monitor Menu191
- Diagnostics Menu196
- Fault Descriptions200
- Programming204
  - Cloning205
- Favorites205
- HHP Settings205
- Plot & Log207
  - Plot207
  - Log207
- CDT Troubleshooting208
- Connection Tests209
SECTION 12 - Electric Vehicle - Troubleshooting and Electrical System213
- General Information213
- Battery Wiring Diagram216
- Sonic Weld, Fuse, and 10K Ohm Resistor Locations217
- Troubleshooting218
  - Troubleshooting the Vehicle with the CDT218
  - Troubleshooting Guide 2221
- Test Procedures224
  - Testing Basics224
SECTION 13 - Electric Vehicle - Electrical Components245
- Key Switch245
- Charge Indicator Light246
- USB Port247
  - USB Port Removal247
  - USB Port Installation248
- Forward/Reverse Rocker Switch248
- Electronics Module Cover250
  - Electronics Module Cover Removal250
  - Electronics Module Cover Installation250
- Tow/Run Switch251
- Motor Controller Output Regulator (MCOR)252
- Reverse Buzzer253
- Electronics Module254
  - Electronics Module Removal254
  - Electronics Module Installation255
- Speed Controller256
- Solenoid257
- Charger Receptacle258
SECTION 14 - Electric Vehicle - Batteries261
- General Information261
- Battery Testing Basics - 8 Volt262
- Battery Testing - 8 Volt263
- Battery Regrouping263
- Battery Replacement265
- Battery Care266
- Single Point Watering System (SPWS)271
  - Initial Maintenance of the SPWS271
  - Watering Batteries with the SPWS271
- Battery Storage273
- Fleet Rotation273
- Deep-Discharge273
- Early Excessive Discharging273
SECTION 15 - Electric Vehicle - Battery Charger275
- General Information276
- External Charger Mounting281
- AC Power Connection282
- The Charge Circuit283
- Charger Operation284
  - Charging Batteries284
- Charger Maintenance287
  - USB Service Port Cleaning and Care287
- Charger Troubleshooting288
- Test Procedures294
- External Charger Repairs297
- Onboard Charger Repairs300
SECTION 16 - Electric Vehicle - Motor305
- General Information305
- External Motor Testing305
- Motor308
  - Motor Removal308
  - Motor Disassembly309
- Motor Component Testing and Inspection312
- Reconditioning the Motor317
  - Motor Specifications317
- Motor Assembly317
- Motor Installation319
SECTION 17 - Electric Vehicle - Transaxle323
- Lubrication323
- Axle Bearing and Shaft323
  - Axle Shaft323
  - Axle Bearing326
- Transaxle Removal327
- Transaxle Disassembly, Inspection, and Assembly329
  - Transaxle Disassembly and Inspection329
  - Transaxle Assembly331
- Transaxle Installation332
SECTION 18 - Gasoline Vehicle - Troubleshooting and Electrical System335
- General Information335
- Troubleshooting Guide336
  - Gasoline Powertrain337
- Fuse and Relay Locations339
- Electrical System340
- Test Procedures341
  - Testing Basics341
SECTION 19 - Gasoline Vehicle - Electrical Components367
- Battery367
  - General Information367
  - Preventive Maintenance368
  - Self-Discharge368
  - Vibration Damage368
  - Battery Removal369
  - Charging the Battery369
  - Battery Installation369
  - Battery Storage370
  - Charging a Dead Battery370
- Ground Cables370
- Starter/Generator370
  - Starter/Generator Removal370
  - Disassembly of the Starter/Generator to Service the Brushes371
  - Brush Inspection and Replacement371
  - Brush Spring Inspection and Replacement372
  - Starter/Generator Assembly372
  - Disassembly of the Starter/Generator to Service the Armature/Commutator373
  - Bearing Cleaning and Inspection374
  - Bearing Removal375
  - Field Coil Assembly375
  - Visual Inspection of Armature375
  - Commutator Cleaning and Inspection376
  - Armature Ground Test377
  - Visual Inspection of Field Coils378
