Club Car Tempo 2020 Maintenance And Service Manual
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Club Car Tempo 2020 Maintenance And Service Manual

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Tempo, Tempo Connect,
and Tempo 2+2
Maintenance and
Service Manual
Electric Vehicle with ERIC Charging System
Gasoline Vehicle with Kohler ECH440 Engine
Gasoline Vehicle with Subaru EX-40 Engine
Manual Number 86753090024
Edition Code C

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Do you have a question about the Tempo 2020 and is the answer not in the manual?

Questions and answers

Dan
March 8, 2025

I have headlights on my tempo. Each unit (left and right) is split into two sections. One lower section is lit any time the key is "on". The upper section only lights when the headlight switch is "on" or pulled. This is normal. My question has to do with the voltage going to each section of the headlight unit. The lower section measures about 8 volts and the upper measures about ****volts. Are these readings normal?

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Summary of Contents for Club Car Tempo 2020

  • Page 1 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Electric Vehicle with ERIC Charging System Gasoline Vehicle with Kohler ECH440 Engine Gasoline Vehicle with Subaru EX-40 Engine Manual Number 86753090024 Edition Code C...
  • Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (1-800-258-2227), or scan this Quick Response (QR) code to be taken to the Club Car dealer locator. Refer to Figure 1. Download a QR code reader such as RedLaser or Barcode Scanner to your cell phone or tablet.
  • Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.
  • Page 5 Serial Number Decal 2843B Figure -1 Serial Number Decal © Copyright 2020 Club Car, LLC Club Car is a registered trademark of Club Car, LLC This manual effective January, 2020 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page iii...

  • Page 7: Table Of Contents

    CONTENTS SECTION 1 — Safety............................1-1 Safety Details ..............................1-1 General Warnings............................1-2 Disabling the Vehicle..........................1-3 Disconnect the Battery - Gasoline Vehicles....................1-3 Connect the Battery - Gasoline Vehicles...................... 1-4 Disconnect the Batteries – Electric Vehicles ....................1-4 Connect the Batteries – Electric Vehicles ....................1-5 Recycling Lead-Acid Batteries ........................
  • Page 8 Gouges, Punctures, Tears, Large Scratches, and Abrasions................. 4-3 Seat Hinge ..............................4-4 Seat Hinge Removal ..........................4-4 Seat Hinge Installation ..........................4-4 Hip Restraint ..............................4-5 Hip Restraint Removal ..........................4-5 Hip Restraint Installation ..........................4-5 Front Body ..............................4-6 Front Body Removal ..........................
  • Page 9 Monsoon Canopy Removal ........................4-38 Monsoon Canopy Installation........................4-39 2+2 Front Canopy Strut Removal......................4-40 2+2 Front Canopy Strut Installation ......................4-41 2+2 Rear Canopy Support Removal......................4-42 2+2 Rear Canopy Support Installation....................... 4-43 2+2 - Rear Body ............................4-44 Seat Backs..............................
  • Page 10 Front Suspension Components........................7-10 Tie Rod End Removal ..........................7-10 Tie Rod Installation ..........................7-12 Leaf Spring Removal ..........................7-12 Leaf Spring Installation..........................7-13 Kingpin and Steering Spindle Removal ..................... 7-14 Kingpin and Steering Spindle Installation....................7-15 Control Arm Removal..........................7-17 Control Arm Installation ..........................
  • Page 11 Periodic Lubrication Schedules........................10-8 Electric Vehicle - Periodic Lubrication Schedule ..................10-8 Gasoline Vehicle - Periodic Lubrication Schedule..................10-9 Air Filter ..............................10-10 Air Filter Removal ...........................10-10 Air Filter Installation ..........................10-10 Kohler ECH440 - Engine Oil ........................10-10 Kohler ECH440 - Engine Oil Viscosity ......................10-10 Kohler ECH440 - Engine Oil Level Inspection ...................
  • Page 12 Pedal Counters............................11-13 Fault Counters............................11-13 Fault Count Odometers ........................... 11-14 Diagnostics Menu ............................11-15 Present Errors Folder..........................11-15 Fault History Folder ..........................11-15 Causes of Faults ............................ 11-16 Fault Recovery ............................11-18 Fault Descriptions............................11-19 Incorrect Password (OEM Access Level Only) ..................11-19 Max Password Tries (OEM Access Level Only) ..................
  • Page 13 Key Switch Installation ..........................13-1 Charge Indicator Light..........................13-2 Testing the Charge Indicator Light......................13-2 Charge Indicator Light Removal........................ 13-2 Charge Indicator Light Installation ......................13-2 USB Port..............................13-3 USB Port Removal........................... 13-3 USB Port Installation ..........................13-4 Forward/Neutral/Reverse Rocker Switch ....................... 13-4 Testing the Forward/Neutral/Reverse Rocker Switch ..................
  • Page 14 Watering Batteries with the SPWS ......................14-11 Battery Storage ............................14-13 Fleet Rotation.............................14-13 Deep-Discharge ............................14-13 Early Excessive Discharging ........................14-13 SECTION 15 — Electric Vehicle - Battery Charger ..................... 15-1 General Information ............................. 15-2 IC 650 Battery Charger Specifications......................15-3 Governmental And Industry Certifications...................... 15-3 European Conformity ..........................
  • Page 15 DC Cord Removal ..........................15-52 DC Cord Installation..........................15-52 SECTION 16 — Electric Vehicle - Motor ......................16-1 General Information ............................. 16-1 External Motor Testing ..........................16-1 Motor ................................16-4 Motor Removal ............................16-4 Motor Disassembly ..........................16-5 Motor Component Testing and Inspection...................... 16-8 Armature Inspection and Testing.......................
  • Page 16 Features of the Electronic Fuel Injection (EFI) System ................19-1 Ground Locations ............................ 19-1 Low Oil Warning Light ..........................19-2 Malfunction Indicator Light........................19-2 Troubleshooting Guide ..........................19-2 Gasoline Powertrain ..........................19-3 Fuse And Relay Locations..........................19-5 Electrical System ............................19-6 Test Procedures ............................
  • Page 17 Transaxle Limit Switch Removal ......................20-27 Transaxle Limit Switch Installation ......................20-27 Brake Light Relay ............................20-28 Brake Light Relay Removal ........................20-28 Brake Light Relay Installation ........................20-29 Fuel Gauge/Hour Meter ..........................20-29 General Information ..........................20-29 Fuel Gauge/Hour Meter Removal ......................20-30 Fuel Gauge/Hour Meter Installation......................20-30 Headlight Switch............................20-31 Headlight Switch Removal........................20-31 Headlight Switch Installation........................20-31...
  • Page 18 Fuel Pump Module............................22-17 General Information ..........................22-17 Fuel Pump Module Removal ........................22-17 Fuel Pump Module Installation.........................22-19 Fuel Tank ..............................22-20 General Information ..........................22-20 Fuel Tank Removal ..........................22-20 Fuel Tank Disposal ..........................22-22 Fuel Tank Storage ..........................22-22 Fuel Tank Installation ..........................22-22 Fuel Filter..............................22-24 General Information ..........................22-24 Fuel Filter Removal..........................22-24 Fuel Filter Installation..........................22-25 SECTION 23 —...
  • Page 19 Disassembly of the Starter/Generator to Service the Brushes ..............27-1 Brush Inspection and Replacement......................27-2 Brush Spring Inspection and Replacement ....................27-2 Starter/Generator Assembly ........................27-3 Disassembly of the Starter/Generator to Service the Armature/Commutator ..........27-4 Bearing Cleaning and Inspection ......................27-5 Bearing Removal .............................
  • Page 20 Testing the Battery ..........................27-30 Preventive Maintenance..........................27-30 Self-Discharge............................27-31 Vibration Damage ...........................27-31 Battery Removal .............................27-32 Charging the Battery ..........................27-32 Battery Installation ..........................27-32 Battery Storage ............................27-33 Charging a Dead Battery.........................27-33 Ground Cables ............................27-33 SECTION 28 — Subaru EX-40 - Engine ......................28-1 General Information ............................. 28-1 Before Servicing ............................
  • Page 21 Fuel Line Removal..........................29-15 Fuel Line Installation ..........................29-16 Fuel Pump Module............................29-17 General Information ..........................29-17 Fuel Pump Module Removal ........................29-18 Fuel Pump Module Installation.........................29-18 Fuel Tank ..............................29-21 General Information ..........................29-21 Fuel Tank Removal ..........................29-21 Fuel Tank Disposal ..........................29-22 Fuel Tank Storage ..........................29-22 Fuel Tank Installation ..........................29-22 Fuel Filter..............................29-24 General Information ..........................29-24...

  • Page 23: Section 1 - Safety

    SECTION 1 — SAFETY SAFETY DETAILS Safety WARNING • This owner’s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual could result in property damage, severe personal injury, or death. It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER, WARNING, or CAUTION.

  • Page 24: General Warnings

    • The vehicle will not provide protection from lightning, flying objects, or other storm-related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.

  • Page 25: Disabling The Vehicle

    SAFETY General Warnings WARNING • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. • Ensure battery connections are clean and properly tightened. Electric vehicles only: • Place Run/Tow switch in the TOW position before disconnecting or connecting the batteries. Failure to heed this warning could result in a battery explosion or severe personal injury.

  • Page 26: Connect The Battery - Gasoline Vehicles

    General Warnings SAFETY CONNECT THE BATTERY - GASOLINE VEHICLES Connect the positive (+) cable (2) (Figure 1-1, Page 1-3). Connect the negative (-) cable (1). Tighten the hardware to 41 lb·in (4.3 N·m). Apply battery terminal protector spray to the battery terminals. DISCONNECT THE BATTERIES –...

  • Page 27: Connect The Batteries - Electric Vehicles

    SAFETY General Warnings CONNECT THE BATTERIES – ELECTRIC VEHICLES DANGER • Batteries disconnected or connected with the Run/Tow switch set to RUN can cause a battery explosion and serious personal injury. Set the Run/Tow switch to TOW before the batteries are disconnected or connected.

  • Page 28: Recycling Lead-Acid Batteries

    Responsibility for environmental protection must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. 1403...

  • Page 29: Section 2 - Vehicle Specifications

    SECTION 2 — VEHICLE SPECIFICATIONS ELECTRIC - VEHICLE SPECIFICATIONS Vehicle Specifications DIMENSIONS DESCRIPTION 2 PASSENGER 4 PASSENGER Length 91.5 in (232 cm) 104 in. (264 cm) Width 47.25 in (120 cm) 47.25 in (120 cm) Height - at steering wheel 48.0 in (122 cm) 48.0 in (122 cm) Height - with canopy...

  • Page 30: Noise And Vibration

    Electric - Vehicle Specifications VEHICLE SPECIFICATIONS NOISE AND VIBRATION DESCRIPTION 2 PASSENGER 4 PASSENGER Drive-by Noise Level To Operator 68.5 dBA (± 2) 68.5 dBA (± 2) EN 12053:2001 Vibration At Driver's Seat 0.6 (m/s²)² (± 0.114) 0.8 (m/s²)² (± 0.072) EN 13059:2002 TRANSAXLE DESCRIPTION...

  • Page 31: Kohler Ech440 - Vehicle Specifications

    VEHICLE SPECIFICATIONS Kohler ECH440 - Vehicle Specifications TERM DEFINITION Gross Trailer Weight The gross trailer weight is the trailer weight plus the weight of the load on the trailer. The vehicle rated capacity is the maximum weight on the vehicle. This capacity includes the weight Vehicle Rated Capacity of: bed load, cargo, occupants, and optional equipment.

  • Page 32: Gasoline Engine

    Kohler ECH440 - Vehicle Specifications VEHICLE SPECIFICATIONS GASOLINE ENGINE DESCRIPTION 2 PASSENGER 4 PASSENGER Horsepower 14 hp (10.4 kw) at 3600 rpm (per SAE J1940) ● ● Fuel Type Gasoline with less than 10% ethanol rating ● ● Fuel Capacity 5.6 gal (21.2 l) ●...

  • Page 33: Subaru Ex-40 - Vehicle Specifications

    VEHICLE SPECIFICATIONS Subaru EX-40 - Vehicle Specifications VEHICLE WEIGHTS AND LOAD CAPACITIES 2 PASSENGER 4 PASSENGER Vehicle Rated Capacity Not Applicable Not Applicable Vehicle Combination Rated Capacity Not Applicable Not Applicable Maximum Gross Vehicle Weight Not Applicable Not Applicable Maximum Gross Vehicle Combination Weight Not Applicable Not Applicable TERM...

  • Page 34: Performance

    Subaru EX-40 - Vehicle Specifications VEHICLE SPECIFICATIONS PERFORMANCE DESCRIPTION 2 PASSENGER 4 PASSENGER 12 to 15 mph (19 to 24 km/h) - factory setting Forward speed (On Level Ground) 19 mph (30.6 km/h) - maximum Curb To Curb 207.8 in (528 cm) 207.8 in (528 cm) TIRES DESCRIPTION...
  • Page 35 VEHICLE SPECIFICATIONS Subaru EX-40 - Vehicle Specifications WARNING • Too much weight in the vehicle can affect the vehicles handling, or cause component failure, resulting in loss of control of the vehicle and serious personal injury. Do not exceed the vehicle load capacities. •...
  • Page 36 Subaru EX-40 - Vehicle Specifications VEHICLE SPECIFICATIONS Pagination Page Page 2-8 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 37: Section 3 - Extended Storage

    SECTION 3 — EXTENDED STORAGE DANGER Extended Storage • See General Warnings on page 1-2. DANGER • Fuel is flammable and explosive. Do not attempt to drain fuel when the engine is hot or while it is running. • Fuel is flammable and explosive. Do not operate the vehicle when fuel is spilled. Correctly clean the spilled fuel.

  • Page 38: Return To Service From Extended Storage - Electric

    Electric Vehicle Extended Storage EXTENDED STORAGE Set the Forward/Neutral/Reverse control (FNR) to N. Turn the key to OFF. Remove the key. Keep the key in a safe area. Put chocks against the wheels. NOTE: Do not engage the park brake. Remove all cargo and personal items.
  • Page 39 EXTENDED STORAGE Electric Vehicle Extended Storage Have a trained technician lubricate the vehicle. Do a daily pre-operation safety checklist. Do a vehicle performance inspection. Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 3-3...

  • Page 40: Gasoline Vehicle Extended Storage

    Gasoline Vehicle Extended Storage EXTENDED STORAGE GASOLINE VEHICLE EXTENDED STORAGE See General Warnings on page 1-2. EXTENDED STORAGE PREPARATION - GASOLINE Examine the battery state of charge (SOC) condition. If the SOC is weak, charge the battery. NOTE: Use an automotive-type 12-volt battery charger rated at 10-amps or less. Turn off all accessories.

  • Page 41: Return To Service From Extended Storage - Gasoline

    EXTENDED STORAGE Gasoline Vehicle Extended Storage Prepare the engine for extended storage: 14.1. Disconnect the spark plug wire (1) (Figure 3-2, Page 3-5). Figure 3-2 Left: Subaru / Right: Kohler 14.2. Use a spark plug socket to remove the spark plug. 14.3.
  • Page 42 Gasoline Vehicle Extended Storage EXTENDED STORAGE Figure 3-3 Left: Kohler / Right: Subaru WARNING • Fuel is flammable and explosive. Make sure that the fuel tube is fully connected. 2.2. Connect the vent tube to the fuel tank vent nipple. Connect the battery.

  • Page 43: Section 4 - Body And Trim

    SECTION 4 — BODY AND TRIM DANGER Body and Trim • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. CLEANING THE WINDSHIELD CAUTION • Do not use a household window cleaner. Use a soft towel and water to clean the windshield. Use mild soap as necessary. CLEANING THE VEHICLE EXTERIOR CAUTION •...

  • Page 44: Cleaning The Vehicle Interior

    Cleaning the Vehicle Interior BODY AND TRIM CLEANING THE VEHICLE INTERIOR CAUTION • Moisture will cause electrical component damage. Do not use a pressure washer or steam cleaner to clean the vehicle. • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat bottom from the vehicle first.

  • Page 45: Minor Scratches And Surface Blemishes

    BODY AND TRIM Body Repair CAUTION • Holding the heat gun too close to the body could melt the body or damage the finish. Do not hold the heat gun closer than 6 inches (15 cm) to the body. Continue heating and bending the body until the original shape returns. Do not hold the gun closer than 6 inches (15 cm) to the body.

  • Page 46: Seat Hinge

    Seat Hinge BODY AND TRIM SEAT HINGE The seat bottom (1) is attached to the vehicle with two hinges (3) that hook into slots in the body. Figure 4-1 Seat Bottom Hinge SEAT HINGE REMOVAL Remove the seat bottom (1) from the vehicle (Figure 4-1). Remove the screws (2).

  • Page 47: Hip Restraint

    BODY AND TRIM Hip Restraint HIP RESTRAINT Figure 4-2 Hip Restraint HIP RESTRAINT REMOVAL Remove the seat bottom (1) from the vehicle (Figure 4-2). Remove the screws (2). Remove the hip restraint (3). HIP RESTRAINT INSTALLATION Align the hip restraint (3) onto the seat bottom (1) (Figure 4-2). Install the screws (2).

  • Page 48: Front Body

    Front Body BODY AND TRIM FRONT BODY G-140198-000018 Figure 4-3 Front Body Page 4-6 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 49: Front Body Removal

    BODY AND TRIM Front Body FRONT BODY REMOVAL Disconnect the two headlight harnesses (1) (Figure 4-3, Page 4-6). Remove the four screws (2). Remove the brow cap (3) from the brow and fascia assembly (4). Pull the front beauty panel (5) up and away from the brow and fascia assembly to disengage the snap tabs. If the vehicle is equipped with a canopy: 5.1.

  • Page 50: Front Bumper

    Front Bumper BODY AND TRIM FRONT BUMPER Figure 4-4 Front Bumper FRONT BUMPER REMOVAL Remove the nuts (3) (Figure 4-4). Remove the bolts (2). Remove the front bumper (1). FRONT BUMPER INSTALLATION Align the front bumper (1) onto the frame (Figure 4-4). Install the bolts (2) and nuts (3).

  • Page 51: Underbody Bracket

    BODY AND TRIM Underbody Bracket UNDERBODY BRACKET The underbody bracket (1) is connected to the front suspension on the front underbody. Figure 4-5 Underbody Bracket UNDERBODY BRACKET REMOVAL Remove the two screws (2) and washer (3) (Figure 4-5). Remove the underbody bracket (1). UNDERBODY BRACKET INSTALLATION Put the underbody bracket (1) into position on the vehicle (Figure 4-5).

  • Page 52: Headlights

    Headlights BODY AND TRIM HEADLIGHTS The headlights are not adjustable. Figure 4-6 Headlights HEADLIGHT REMOVAL Disconnect the headlight harness. Remove the front beauty panel (1) (Figure 4-6). Remove the screws (2). Remove the headlight (3). HEADLIGHT INSTALLATION Install the headlight (3) (Figure 4-6). Install the screws (2).

  • Page 53: Instrument Panel

    BODY AND TRIM Instrument Panel INSTRUMENT PANEL Figure 4-7 Instrument Panel INSTRUMENT PANEL REMOVAL Remove the screws (1 and 2) (Figure 4-7). Tilt instrument panel (3) up to release it from the dash assembly (4). Disconnect the electrical connector on the passenger side. INSTRUMENT PANEL INSTALLATION Connect the electrical connector on the passenger side (Figure 4-7).

  • Page 54: Dash Assembly

    Dash Assembly BODY AND TRIM DASH ASSEMBLY Figure 4-8 Dash Assembly DASH ASSEMBLY REMOVAL Remove the instrument panel (1) (Figure 4-8). Remove the screws (2). Disconnect the USB receptacle. Remove the dash assembly (3). DASH ASSEMBLY INSTALLATION Put the dash assembly (3) on vehicle (Figure 4-8). Make sure tabs on the forward edge engage to front underbody.

  • Page 55: Floor Mat And Retainers

    BODY AND TRIM Floor Mat and Retainers FLOOR MAT AND RETAINERS Figure 4-9 Floor Mat And Retainers FLOOR MAT REMOVAL Remove the screws (2) (Figure 4-9). Remove the floor mat (3) from under the floor mat retainers (1). FLOOR MAT INSTALLATION Install the floor mat (3) under the floor mat retainers (Figure 4-9).

  • Page 56: Kick Plate And Charger Receptacle Bezel - Electric Vehicles

    Kick Plate and Charger Receptacle Bezel – Electric Vehicles BODY AND TRIM Make sure that the floor mat (3) is correctly positioned beneath the top flange of the floor mat retainer. Install the two screws (2). Do not tighten the screws. Install the push rivets (4) (Figure 4-9, Page 4-13).

  • Page 57: Kick Plate And Charger Receptacle Bezel Installation

    Kick Plate and Charger Receptacle Bezel BODY AND TRIM – Electric Vehicles Figure 4-10 Kick Plate and Charger Receptacle Bezel Removal Use the charger bezel tool to remove charger receptacle bezel (1) from the kick plate (2) (Figure 4-10, Page 4-15). Remove the floor mat.
  • Page 58 Kick Plate and Charger Receptacle Bezel – Electric Vehicles BODY AND TRIM Figure 4-11 Kick Plate and Charger Receptacle Bezel Installation Install the kick plate (3). Make sure that the front lower edge of the rear beauty panel mates with the kick plate. Install the three screws (1) and washers (2).

  • Page 59: Kick Plate - Gasoline Vehicles

    BODY AND TRIM Kick Plate – Gasoline Vehicles KICK PLATE – GASOLINE VEHICLES Figure 4-12 Kick Plate – Gasoline Vehicles KICK PLATE REMOVAL Remove the floor mat. Remove the three screws (1) and washers (2). Remove the two front screws (4). Raise the forward portion of the rear beauty panel to disengage it from the tabs on the upper portion of the kick plate.

  • Page 60: Access Panel

    Access Panel BODY AND TRIM ACCESS PANEL Figure 4-13 Access Panel ACCESS PANEL REMOVAL Remove the two push rivets (1) (Figure 4-13). Remove the access panel (2). ACCESS PANEL INSTALLATION Install the access panel (2) onto the rear underbody (Figure 4-13). Install the two push rivets (1).

  • Page 61: Visage Display Unit Overhead Baskets

    BODY AND TRIM Visage Display Unit Overhead Baskets VISAGE DISPLAY UNIT OVERHEAD BASKETS OVERHEAD BASKET REMOVAL Remove the screw (1) (Figure 4-14, Page 4-19). Figure 4-14 Overhead Basket Release the tab (2) and remove the overhead basket (3). OVERHEAD BASKET INSTALLATION Align the overhead basket (3) with the display unit support (Figure 4-14, Page 4-19).