  - Starter/Generator Rework378
  - Starter/Generator Assembly378
  - Starter/Generator Installation381
  - Belt Tension Adjustment for EFI Engines382
- Solenoid384
  - Solenoid Removal384
  - Solenoid Installation385
- Voltage Regulator386
  - Voltage Regulator Removal386
  - Voltage Regulator Installation387
- Engine Control Unit (ECU)387
  - Engine Control Unit Removal387
  - Engine Control Unit Installation388
- Fuel Level Sending Unit388
- Maintenance/Operate Switch388
  - Maintenance/Operate Switch Removal388
  - Maintenance/Operate Switch Installation389
- Accelerator Pedal Limit Switch389
- Kill Limit Switch390
- Multi-Purpose Buzzer Limit Switch390
  - Multi-Purpose Buzzer Limit Switch Removal390
  - Multi-Purpose Buzzer Limit Switch Installation391
- Neutral Lockout Limit Switch391
  - Neutral Lockout Limit Switch Removal391
  - Neutral Lockout Limit Switch Installation392
- Transaxle Limit Switch393
  - Transaxle Limit Switch Removal393
  - Transaxle Limit Switch Installation393
- Brake Light Relay394
  - Brake Light Relay Removal394
  - Brake Light Relay Installation395
- Fuel Gauge/Hour Meter395
  - General Information395
  - Fuel Gauge/Hour Meter Removal396
  - Fuel Gauge/Hour Meter Installation396
- Headlight Switch397
  - Headlight Switch Removal397
  - Headlight Switch Installation397
- Key Switch398
  - Key Switch Removal398
  - Key Switch Installation398
- Low Oil Warning Light399
  - Low Oil Warning Light Removal399
  - Low Oil Warning Light Installation399
- Malfunction Indicator Light (MIL)400
  - Malfunction Indicator Light Removal400
  - Malfunction Indicator Light Installation400
- Multi-Purpose Buzzer401
  - Multi-Purpose Buzzer Removal401
  - Multi-Purpose Buzzer Installation401
- USB Receptacle402
  - USB Receptacle Removal402
  - USB Receptacle Installation402
- Oxygen Sensor403
  - Oxygen Sensor Removal403
  - Oxygen Sensor Installation403
SECTION 20 - Gasoline Vehicle - Engine405
- General Information405
  - Before Servicing405
- Engine Removal406
- Engine Installation409
- Snubber412
  - Snubber Removal412
  - Snubber Installation412
SECTION 21 - Gasoline Vehicle - Fuel System413
- General Information413
  - EFI System Features/Specifications413
- Engine Control Linkages414
- Air Intake System422
  - Air Cleaner Removal422
  - Air Cleaner Installation422
- Relieving Fuel Pressure423
  - To Relieve Fuel Pressure423
- Carbon Canister424
  - Carbon Canister Removal424
  - Carbon Canister Installation424
- Fuel Line425
  - Fuel Line Removal425
  - Fuel Line Installation427
- Fuel Pump Module429
- Fuel Tank432
- Fuel Filter436
SECTION 22 - Gasoline Vehicle - Exhaust System439
- Muffler439
  - Muffler Removal439
  - Muffler Installation440
SECTION 23 - Gasoline Vehicle - Clutches441
- General Information441
- Troubleshooting441
- Drive Belt443
  - Drive Belt Removal443
  - Drive Belt Installation443
- Drive Clutch444
- Driven Clutch452
SECTION 24 - Gasoline Vehicle - Transaxle459
- General Information459
- Rear Hubs462
  - Rear Hub Removal462
  - Rear Hub Installation462
- Axle Tubes, Axle Shafts and Wheel Bearings464
- Transaxle Removal467
- Transaxle Installation470
- Forward/Neutral/Reverse Handle471
  - Forward/Neutral/Reverse Handle Removal471
  - Forward/Neutral/Reverse Handle Installation471
- Shifter Cable471
SECTION 25 - Kohler Engine Service Manual475
SECTION 26 - Wiring Diagrams477
- General Information477
- Engine Harness Wiring Diagram Table478
Index499

Brand	Club Car
Model	Precedent
Category	Golf Cars
Language	English

Club Car Precedent Maintenance And Service Manual

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