  • Page 62: Overhead Speaker Basket Removal

    Visage Display Unit Overhead Baskets BODY AND TRIM OVERHEAD SPEAKER BASKET REMOVAL Remove the screw (1) (Figure 4-15, Page 4-20). Figure 4-15 Overhead Speaker Basket Release the tab (2) and remove the overhead speaker basket (3). Disconnect the electrical connector (4). OVERHEAD SPEAKER BASKET INSTALLATION Connect the electrical connector (4) (Figure 4-15, Page 4-20).

  • Page 63: Two-Passenger - Canopy

    BODY AND TRIM Two-Passenger - Canopy TWO-PASSENGER - CANOPY TWO-PASSENGER CANOPY REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. Figure 4-16 Two-Passenger Canopy Removal Remove the nuts (1), washer (2), and bolts (3) from the canopy (4) and each front canopy strut (Figure 4-16). Remove the nuts (6), washer (7), and bolts (8) from the canopy and each rear canopy support.

  • Page 64: Two-Passenger Canopy Installation

    Two-Passenger - Canopy BODY AND TRIM TWO-PASSENGER CANOPY INSTALLATION Figure 4-17 Two-Passenger Canopy Installation Put the canopy (4) on top of the front and rear canopy supports (Figure 4-17). Make sure that the front supports are correctly positioned between the molded tabs on the underside of the canopy. Make sure that the molded protrusions at the rear of the canopy extend into the top of the rear supports.
  • Page 65 BODY AND TRIM Two-Passenger - Canopy Figure 4-18 Two-Passenger Canopy With Visage Display Unit Removal Remove the nuts (4), washer (5), and bolts (6) from each rear canopy support. Remove the canopy (7). Disconnect the canopy harness (8). Remove the screws (9) (Figure 4-19, Page 4-23). Figure 4-19 Visage Display Unit Removal Remove the Visage display unit (VDU) (10) from the display unit support.

  • Page 66: Two-Passenger Canopy With Visage Display Unit Installation

    Two-Passenger - Canopy BODY AND TRIM TWO-PASSENGER CANOPY WITH VISAGE DISPLAY UNIT INSTALLATION Put the tabs of the display unit support (12) into the front canopy struts (Figure 4-20, Page 4-24). Figure 4-20 Visage Display Unit Installation Install the display unit support onto the front canopy struts. Connect the display unit harness (11).
  • Page 67 BODY AND TRIM Two-Passenger - Canopy Connect the strut harness to the canopy harness (8) (Figure 4-21, Page 4-25). Figure 4-21 Two-Passenger Canopy With Display Unit Installation Install the canopy (7) on top of the front and rear canopy supports. Install the bolts (3), washers (2), and nuts (1).

  • Page 68: Two-Passenger Front Canopy Strut Removal

    Two-Passenger - Canopy BODY AND TRIM TWO-PASSENGER FRONT CANOPY STRUT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 69: Two-Passenger Front Canopy Strut Installation

    BODY AND TRIM Two-Passenger - Canopy TWO-PASSENGER FRONT CANOPY STRUT INSTALLATION Figure 4-23 Front Canopy Strut Installation Install the front canopy strut (3) onto the vehicle (Figure 4-23). Install the front canopy strut cover (2) onto the front canopy strut. Install the screws (4).

  • Page 70: Two-Passenger Rear Canopy Support Removal

    Two-Passenger - Canopy BODY AND TRIM TWO-PASSENGER REAR CANOPY SUPPORT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 71: Two-Passenger Rear Canopy Support Installation

    BODY AND TRIM Two-Passenger - Rear Body TWO-PASSENGER REAR CANOPY SUPPORT INSTALLATION Figure 4-25 Rear Canopy Support Installation Install the rear canopy support (2) into the structural accessory module (SAM) (Figure 4-25). Install the screw (1). Tighten the screw to 88 lb·in (10 N·m). Install the canopy.

  • Page 72: Structural Accessory Module (Sam)

    Two-Passenger - Rear Body BODY AND TRIM STRUCTURAL ACCESSORY MODULE (SAM) Figure 4-26 SAM SAM Removal If the vehicle has a canopy, remove the rear canopy supports from the SAM (2) (Figure 4-26). Remove the four bolts (1). SAM Installation Position the SAM (2) over its mounting holes (Figure 4-26).

  • Page 73: Seat Back

    BODY AND TRIM Two-Passenger - Rear Body SEAT BACK Figure 4-27 Seat Back Seat Back Removal Remove the two screws (1) (Figure 4-27). Remove the seat back (2) from the SAM (3). Seat Back Installation Put the seat back (2) on the SAM (3) (Figure 4-27). Install the two screws (1).

  • Page 74: Bag Rack Assembly

    Two-Passenger - Rear Body BODY AND TRIM BAG RACK ASSEMBLY Figure 4-28 Bag Rack Bag Rack Removal Remove the two screws (1) (Figure 4-28). Remove the bag rack (2) from the SAM (3). Bag Rack Installation Install the bag rack (2) onto the SAM (3) (Figure 4-28). Install the two screws (1).

  • Page 75: Bag Strap

    BODY AND TRIM Two-Passenger - Rear Body BAG STRAP Figure 4-29 Bag Strap Bag Strap Removal Remove the push rivets (1) and screw (2) (Figure 4-29). Remove the bag strap (3) from the bag rack (4). Bag Strap Installation Install the bag strap (3) onto the bag rack (4) (Figure 4-29). Install the push rivets (1) and screw (2).

  • Page 76: Sweater Basket

    Two-Passenger - Rear Body BODY AND TRIM SWEATER BASKET Figure 4-30 Sweater Basket Sweater Basket Removal Remove the three screws (1) (Figure 4-30). Remove the sweater basket (2) from the bag rack (3). Sweater Basket Installation Install the sweater basket (2) onto the bag rack (3) (Figure 4-30). Install the three screws (1).

  • Page 77: Rear Beauty Panel

    BODY AND TRIM Two-Passenger - Rear Body REAR BEAUTY PANEL Two-passenger rear beauty panel procedures. Figure 4-31 Rear Beauty Panel Rear Beauty Panel Removal Remove the structural accessory module (SAM). Remove the screws (1) (Figure 4-31). Remove the canopy support brackets (2). Remove the four screws (3).

  • Page 78: Rear Underbody

    Two-Passenger - Rear Body BODY AND TRIM REAR UNDERBODY Two-passenger rear underbody procedures. Figure 4-32 Rear Underbody Rear Underbody Removal Remove the structural accessory module (SAM). Remove the rear beauty panel. Remove remove the four screws (1) (Figure 4-32). Lift the rear edge of the rear underbody (2) until the front portion slides out from beneath the front underbody. Remove the rear underbody from the vehicle.

  • Page 79: Rear Crossmember

    BODY AND TRIM Two-Passenger - Rear Body REAR CROSSMEMBER Two-passenger rear crossmember procedures. Figure 4-33 Rear Crossmember Rear Crossmember Removal Remove the four bolts (1) (Figure 4-33) . Remove the rear crossmember (2). Rear Crossmember Installation Install the rear crossmember (2) onto the vehicle (Figure 4-33). Make sure that the J-clips (3) are installed on the inside of the frame rail.

  • Page 80: 2+2 - Monsoon Canopy

    2+2 - Monsoon Canopy BODY AND TRIM 2+2 - MONSOON CANOPY MONSOON CANOPY REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. Remove the nuts (1), washers (2), and bolts (3) from the front canopy strut (4) (Figure 4-34). Figure 4-34 Canopy Removal - Front Canopy Strut Remove the screws (5) (Figure 4-35).

  • Page 81: Monsoon Canopy Installation

    BODY AND TRIM 2+2 - Monsoon Canopy MONSOON CANOPY INSTALLATION Put the canopy (6) on top of the front and rear canopy supports (Figure 4-36). Install the screws (5). Tighten the screws to 80 lb·in (9 N·m). Figure 4-36 Canopy Installation - Rear Canopy Support Install the bolts (3), washers (2), and nuts (1) to secure the front canopy strut (4) (Figure 4-37).

  • Page 82: 2+2 Front Canopy Strut Removal

    2+2 - Monsoon Canopy BODY AND TRIM 2+2 FRONT CANOPY STRUT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 83: 2+2 Front Canopy Strut Installation

    BODY AND TRIM 2+2 - Monsoon Canopy 2+2 FRONT CANOPY STRUT INSTALLATION Figure 4-39 Front Canopy Strut Installation Install the front canopy strut (3) onto the vehicle (Figure 4-39). Install the front canopy strut cover (2) onto the front canopy strut. Install the screws (4).

  • Page 84: 2+2 Rear Canopy Support Removal

    2+2 - Monsoon Canopy BODY AND TRIM 2+2 REAR CANOPY SUPPORT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 85: 2+2 Rear Canopy Support Installation

    BODY AND TRIM 2+2 - Monsoon Canopy 2+2 REAR CANOPY SUPPORT INSTALLATION Figure 4-41 Rear Canopy Support Installation Install the rear canopy support (3) into the rear underbody (Figure 4-41). Install the brackets (2) onto the rear canopy support. Install the screws (1). Tighten the screws to 80 lb·in (9 N·m). Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 4-43...

  • Page 86: 2+2 - Rear Body

    2+2 - Rear Body BODY AND TRIM 2+2 - REAR BODY SEAT BACKS Seat Back Removal Figure 4-42 Remove the screws (1) from the front seat back (2) (Figure 4-42). Remove the front seat back. Remove the screws (3) from the rear seat back (4). Remove the rear seat back.
  • Page 87 BODY AND TRIM 2+2 - Rear Body Seat Back Installation Figure 4-43 Seat Back Installation Install the front seat back (1) onto the seat support (2). Make sure the seat support tab (3) is installed in the front seat back (Figure 4-43). Install the screws (4).

  • Page 88: Fixed Rear Seat

    2+2 - Rear Body BODY AND TRIM FIXED REAR SEAT 2+2 fixed rear seat procedures. Fixed Rear Seat Bottom Removal Figure 4-44 Fixed Rear Seat Bottom Remove the screws (1) (Figure 4-44). Lift and remove the rear seat bottom (2). Fixed Rear Seat Bottom Installation Install the rear seat bottom tabs into the seat supports.
  • Page 89 BODY AND TRIM 2+2 - Rear Body Fixed Rear Seat Hinge Removal Figure 4-45 Fixed Rear Seat Hinge Remove the rear seat bottom. Remove the screws (1) (Figure 4-45). Remove the hinge (2). Fixed Rear Seat Hinge Installation Install the hinge (2) onto the rear seat bottom (Figure 4-45). Install the screws (1).
  • Page 90 2+2 - Rear Body BODY AND TRIM Fixed Rear Seat Hip Restraint Removal Figure 4-46 Fixed Rear Seat Hip Restraint Remove the screws (1) (Figure 4-46). Remove the strut angle (2). Remove the screws (3). Lift and remove the hip restraint (4). Fixed Rear Seat Hip Restraint Installation Install the rear hip restraint (4) onto the foot deck.

  • Page 91: Fold-Down Rear Seat

    BODY AND TRIM 2+2 - Rear Body FOLD-DOWN REAR SEAT 2+2 fold-down rear seat procedures. Fold-Down Rear Seat Bottom Removal Figure 4-47 Fold-Down Rear Seat Bottom Remove the screws (1) (Figure 4-47). Remove the rear seat bottom (2) from the fold-down hinge (3). Fold-Down Rear Seat Bottom Installation Put the rear seat bottom (2) onto the fold-down hinge (3) (Figure 4-47).
  • Page 92 2+2 - Rear Body BODY AND TRIM Fold-Down Rear Seat Assembly Removal Figure 4-48 Fold-Down Rear Seat Assembly Remove the screws (1) (Figure 4-48). Remove the bolts (2) and nuts (3). Remove the bolts (4) washers (5), and nuts (6). Remove the rear seat assembly (7).
  • Page 93 BODY AND TRIM 2+2 - Rear Body Fold-Down Rear Seat Hip Restraint Removal Figure 4-49 Fold-Down Rear Seat Hip Restraint Remove the screws (1) (Figure 4-49). Remove the strut angle (2). Remove the screws (3). Lift and remove the hip restraint (4). Fold-Down Rear Seat Hip Restraint Installation Install the rear hip restraint (4) onto the foot deck (Figure 4-49).
  • Page 94 2+2 - Rear Body BODY AND TRIM Side Frame Removal Figure 4-50 Side Frame Remove the bolt (1), washers (2), and nut (3) (Figure 4-50). Remove the nut (4) and bolt (5). Remove the side frame (6). Side Frame Installation Install the side frame (6) onto the foot deck (Figure 4-50).

  • Page 95: Seat Support

    BODY AND TRIM 2+2 - Rear Body SEAT SUPPORT 2+2 seat support procedures. Figure 4-51 2+2 Seat Support Seat Support Removal Remove the seat backs. Remove the hip restraints. Remove the rear seat bottom assembly. Remove the screws (1) (Figure 4-51). Remove the screw (2).

  • Page 96: Foot Deck - 2+2

    2+2 - Rear Body BODY AND TRIM FOOT DECK - 2+2 2+2 foot deck procedures. Foot Deck Removal Figure 4-52 Foot Deck (2+2) Removal Support the foot deck. Remove the screws (1) (Figure 4-52). Remove the screws (2). Remove the bolts (3) and the foot deck. Page 4-54 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...
  • Page 97 BODY AND TRIM 2+2 - Rear Body Foot Deck Disassembly Figure 4-53 Foot Deck (2+2) Disassembly Remove the push rivets (1) (Figure 4-53). Remove the floormat (2). Remove the screws (3). Remove the foot deck (4). Remove the screws (5). Remove the handrail (6) from the foot deck support (7).
  • Page 98 2+2 - Rear Body BODY AND TRIM Foot Deck Assembly Figure 4-54 Foot Deck (2+2) Assembly Make sure the J-clips (1) are installed on the foot deck support (2) (Figure 4-54). Install the handrail (3) into the foot deck support. Install the screws (4).
  • Page 99 BODY AND TRIM 2+2 - Rear Body Foot Deck Installation Figure 4-55 Foot Deck (2+2) Installation Support the foot deck. Install the bolts (3) (Figure 4-55). Tighten the bolts to 22 lb·ft (30 N·m). Install the screws (2). Tighten the screws to 13 lb·ft (18 N·m). Install the screws (1).

  • Page 100: Rear Beauty Panel (2+2 Vehicles)

    2+2 - Rear Body BODY AND TRIM REAR BEAUTY PANEL (2+2 VEHICLES) 2+2 rear body component procedures. Figure 4-56 2+2 Rear Beauty Panel Rear Beauty Panel Removal Remove the front seat bottom. Remove the rear seat assembly. Remove the forward / neutral / reverse (FNR) control. Remove the screws (1) (Figure 4-56).

  • Page 101: Rear Underbody

    BODY AND TRIM 2+2 - Rear Body REAR UNDERBODY Figure 4-57 2+2 Rear Underbody Rear Underbody Removal Remove the rear beauty panel. Remove the access panel. Remove the screws (1) (Figure 4-57). Lift the rear edge of the rear underbody (2) until the front portion slides out from beneath the front underbody. Remove the rear underbody from the vehicle.
  • Page 102 2+2 - Rear Body BODY AND TRIM Pagination Page Page 4-60 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 103: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP DANGER Accelerator and Brake Pedal Group • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. PEDAL GROUP – ELECTRIC VEHICLE PEDAL GROUP REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles on page 1-4.
  • Page 104 Pedal Group – Electric Vehicle ACCELERATOR AND BRAKE PEDAL GROUP Remove the fastener (3) (Figure 5-2). Figure 5-2 Pedal Group Removal Remove the cover (4). Loosen the jam nuts on each side of the turnbuckle (5). Remove the turnbuckle from the pedal assembly. Disconnect the wire harnesses (6).

  • Page 105: Pedal Group Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – Electric Vehicle PEDAL GROUP INSTALLATION Connect the wire harnesses (1) (Figure 5-3). Figure 5-3 Pedal Group Installation Install the driver side screws (2). Tighten the driver side screws to 97 lb·in (11 N·m). Install the passenger side screws (3).
  • Page 106 Pedal Group – Electric Vehicle ACCELERATOR AND BRAKE PEDAL GROUP Install the floor mat (8) over the pedal group (Figure 5-4). Figure 5-4 Floor Mat and Retainer Installation Install the floor mat retainer (9). Connect the batteries. See Connect the Batteries – Electric Vehicles, Section 1, Page 1-5. Page 5-4 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 107: Pedal Group - Gasoline Vehicle

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – Gasoline Vehicle PEDAL GROUP – GASOLINE VEHICLE See General Warnings on page 1-2. PEDAL GROUP REMOVAL Disconnect battery and spark plug wire. Remove the floor mat retainer (1) (Figure 5-5). Figure 5-5 Pull the floor mat (2) over the pedal group.

  • Page 108: Throttle Position Sensor

    Pedal Group – Gasoline Vehicle ACCELERATOR AND BRAKE PEDAL GROUP Remove the fastener (3) (Figure 5-6). Figure 5-6 Remove the cover plate (4). Loosen the jam nuts on each side of turnbuckle (5). Remove the turnbuckle from the pedal assembly. Loosen the two nuts (6) on the accelerator cable and lift the cable from its mounting bracket.

  • Page 109: Pedal Group Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – Gasoline Vehicle PEDAL GROUP INSTALLATION Connect the accelerator cable clip (1) to the accelerator pedal (Figure 5-7). CAUTION • Make sure the accelerator cable is properly seated to the pedal group. Figure 5-7 Connect the wire harness (2) to the throttle position sensor.
  • Page 110 Pedal Group – Gasoline Vehicle ACCELERATOR AND BRAKE PEDAL GROUP Install the floor mat (8) over the pedal group (Figure 5-8). Figure 5-8 Install the floor mat retainer (9). Connect battery and spark plug wire. Page 5-8 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 111: Debris Shields

    ACCELERATOR AND BRAKE PEDAL GROUP Debris Shields DEBRIS SHIELDS Debris shields on the top face of the pedal group prevent excessive debris from contacting the moving parts of the pedal group. Figure 5-9 Debris Shields DEBRIS SHIELDS REMOVAL Use a flat blade screw driver to release the tabs (1) and remove the primary debris shield (2) (Figure 5-9). Remove the auxiliary debris shield (3).

  • Page 112: Accelerator Pedal

    Accelerator Pedal ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR PEDAL Figure 5-10 Electric vehicle shown. Gasoline vehicle is typical. ACCELERATOR PEDAL REMOVAL Remove the pedal group. Remove the debris shields. Remove the screws (1) (Figure 5-10). Turn the accelerator pedal assembly (2) and remove through bottom of pedal group mounting plate. ACCELERATOR PEDAL INSTALLATION Install the accelerator pedal assembly (2) through bottom of pedal group mounting plate (Figure 5-10).

  • Page 113: Brake Pedal

    ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal BRAKE PEDAL Figure 5-11 BRAKE PEDAL REMOVAL Remove the pedal group. Remove the debris shields. Remove the screws (1) (Figure 5-11). Remove the brake pedal assembly (2) through bottom of pedal group mounting plate. BRAKE PEDAL INSTALLATION Install the brake pedal assembly (2) through bottom of pedal group mounting plate (Figure 5-11).
  • Page 114 Brake Pedal ACCELERATOR AND BRAKE PEDAL GROUP Pagination Page Page 5-12 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 115: Section 6 - Wheel Brake Assemblies

    SECTION 6 — WHEEL BRAKE ASSEMBLIES WARNING Wheel Brake Assemblies Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled. Wear approved eye and respiratory protection when disassembling and cleaning brake mechanisms.

  • Page 116: Brake Shoe Removal

    Brake Shoe Removal WHEEL BRAKE ASSEMBLIES Loosen the left-hand thread jam nut (1) and right-hand thread jam nut (2) (Figure 6-1). Figure 6-1 Loosen the turnbuckle (3) to release tension on the bell crank. Remove the lugs nuts from the rear wheel. Remove the rear wheel.
  • Page 117 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Electric Vehicle: Remove the axle shaft. Gasoline Vehicle: Remove the wheel hub assembly. Using needle nose pliers, turn the retainer pin (1) 90° to remove the shoe retainer clip (2) (Figure 6-3). CAUTION • The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed. Figure 6-3 Hold both brake shoes and pull them, together with the springs, out of the brake assembly (Figure 6-4).

  • Page 118: Brake Assembly Cleaning

    Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Remove adjuster wheel (1) with two washers (2 and 3) from the backing plate (Figure 6-5). Figure 6-5 Clean the brake assembly. BRAKE ASSEMBLY CLEANING Carefully clean the brake backing plate (1) and all of its mechanical components (Figure 6-6). Figure 6-6 Remove the dust cover (2) from backing plate and wipe with a clean damp cloth.
  • Page 119 WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning Lubricate the slide (1) with dry moly lubricant (Figure 6-7). Figure 6-7 Make sure that the slide can easily move back and forth. Install the dust cover onto the backing plate. WARNING • Apply grease carefully when performing the following steps. Do not allow any grease to get onto the friction surfaces of the brake shoe pads or the brake drum.
  • Page 120 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning ® BR2-Plus or equivalent) to each end of both brake shoes and into the slots in the brake shoe mounting block as shown (Figure 6-9).

  • Page 121: Brake Shoe Installation

    WHEEL BRAKE ASSEMBLIES Brake Shoe Installation BRAKE SHOE INSTALLATION WARNING • When installing brake shoes, the shoes must be oriented with tips stamped 10 inserted into the mounting block anchor piston slots rather than into the brake actuator slots. Incorrectly installed brake shoes will be too tight and make adjustment of the brake impossible.
  • Page 122 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES Install the first shoe (1) in the slots in the mounting block anchor piston (2) and the brake actuator (3) (Figure 6-13). Make sure that the stamped end of the shoe in the mounting block anchor piston. See detail A. NOTE: 10 is stamped into one of the shoe flanges.
  • Page 123 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Use a flatblade screwdriver to lift the adjusting arm (1) off of the adjusting wheel (2) (Figure 6-15). Figure 6-15 Turn the adjusting wheel upward until it stops. Remove the screwdriver. Electric Vehicle: Install the axle shaft. Gasoline Vehicle: Install the wheel hub assembly.

  • Page 124: Brake Cable Equalizer Adjustment

    Brake Cable Equalizer Adjustment WHEEL BRAKE ASSEMBLIES Adjust the brake cable equalizer. Electric Vehicle: Connect the batteries. Gasoline Vehicle: Connect battery and spark plug wire. BRAKE CABLE EQUALIZER ADJUSTMENT Make sure that the brake pedal is in the fully up position. Adjust the turnbuckle (1) until the distance (A) between the top of the brake cable equalizer (2) and the upper flange surface (3) is 2 inches (±1/16) (51 mm (±1.6) (Figure 6-17).
  • Page 125 WHEEL BRAKE ASSEMBLIES Brake Cable Equalizer Adjustment WARNING • Reduced braking force could result if the jam nuts are not tightened in the proper sequence. Tighten the rear jam nut first to 208 lb·in (23.5 N·m), then tighten the front jam nut to 208 lb·in (23.5 N·m). For optimal performance, drive the vehicle and apply the brakes approximately 20 times to burnish the shoes, center the clusters, and adjust the brake mechanism.

  • Page 126: Brake Cluster

    Brake Cluster WHEEL BRAKE ASSEMBLIES BRAKE CLUSTER BRAKE CLUSTER REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect battery and spark plug wire. Loosen the lug nuts on the rear wheel. Lift the rear of the vehicle. WARNING •...
  • Page 127 WHEEL BRAKE ASSEMBLIES Brake Cluster Remove and discard the bow tie pin (1) (Figure 6-20). Figure 6-20 Remove the clevis pin (2). Remove the brake cable (3) from the brake actuator arm. Remove the brake drum (1) (Figure 6-21). If the brake drum cannot be easily removed: NOTE: When servicing vehicles with severely worn brake shoes and when the drums cannot be removed by normal methods, use the following steps to minimize damage to the brake cluster and brake components.

  • Page 128: Brake Cluster Installation

    Brake Cluster WHEEL BRAKE ASSEMBLIES Electric Vehicle: Remove the axle shaft. Gasoline Vehicle: Remove the wheel hub assembly. Remove the bolts (1) and lock nuts (2) (Figure 6-22). Discard the lock nuts. Figure 6-22 Remove the brake cluster (3). BRAKE CLUSTER INSTALLATION CAUTION •...
  • Page 129 WHEEL BRAKE ASSEMBLIES Brake Cluster Electric Vehicle: Install the axle shaft. Gasoline Vehicle: Install the wheel hub assembly. Install the brake drum. Install the brake cable (1) on the brake actuator arm (Figure 6-24). Figure 6-24 Install the brake cable clevis pin (2). Install the new bow tie pin (3).

  • Page 130: Brake Cable

    Brake Cable WHEEL BRAKE ASSEMBLIES BRAKE CABLE BRAKE CABLE REMOVAL Special Tools Needed Brake Cable Release Tool NOTE: Refer to the Illustrated Parts Catalog for service tool part numbers. Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect the battery and spark plug wire.
  • Page 131 WHEEL BRAKE ASSEMBLIES Brake Cable Lift the brake actuator rod and equalizer bracket (1) (Figure 6-26). Figure 6-26 Remove the brake cables (2) from the equalizer bracket. Remove the nut (1) (Figure 6-27). Do not remove bolt (2). Figure 6-27 Remove the mounting tab (3) of the brake cable from the bolt.
  • Page 132 Brake Cable WHEEL BRAKE ASSEMBLIES Use a brake cable release tool to compress the retaining clips (1) on the end of the cable housing enough to slide the cable end out of the hole in the frame (Figure 6-28). Figure 6-28 Remove and discard the bow tie locking pin (1) (Figure 6-29).

  • Page 133: Brake Cable Installation

    WHEEL BRAKE ASSEMBLIES Brake Cable BRAKE CABLE INSTALLATION NOTE: The driver-side and passenger-side brake cables are not interchangeable. The driver-side cable is shorter than the passenger-side cable. Make sure the correct cable is used on the correct side. Be sure to orient the cable so that the clevis end goes to the wheel rather than to the equalizer bracket. Insert the end of the new brake cable through the hole in the frame (Figure 6-30).
  • Page 134 Brake Cable WHEEL BRAKE ASSEMBLIES Insert the rear cable housing into the shock mount bracket (1) (Figure 6-32). Figure 6-32 Make sure that the clips on the housing end secure the cable in position. Install the brake cable (2) on the brake actuator arm. Install the brake cable clevis pin (3).

  • Page 135: Section 7 - Steering And Front Suspension

    SECTION 7 — STEERING AND FRONT SUSPENSION DANGER Steering and Front Suspension • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.

  • Page 136: Steering Wheel Installation

    Steering Wheel STEERING AND FRONT SUSPENSION Remove the screws (1) (Figure 7-1). Figure 7-1 Remove the cover (2). Remove the steering wheel retaining bolt (3). Put the puller anvil (4) through the top opening of the steering wheel (5). Insert the anvil feet through the two slots in the base plate (marked “B”) (6). Turn the anvil screw (7) clockwise until the base plate contacts the bottom of the steering wheel at the steering column.

  • Page 137: Steering Column

    STEERING AND FRONT SUSPENSION Steering Column Install steering wheel retaining bolt (3). Tighten the bolt to 37 lb·ft (50 N·m). Put the cover (4) on the steering wheel. Install the screws (5). Tighten the screws to 15 lb·in (1.7 N·m). STEERING COLUMN STEERING COLUMN REMOVAL Figure 7-3 Steering Column Removal...

  • Page 138: Steering Column Installation

    Rack and Pinion STEERING AND FRONT SUSPENSION STEERING COLUMN INSTALLATION Figure 7-4 Steering Column Installation Apply a light coat of anti-seize or lubricating compound to the pinion shaft (1) (Figure 7-4). Install the universal joint (2) onto pinion shaft. Install the bolt (3) and tighten by hand. Do not fully tighten the bolt. Install the steering column mounting bracket (4) on the vehicle frame.

  • Page 139: Rack And Pinion Inspection

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION INSPECTION Look for obvious damage to the chassis, where the rack and pinion is mounted, and the rack and pinion housing. Particularly check the housing for broken mounting points. Compare the toe-in against the specification. See Tow-in Adjustment. If obvious visible damage is found, such as a bent tie rod, check the steering gear for abnormal free-play, noise, binding or clunking while it is under a load.

  • Page 140: Rack And Pinion Installation

    Rack and Pinion STEERING AND FRONT SUSPENSION Remove the universal joint from the pinion shaft (7). Remove the rack and pinion assembly. RACK AND PINION INSTALLATION Apply a light coat of anti-seize lubricating compound to the pinion shaft (1) (Figure 7-6). Figure 7-6 Rack and Pinion Installation Install the universal joint (2) onto the pinion shaft.

  • Page 141: Front Suspension

    STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings on page 1-2. LUBRICATION Two grease fittings are provided (one in each spindle housing). Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedules on page 10-8. CAUTION •...
  • Page 142 Front Suspension STEERING AND FRONT SUSPENSION If there is not an equal amount of space (B) between each tire and the framing square (Figure 7-7), go to step 4. Loosen the four bolts (1). Do not remove the bolts (Figure 7-8). Figure 7-8 Adjust Camber Loosen the nut (2) on the adjustment eccentric (3) in the center of the spring.
  • Page 143 STEERING AND FRONT SUSPENSION Front Suspension Measure the distance between the marks on the forward-facing surfaces of the tires (Figure 7-9). NOTE: The front measurement must be less than the rear measurement. Figure 7-9 Check Toe-In Subtract the measurement on the front of the tires from the measurement on the rear of the tires. The difference is the toe-in.

  • Page 144: Front Suspension Components

    Front Suspension Components STEERING AND FRONT SUSPENSION Figure 7-11 9.5. Tighten the jam nuts on both ends of each drag link to 26 lb·ft (35 N·m). 9.6. Check the toe-in. 9.7. Repeat the adjustment procedure if necessary. 9.8. After the toe-in adjustment is made and with wheels in the straight ahead position, the steering wheel should be at the center of its travel.
  • Page 145 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-12 Remove the retaining nut (2). Lift the tie rod (3) from the hole in the spindle tab. Remove the tie rod end from the drag link. Apply a light coat of anti-seize lubricating compound to the threads (4). Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 7-11...

  • Page 146: Tie Rod Installation

    Front Suspension Components STEERING AND FRONT SUSPENSION TIE ROD INSTALLATION Install tie rod end (1) onto the drag link (2) to a depth of 1/2 inch (12.5 mm) (Figure 7-13). WARNING • The tie rod ends must be threaded into the rod at least 5/16 of an inch (8 mm). Failure to thread deep enough may cause tie rod ends to separate from the rod during adjustment or while being operated, possibly resulting in loss of vehicle control and severe personal injury.

  • Page 147: Leaf Spring Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components Remove the bolts (1) from the bottom of each kingpin (2) (Figure 7-14). Figure 7-14 Remove the four bolts (3) and bottom spring plate (4). Remove the leaf spring (5). Check the condition of the urethane bushings (6) and steel sleeves (7). Replace any that are worn or damaged. LEAF SPRING INSTALLATION Install the urethane bushings (1) and steel sleeves (2) into leaf spring eyes (Figure 7-15).

  • Page 148: Kingpin And Steering Spindle Removal

    Front Suspension Components STEERING AND FRONT SUSPENSION KINGPIN AND STEERING SPINDLE REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect the battery and spark plug wire. Remove the front wheels. Remove and discard the lock nut (1) (Figure 7-16). Figure 7-16 Remove the front hub (2).

  • Page 149: Kingpin And Steering Spindle Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components 11.2. If the wave washer bottom to crest height dimension is less than 0.040 inch (1 mm), replace the washer. Remove the bolt (6) and the kingpin. Inspect the kingpin and spindle. If either is worn or damaged, it must be replaced. Inspect the spindle bushings.
  • Page 150 Front Suspension Components STEERING AND FRONT SUSPENSION Figure 7-19 Install the nut (3). Tighten the nut to 70 lb·ft (95 N·m). Install the front hubs (4). Install the nut (5). Install the front wheels. Adjust the camber and toe-in. Electric Vehicle: Connect the batteries. Gasoline Vehicle: Connect the battery and spark plug wire.

  • Page 151: Control Arm Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components CONTROL ARM REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect the battery and spark plug wire. Remove the front wheels. Remove the bolts (1) (Figure 7-20). Figure 7-20 Move the rack and pinion (2) to allow clearance for the control arm bolts.

  • Page 152: Front Shock Absorber Inspection

    Front Suspension Components STEERING AND FRONT SUSPENSION Figure 7-22 Install the bolts (2 and 3). Tighten the bolts to 30 lb·ft (41 N·m). Move the rack and pinion (1) into position (Figure 7-23). Figure 7-23 Install the bolts (2).Tighten the bolts to 22 lb·ft (30 N·m). Install the front wheels.

  • Page 153: Front Shock Absorber Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-24 FRONT SHOCK ABSORBER REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect the battery and spark plug wire. Remove the upper bolt (1) (Figure 7-25). Figure 7-25 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 7-19...

  • Page 154: Front Shock Absorber Installation

    Front Suspension Components STEERING AND FRONT SUSPENSION Remove the lower bolt (2). Remove the shock absorber (3). FRONT SHOCK ABSORBER INSTALLATION Make sure that the front shock absorbers (3) have the same part number (Figure 7-25). Install the shock absorber. Install the bolts (1 and 2).

  • Page 155: Front Wheel Hubs

    STEERING AND FRONT SUSPENSION Front Wheel Hubs FRONT WHEEL HUBS FRONT WHEEL FREE PLAY INSPECTION NOTE: The front wheel bearings are pressed into the spindle and are not serviceable. If excessive free-play is detected the entire hub should be replaced. Disable the vehicle.

  • Page 156: Front Wheel Hub Installation

    Front Wheel Hubs STEERING AND FRONT SUSPENSION FRONT WHEEL HUB INSTALLATION Apply a light coat of anti-seize lubricant to the spindle shaft (1) (Figure 7-27). Figure 7-27 Install the hub assembly (2) onto the spindle shaft. Install the new lock nut (3). Tighten the lock nut to 50 lb·ft (68 N·m). Rotate the hub.

  • Page 157: Section 8 - Wheels And Tires

    SECTION 8 — WHEELS AND TIRES DANGER Wheels and Tires • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. •...

  • Page 158: Lift The Front Of The Vehicle

    Lift The Vehicle WHEELS AND TIRES LIFT THE FRONT OF THE VEHICLE Use a jack and jack stands rated for the vehicle. Figure 8-1 Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect battery and spark plug wire. Place the jack in the center of the lift point (Figure 8-1, Page 8-2).
  • Page 159 WHEELS AND TIRES Lift The Vehicle Figure 8-2 Top: Gasoline / Bottom: Electric Disable the vehicle. Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 8-3...

  • Page 160: Lower The Rear Of The Vehicle

    Tires WHEELS AND TIRES Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect battery and spark plug wire. Place the jack in the center of the lift point (Figure 8-2, Page 8-3). Lift the rear of the vehicle. Put jack stands under the frame rails.

  • Page 161: Tire Repair

    Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at your local Club Car dealer. When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal.

  • Page 162: Tire Installation

    Tires WHEELS AND TIRES TIRE INSTALLATION WARNING • While mounting or inflating tire, keep hands, fingers, etc. from exposed areas between the tire bead and rim. The tire must be installed from the valve stem side of the rim. Clean both tire beads to remove dirt or other foreign matter. Where the tire beads seat, clean the wheel rim with a wire brush.

  • Page 163: Wheel Assembly

    WHEELS AND TIRES Wheel Assembly WHEEL ASSEMBLY See General Warnings on page 1-2. WHEEL ASSEMBLY REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect battery and spark plug wire. Remove the wheel cover. Loosen the lug nuts.
  • Page 164 Wheel Assembly WHEELS AND TIRES Pagination Page Page 8-8 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 165: Section 9 - Rear Suspension

    SECTION 9 — REAR SUSPENSION See General Warnings Section. Rear Suspension GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. It consists of two leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame. SHOCK ABSORBERS The following procedures are the same for all vehicles.

  • Page 166: Rear Shock Absorber Removal

    Shock Absorbers REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL Figure 9-2 Rear Shock Absorber Removal Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect battery and spark plug wire. Remove the nut (1), cup washer (2), and rubber bushing (3) from the top of the shock absorber (Figure 9-2, Page 9-2).

  • Page 167: Rear Shock Absorber Installation

    REAR SUSPENSION Shock Absorbers REAR SHOCK ABSORBER INSTALLATION Figure 9-3 Rear Shock Absorber Installation Install the cup washers (1) and rubber bushings (2) onto the shock absorber (3) (Figure 9-3, Page 9-3). Install the bottom stem of the shock absorber into the shock mount bracket (4). Install the top stem of the shock absorber into the frame shock mount (5).

  • Page 168: Panhard And Bracket

    Panhard and Bracket REAR SUSPENSION PANHARD AND BRACKET Figure 9-4 Panhard and Bracket PANHARD AND BRACKET REMOVAL Disable the vehicle. Electric Vehicle: Disconnect the batteries and discharge the controller. Gasoline Vehicle: Disconnect battery and spark plug wire. Remove the bolts (1) (Figure 9-4, Page 9-4). Remove the panhard (2).

  • Page 169: Leaf Springs (Two-Passenger)

    REAR SUSPENSION Leaf Springs (Two-Passenger) LEAF SPRINGS (TWO-PASSENGER) LEAF SPRING REMOVAL (TWO-PASSENGER) WARNING • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position.
  • Page 170 Leaf Springs (Two-Passenger) REAR SUSPENSION Remove the nut (5), cup washer (6), and rubber bushing (7) from the bottom stem of the shock absorber (Figure 9-6). Figure 9-6 Leaf Spring Removal - Two-Passenger Remove the nuts (8) and the U-bolt (9) securing the spring to the transaxle. Remove the shock mount bracket (10) and the U-bolt.

  • Page 171: Leaf Spring Installation (Two-Passenger)

    REAR SUSPENSION Leaf Springs (Two-Passenger) LEAF SPRING INSTALLATION (TWO-PASSENGER) CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle. Install the front of the leaf spring (1) onto the vehicle frame (Figure 9-7). Figure 9-7 Leaf Spring Installation - Two-Passenger Install the bolt (2) and nut (3).

  • Page 172: Leaf Springs (Four-Passenger)

    Leaf Springs (Four-Passenger) REAR SUSPENSION Install the brake cable onto the shock mount bracket (1) (Figure 9-8). Figure 9-8 Install the cable end (2) onto the brake lever. Install the clevis pin (3) and the bow tie locking pin (4). Lower and remove the floor jack under the transaxle.
  • Page 173 REAR SUSPENSION Leaf Springs (Four-Passenger) Figure 9-9 Remove the cable end (3) from the brake lever. Remove the brake cable from the shock mount bracket (4). Remove the nut (5), cup washer (6), and rubber bushing (7) from the bottom stem of the shock absorber (Figure 9-10, Page 9-9).

  • Page 174: Leaf Spring Installation (Four-Passenger)

    Leaf Springs (Four-Passenger) REAR SUSPENSION Remove the nut (15) and bolt (16) from the front of the leaf spring and remove the leaf spring. Examine the bushings (17) and sleeves (18) in the spring eyes. 14.1. If the bushings or sleeves are worn or have damage, replace them. LEAF SPRING INSTALLATION (FOUR-PASSENGER) CAUTION •...

  • Page 175: Leaf Springs (Four-Passenger - Heavy Duty With Panhard)

    Leaf Springs (Four-Passenger - Heavy Duty REAR SUSPENSION With Panhard) Figure 9-12 Install the cable end (2) onto the brake lever. Install the clevis pin (3) and the bow tie locking pin (4). Lower and remove the floor jack under the transaxle. Install the tire and wheel assembly.
  • Page 176 Leaf Springs (Four-Passenger - Heavy Duty With Panhard) REAR SUSPENSION Figure 9-13 Remove the cable end (3) from the brake lever. Remove the brake cable from the shock mount bracket (4). Remove the nut (5), cup washer (6), and rubber bushings (7) from the lower mounting stem of the shock absorber (Figure 9-14).

  • Page 177: Leaf Spring Installation (Four-Passenger - Heavy Duty With Panhard)

    Leaf Springs (Four-Passenger - Heavy Duty REAR SUSPENSION With Panhard) Inspect the bushings (16) and sleeves (17) in the spring eyes and replace them if they are worn or damaged. LEAF SPRING INSTALLATION (FOUR-PASSENGER - HEAVY DUTY WITH PANHARD) CAUTION •...
  • Page 178 Leaf Springs (Four-Passenger - Heavy Duty With Panhard) REAR SUSPENSION Install the brake cable onto the shock mount bracket (1) (Figure 9-16). Figure 9-16 Install the cable end (2) onto the brake lever. Install the clevis pin (3) and the bow tie locking pin (4). Lower and remove the floor jack under the transaxle.

  • Page 179: Section 10 - Vehicle Maintenance

    Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.

  • Page 180: Performance Inspection

    When the pedal is released it should return to the original position. All Club Car vehicles operate at reduced speed in reverse.

  • Page 181: Maintenance

    When the pedal is released it should return to the original position. All Club Car vehicles operate at reduced speed in reverse.

  • Page 182: Periodic Service Schedules

    Periodic Service Schedules VEHICLE MAINTENANCE WARNING • Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wiring. Never allow a positive wire to touch the vehicle frame, engine, or other metal component. PERIODIC SERVICE SCHEDULES WARNING •...
  • Page 183 VEHICLE MAINTENANCE Periodic Service Schedules INTERVAL DESCRIPTION Do an inspection of the deionizer. Quarterly Do an inspection of the SPWS. Use WD-40 to lubricate the battery charger receptacle. Have a trained technician examine and lubricate the brake system: • Examine the brake shoes. Replace as necessary. •...

  • Page 184: Gasoline Vehicle - Periodic Service Schedule

    Periodic Service Schedules VEHICLE MAINTENANCE GASOLINE VEHICLE - PERIODIC SERVICE SCHEDULE INTERVAL DESCRIPTION Initial: 100 hours Change the engine oil. Do the Pre-Operation and Daily Safety Checklist. Daily Do the Performance Inspection. Examine the engine oil level. Examine the tire pressure. Clean the engine compartment and underside of the vehicle.
  • Page 185 VEHICLE MAINTENANCE Periodic Service Schedules INTERVAL DESCRIPTION Have a trained technician examine the drive belt and starter/generator belt. Replace and adjust as necessary. Have a trained technician examine the engine: • Examine the engine for leaks around gaskets, fill plug, etc. •...

  • Page 186: Periodic Lubrication Schedules

    Periodic Lubrication Schedules VEHICLE MAINTENANCE PERIODIC LUBRICATION SCHEDULES ELECTRIC VEHICLE - PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE – ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Charger receptacle WD-40 ® Semiannually by owner or trained technician (every 50 Brake system, per maintenance and Dry Moly Lube, white lithium grease NLGI #2 hours of operation or 100 service manual.

  • Page 187: Gasoline Vehicle - Periodic Lubrication Schedule

    VEHICLE MAINTENANCE Periodic Lubrication Schedules GASOLINE VEHICLE - PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Shifter cable pivots Dry Moly Lube Semiannually by owner or trained technician (every 50 Brake system, per maintenance and Dry Moly Lube, white lithium grease NLGI #2 hours of operation or every service manual.

  • Page 188: Air Filter

    Air Filter VEHICLE MAINTENANCE AIR FILTER Figure 10-3 Air Filter AIR FILTER REMOVAL Before the air filter is removed: • Disable the vehicle. To remove the air filter: Release the latch (1) (Figure 10-3, Page 10-10). Remove the air cleaner cover (2). Remove the air filter (3).

  • Page 189: Kohler Ech440 - Engine Oil Level Inspection

    VEHICLE MAINTENANCE Kohler ECH440 - Engine Oil Figure 10-4 Engine Oil Viscosity KOHLER ECH440 - ENGINE OIL LEVEL INSPECTION Before the engine oil is examined: • Disable the vehicle. To examine the engine oil: Remove the dipstick (1) (Figure 10-5, Page 10-11). Figure 10-5 Dipstick Make sure that there is oil on the dipstick.

  • Page 190: Kohler Ech440 - Engine Oil Replacement

    Kohler ECH440 - Engine Oil VEHICLE MAINTENANCE Remove the dipstick. Make sure that the oil level is between the maximum (1) and minimum (2) indicators (Figure 10-6, Page 10-12). Figure 10-6 Dipstick Indicators If the oil level is below the minimum indicator, add engine oil. Install the dipstick.
  • Page 191 VEHICLE MAINTENANCE Kohler ECH440 - Engine Oil Figure 10-7 Dipstick Clean the area around the oil drain plug (2) (Figure 10-8, Page 10-13). Figure 10-8 Oil Drain Plug Put a drain pan below the oil drain plug. Remove the oil drain plug. Drain the oil fully.

  • Page 192: Kohler Ech440 - Add Engine Oil

    Kohler ECH440 - Engine Oil VEHICLE MAINTENANCE Add 39 fl-oz (1.1 l) of recommended engine oil (Figure 10-9, Page 10-14). Figure 10-9 Engine Oil Fill Location Install the dipstick. Connect the battery. KOHLER ECH440 - ADD ENGINE OIL CAUTION • Do not remove the dipstick while the engine is on. CAUTION •...
  • Page 193 VEHICLE MAINTENANCE Kohler ECH440 - Engine Oil Figure 10-10 Dipstick Add engine oil until the oil level is between the maximum (1) and minimum (2) indicators (Figure 10-11, Page 10-15). Figure 10-11 Dipstick Indicators Install the dipstick. Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 10-15...

  • Page 194: Refuel

    Refuel VEHICLE MAINTENANCE REFUEL DANGER • Fuel is flammable and explosive. Do not add fuel with the key set to ON. Before fuel is added, turn the key switch to OFF. • Fuel is flammable and explosive. Do not fill the fuel tank when the engine is on or hot. Wait for the engine temperature to decrease before fuel is added.
  • Page 195 VEHICLE MAINTENANCE Refuel Remove the fill cap (1) (Figure 10-12). Figure 10-12 Fill the fuel tank with the recommended fuel. Install the fuel cap. Lower the seat bottom. Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 10-17...
  • Page 196 Refuel VEHICLE MAINTENANCE Pagination Page Page 10-18 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 197: Section 11 - Controller Diagnostic Tool (Cdt)

    SECTION 11 — CONTROLLER DIAGNOSTIC TOOL (CDT) DANGER Controller Diagnostic Tool (CDT) • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. NOTE: The information presented in this section addresses the following: • The Controller Diagnostic Tool (CDT) handheld programmer which replaced the IQDM series 2 handset. •...

  • Page 198: General Information

    General Information CONTROLLER DIAGNOSTIC TOOL (CDT) GENERAL INFORMATION The CDT is used to adjust and save parameter settings of the controller, monitor real-time data, and perform diagnostics and troubleshooting of the electric vehicle. FEATURES • Batteries: Two AA batteries provide power for the CDT’s real-time clock and they allow for use of the CDT when not connected to a vehicle.

  • Page 199: Plugging The Cdt Into The Vehicle

    CONTROLLER DIAGNOSTIC TOOL (CDT) Plugging the CDT into the Vehicle PLUGGING THE CDT INTO THE VEHICLE Figure 11-2 Communication Port Under Instrument Panel Connect one end of the cable to the port located on the bottom of the CDT. Connect the cable adaptor to the CDT cable. Find the communication port on the vehicle (Figure 11-2, Page 11-3).

  • Page 200: Quick Reference Guide - Eric Charging System

    Quick Reference Guide – ERIC Charging System CONTROLLER DIAGNOSTIC TOOL (CDT) QUICK REFERENCE GUIDE – ERIC CHARGING SYSTEM OPERATION: Change screen contrast for better viewing by selecting the following: HPP Settings, Backlight Preset Favorites: Select a frequently viewed screen, press “Add to” softkey, highlight “Favorites”, press “Select” softkey. CONTROLLER FAULTS: Anti Tamper: If car is not equipped with Visage, make sure Control Main Driver Off: Replace controller.

  • Page 201: System Info

    CONTROLLER DIAGNOSTIC TOOL (CDT) System Info SYSTEM INFO The System Info menu is accessed by using the arrow keys to highlight System Info and pressing the Select softkey to activate the menu. The System Info selection displays information pertaining to the controller. The information provided from this menu selection includes: MODEL NUMBER Displays the model number of the controller.

  • Page 202: Parameters

    Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) PARAMETERS The Parameters menu is accessed by using the arrow keys to highlight Parameters and pressing the Select softkey to activate the menu. The Parameters menu is where you can view and modify the settings of the controller's adjustable parameters. Navigate through this complex menu using the arrow keys, +/- keys, and softkeys.
  • Page 203 CONTROLLER DIAGNOSTIC TOOL (CDT) Parameters When going down an incline with the accelerator pedal partially pressed, the motor braking function will activate to assist the operator in maintaining a speed less than the top speed setting. For example, if the vehicle is going down an incline with the accelerator pedal pressed half way, the motor braking function will activate to assist the operator in maintaining a speed approximately half of the speed setting defined in the Program Menu.

  • Page 204: Amp Hours

    Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) Anti-Tamper The anti-tamper setting defines maximum speed if the Anti-Tamper fault is triggered (e.g. controller is disconnected from the Guardian or Visage system). These speeds can only be activated if the Control Mode option is set to 1 (Guardian/Visage) and are intended to be a deterrent.

  • Page 205: Vehicle Id

    15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. NOTE: If controller is replaced, the information below must be entered into the new controller. See Speed Controller Installation, Section 13, Page 13-12.

  • Page 206: Batt Voltage

    Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) NOTE: Values appearing in these menus represent approximate measurements made by the controller and may differ from measurements made by external instruments. Since the Monitor menu is updated while the vehicle is in operation, the trained technician has the ability to monitor the status of several components in conditions or locations where a problem with vehicle performance has been reported.

  • Page 207: Field Current

    CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu FIELD CURRENT Displays the motor field current (in amperes). ARMATURE PWM Displays motor armature PWM (pulse width modulation). The range of pulse width modulation is 0% to 100%. When the vehicle is operating at full speed, the pulse width modulation should be at 100%. FIELD PWM Displays motor field PWM (pulse width modulation).

  • Page 208: Led Driver

    “private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 11-8.

  • Page 209: Amp Hours Display

    CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu Completed Charges Displays the number of completed charge cycles. Interrupted Charges Displays the number of interrupted charge cycles. Storage Charges Displays the number of storage charge cycles. AMP HOURS DISPLAY Signed Battery Current While driving the vehicle, this displays either the current being pulled out of the batteries or the current being returned to the batteries during regenerative motor braking.

  • Page 210: Fault Count Odometers

    Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) FAULT COUNT ODOMETERS The Fault Count Odometers indicate the odometer reading associated with the last occurrence of each fault type. Will indicate 0.0 (miles) if the fault occurred before the last clearing of fault history. Page 11-14 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 211: Diagnostics Menu

    CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu DIAGNOSTICS MENU CAUTION • A failed motor will damage the controller. Always inspect the motor before replacing the controller. See External Motor Testing, Section 16, Page 16-1. NOTE: The software is subject to frequent updates, and this manual may span many versions. Be aware that some faults listed in this manual may not display in the CDT, indicating older software.

  • Page 212: Causes Of Faults

    Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) CAUSES OF FAULTS Some common causes of faults are: • Loose, broken, or disconnected wires or connectors • Failed components • Improper adjustment or installation of electrical or mechanical components (examples: brake adjustment, improper MCOR installation) •...
  • Page 213 CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu CONTROLLER FAULT CONTROLLER RESPONSE VEHICLE RESPONSE HW FAILSAFE A, B, C Vehicle comes to a stop THROTTLE FAULT A, C Vehicle comes to a stop SPEED SENSOR Vehicle runs at slow speed MAIN WELDED Vehicle runs at slow speed MAIN DRIVER ON A, B...

  • Page 214: Fault Recovery

    Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) FAULT RECOVERY When a fault is detected by the controller, the controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem, such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.

  • Page 215: Fault Descriptions

    The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 11-8. See also Password Tries (OEM Access Level Only) on page 11-12.

  • Page 216: Thermal Cutback

    Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) THERMAL CUTBACK If the controller heatsink temperature is found to be in excess of 185 °F (±9) (85 °C (±5)) or below –13 °F (±9) (–25 °C (±5)), the thermal cutback fault is detected. What it means: Heatsink temperature rises above 185 °F (85 °C).

  • Page 217: Main Welded

    CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions What it means: This is a symptom, not a cause. The controller records the number of times this occurs. What to do: Charge batteries. If fault occurs more frequently than normal, test battery pack. Section 14 — Electric Vehicle - Batteries MAIN WELDED If the speed controller detects that the solenoid contacts are welded closed, a main welded fault is detected.

  • Page 218: Main Dropout (1 Or 2)

    Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) large solenoids should read 180 to 190 ohms; small solenoids 200 to 250 ohms), a broken blue/white wire at the 16-pin controller plug or its terminal is loose in the 16-pin plug. MAIN DROPOUT (1 OR 2) If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault is detected.

  • Page 219: Fld (Field) Missing

    CONTROLLER DIAGNOSTIC TOOL (CDT) Programming FLD (FIELD) MISSING If the speed controller is operating at a duty cycle of greater than 90% (almost full speed) and the field current is less than 3 amps, a field missing fault is detected by the speed controller. CAUTION •...

  • Page 220: Cloning

    Favorites CONTROLLER DIAGNOSTIC TOOL (CDT) CLONING Use the “Restore .cpf File” function to clone a controller with a saved .cpf file stored in the CDT. If using an OEM-level CDT, after you highlight a stored .cpf file and choose “Restore,” a pop-up window will ask whether you want to enable Advanced Cloning (“Yes”/“No”) using the softkeys.
  • Page 221 CONTROLLER DIAGNOSTIC TOOL (CDT) HHP Settings MENU ITEM DESCRIPTIONS Keytone You can choose between several tones to sound each time you press a key, or you can turn the keytone Off for silent programmer operation. Auto Poweroff (battery) You can set the idle time before the programmer will automatically power off when it is powered by its own batteries (i.e., when the control system is not running, or when the programmer is not connected to the control system).

  • Page 222: Plot & Log

    Plot & Log CONTROLLER DIAGNOSTIC TOOL (CDT) PLOT & LOG The Plot & Log menu selection allows the user, with the Plot program, to plot real-time variables on the CDT display screen; or, with the Log program, to create a log file of variable values to view later in a spreadsheet program on a PC. The first step is to add the desired items to the Plot Variable List or the Log Variable List.

  • Page 223: Cdt Troubleshooting

    CONTROLLER DIAGNOSTIC TOOL (CDT) CDT Troubleshooting CDT TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...

  • Page 224: Connection Tests

    Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the CDT cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries – loose terminals or corrosion Section 14 —...
  • Page 225 CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests Place the black (–) probe on each of the pins, one at a time, on the other plug of the adaptor. The multimeter should indicate continuity on only one pin. If any other reading is obtained, the adaptor must be replaced.
  • Page 226 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) 4.3.1. Disconnect the square four-pin connector (3) from the controller. 4.3.2. Connect the handset cord to the handset. 4.3.3. Connect the other end of the handset cord (without the adapter) (4) to the four-pin connector of the controller (2) (Figure 11-4, Page 11-30).
  • Page 227 SECTION 12 — ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM DANGER Electric Vehicle - Troubleshooting and Electrical System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. • Shorting of battery terminals can cause personal injury or death. –...

  • Page 228: Section 12 - Electric Vehicle - Troubleshooting And Electrical System

    ELECTRIC VEHICLE - TROUBLESHOOTING General Information AND ELECTRICAL SYSTEM STATUS CONDITION Normal Operation ON (Constant) Battery SOC is less than 20% but more than 10%. ON (Flash ON and OFF) Battery SOC is less than 10%. ON (Flash ON and OFF three times) The batteries charging has started.

  • Page 229: Battery Wiring Diagram

    ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Battery Wiring Diagram BATTERY WIRING DIAGRAM 2-passenger vehicle battery cables are all 6-gauge. 4-passenger vehicle battery cables are all 4-gauge. Figure 12-2 Battery Wiring Diagram Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 12-3...

  • Page 230: Sonic Weld, Fuse, And 10K Ohm Locations

    ELECTRIC VEHICLE - TROUBLESHOOTING Sonic Weld, Fuse, and 10k Ohm Locations AND ELECTRICAL SYSTEM SONIC WELD, FUSE, AND 10K OHM LOCATIONS 2783 Figure 12-3 Sonic Weld and 10k Ohm Resistor Locations (Approximate) Page 12-4 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 231: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE CDT Club Car recommends the use of the CDT handset for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the CDT handset. See Controller Diagnostic Tool (CDT) on page 11-1 for operating instructions.
  • Page 232 ELECTRIC VEHICLE - TROUBLESHOOTING Troubleshooting AND ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor speed sensor Repair and/or connect the three-pin connector or broken wire to the motor speed sensor Monitor Menu – SPEED PULSES menu item indicates that speed pulses are OFF when Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector...
  • Page 233 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector the MCOR or broken wire to the MCOR Diagnostic Menu – THROTTLE FAULT fault Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector code...

  • Page 234: Troubleshooting Guide 2

    ELECTRIC VEHICLE - TROUBLESHOOTING Troubleshooting AND ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE 2 In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1, use Troubleshooting Guide 2. If an CDT handset is unavailable, use Troubleshooting Guide 2. Page 12-8 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...
  • Page 235 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – batteries discharged Charge batteries Batteries – battery connections Check vehicle wiring. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
  • Page 236 ELECTRIC VEHICLE - TROUBLESHOOTING Troubleshooting AND ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 12 – Motor Speed Sensor on Speed sensor disconnected or failed page 12-24 To change the programmed top speed of the Incorrect speed setting vehicle, an CDT handset must be used Wiring –...

  • Page 237: Test Procedures

    ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 238 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM CAUTION • Be careful not to damage the wire or terminal when back-probing. • When testing voltage, the batteries must remain connected. • When testing voltage, unless specifically directed to do otherwise in a procedure, connect the black (–) probe of the multimeter to the negative post of battery no.
  • Page 239 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Access the Monitor menu and select BATT VOLTAGE by using the SCROLL DISPLAY buttons. The CDT should indicate at least 48 volts. See following NOTE. If not, check for loose battery connections or a battery installed in reverse polarity.
  • Page 240 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 6 (-). 2500-30100-10411 Figure 12-5 Battery Discharge Test Turn the discharge machine on and record the voltage reading of battery pack while under load. A fully charged set of batteries in good condition should read between 46 and 49 volts while under load.
  • Page 241 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures If the CDT display screen begins to work, proceed to step 5; otherwise, perform the following procedure, Tow/Run Switch Test without the CDT Handset. With the CDT still connected to vehicle, place Tow/Run Switch in TOW position. If the CDT display screen goes blank, the Tow/Run switch and connecting wires are operating correctly.
  • Page 242 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM 3.3. If the red wire side does not show BPV, replace fuse. 3.4. If the pink wire side does not show BPV, make sure Tow/Run switch in the RUN position. If it is in RUN, inspect Tow/Run switch, red-to-pink wire spade connector near the solenoid, and sonic welds 5 and 8.
  • Page 243 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Pin 6 Green Wire: Access the controller by removing the access panel in the rear body. See following NOTE. NOTE: The easiest way to test the key switch and MCOR Limit Switch is to check the pin 6 green wire in the 16-pin connector.
  • Page 244 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM 3.2. Place the Forward/Neutral/Reverse switch in the FORWARD position. The CDT should indicate that FORWARD INPUT is ON. If the CDT indicates any other reading, check vehicle wiring. Also check the 16-pin connector at the speed controller.
  • Page 245 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 7 – Solenoid Activating Coil See General Warnings on page 1-2. NOTE: This is a resistance test. Be aware that one of two different solenoids may be found on the vehicle. Visually, the production solenoid is smaller than the service replacement.
  • Page 246 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Place the Tow/Run switch in the TOW position and connect the batteries. See Connect the Batteries – Electric Vehicles on page 1-5. TEST PROCEDURE 9 – Solenoid Continuity See General Warnings on page 1-2. Solenoid Continuity Test with the CDT Handset If necessary, see Testing Basics on page 12-11.
  • Page 247 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures tire should rotate and the multimeter should show a change in resistance. If not, replace the solenoid. See Solenoid Removal on page 13-13. TEST PROCEDURE 10 – Charger Interlock See General Warnings on page 1-2. Controller Interlock Function Test with the CDT Handset If necessary, see Testing Basics on page 12-11.
  • Page 248 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM If the meter does not indicate continuity, check and repair related connections, Tow/Run switch and wiring. If necessary, replace affected wire harness, charger receptacle or Tow/Run switch. When finished, install 15-amp fuse and fuse cover. TEST PROCEDURE 11 –...
  • Page 249 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures WARNING • The key switch should be placed in the OFF position and left in the OFF position for the duration of this test. With the batteries connected, place Tow/Run switch in RUN. Using a multimeter set to 200 volts DC, place red (+) probe on battery no.
  • Page 250 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 12 – Motor Speed Sensor See General Warnings on page 1-2. Motor Speed Sensor Test without any Tool CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
  • Page 251 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 4.1. With Tow/Run switch in the RUN position and using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 6 (6 x 8-Volt battery set) negative post and place red (+) probe on red wire terminal socket in three-pin connector.
  • Page 252 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM As the accelerator pedal is pressed, the voltage reading should increase from approximately 5 volts RMS when the MCOR limit switch closes, to approximately 48 volts RMS with the accelerator pedal fully pressed. See following NOTE.
  • Page 253 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 15 – 16-Pin Connector See General Warnings on page 1-2. Pin 1 – White Pin 5 – Light Blue Pin 9 – Gray Pin 13 – White/Black Pin 2 – Yellow Pin 6 –...
  • Page 254 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM If 16-pin must be disconnected: Keep the 16-pin connector disconnected from the controller. With Tow/Run switch in the TOW position, reconnect the batteries. See Connect the Batteries – Electric Vehicles on page 1-5. Place the Tow/Run switch in the RUN position and then check the appropriate wires.
  • Page 255 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures PERFORM TEST WITH 16-PIN CONTROLLER INPUTS CONNECTED TO CONTROLLER? (IF TEST PROCEDURE YES, BACK-PROBE TO TEST) FORWARD INPUT BPV from Forward/Neutral/Reverse switch in Pin 8 – Brown FWD (Key switch either ON or OFF) B+ INPUT Pin 9 –...
  • Page 256 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM If necessary, see Testing Basics on page 12-11. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles on page 1-4. Remove the instrument panel. See Key Switch Removal, Section 13, Page 13-1. Disconnect the orange/white and pink wires from the reverse buzzer.
  • Page 257 ELECTRIC VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures – Condition of the 9-pin connector behind instrument panel. – Condition of the yellow/green wire terminal in the instrument panel wire harness. – Continuity of the wires in the wire harnesses. If no problems exist in the above items, replace the charge indicator light.
  • Page 258 ELECTRIC VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Pagination Page Page 12-32 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 259: Section 13 - Electric Vehicle - Electrical Components

    SECTION 13 — ELECTRIC VEHICLE - ELECTRICAL COMPONENTS DANGER Electric Vehicle - Electrical Components • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. KEY SWITCH See General Warnings on page 1-2. TESTING THE KEY SWITCH See the appropriate troubleshooting section for the type of electrical system used in the vehicle.

  • Page 260: Charge Indicator Light

    ELECTRIC VEHICLE - ELECTRICAL Charge Indicator Light COMPONENTS Figure 13-1 Instrument Panel Removal Figure 13-2 Key Switch CHARGE INDICATOR LIGHT See General Warnings on page 1-2. TESTING THE CHARGE INDICATOR LIGHT See Test Procedure 17 – Charge Indicator Light on page 12-30. CHARGE INDICATOR LIGHT REMOVAL Disconnect the batteries and discharge the controller.

  • Page 261: Usb Port

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS USB Port 2787 Figure 13-3 Charge Indicator Light USB PORT The 5–volt 3 amp USB port (Figure 13-4) provides electricity to power and recharge portable devices. The USB port is not designed for the transfer of data. Figure 13-4 USB Port USB PORT REMOVAL Remove the instrument panel to access the USB port wires and lock tabs (Figure 13-5, Page 13-4).

  • Page 262: Usb Port Installation

    ELECTRIC VEHICLE - ELECTRICAL Forward/Neutral/Reverse Rocker Switch COMPONENTS Figure 13-5 USB Port Removal Figure 13-6 USB Port Installation USB PORT INSTALLATION Put the USB port wires into the dash. Push the USB port into the dash. Connect the red instrument panel wire to the red USB port wire (1) (Figure 13-6, Page 13-4). Connect the black instrument panel wire to the black USB port wire (2).

  • Page 263: Forward/Neutral/Reverse Rocker Switch Installation

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Forward/Neutral/Reverse Rocker Switch Figure 13-7 Forward/Neutral/Reverse Rocker Switch FORWARD/NEUTRAL/REVERSE ROCKER SWITCH INSTALLATION Route the three wires through bezel. Connect the blue (4), orange (5) and brown (6) wires to the rocker switch (3), exactly as shown in (Figure 13-7, Page 13-5). Orient the rocker switch (3) so the terminals are towards the front of the housing (1).

  • Page 264: Electronics Module Cover

    ELECTRIC VEHICLE - ELECTRICAL Electronics Module Cover COMPONENTS ELECTRONICS MODULE COVER See General Warnings on page 1-2. The electronics module cover needs to be removed to gain access to the speed controller, Tow/Run switch, and solenoid. ELECTRONICS MODULE COVER REMOVAL Disconnect the batteries and discharge the controller.

  • Page 265: Tow/Run Switch

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Tow/Run Switch Figure 13-8 Access and Remove Electronics Module Cover TOW/RUN SWITCH See General Warnings on page 1-2. TESTING THE TOW/RUN SWITCH See Test Procedure 3 – Tow/Run Switch on page 12-14. TOW/RUN SWITCH REMOVAL Disconnect the batteries and discharge the controller.

  • Page 266: Motor Controller Output Regulator (Mcor)

    ELECTRIC VEHICLE - ELECTRICAL Motor Controller Output Regulator (MCOR) COMPONENTS Figure 13-9 Tow/Run Switch MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings on page 1-2. The pedal group for the electric vehicle includes a Motor Controller Output Regulator (MCOR) mounted on the side of the pedal group.

  • Page 267: Reverse Buzzer

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Reverse Buzzer Connect the batteries. See Connect the Batteries – Electric Vehicles on page 1-5. REVERSE BUZZER See General Warnings on page 1-2. TESTING THE REVERSE BUZZER See 12-29. REVERSE BUZZER REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles on page 1-4.

  • Page 268: Electronics Module

    ELECTRIC VEHICLE - ELECTRICAL Electronics Module COMPONENTS ELECTRONICS MODULE See General Warnings on page 1-2. While it is not necessary to remove the electronics module from the vehicle, access to individual components may be easier with the module removed. ELECTRONICS MODULE REMOVAL Disconnect the batteries and discharge the controller (1).

  • Page 269: Electronics Module Installation

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Electronics Module 2771 Figure 13-11 Controller and Solenoid Removal ELECTRONICS MODULE INSTALLATION Return electronics module (3) to its location in vehicle but leave it tilted forward. Complete connections to the controller (1), the Tow/Run switch (5) and the solenoid (4) per the electrical schematics.

  • Page 270: Speed Controller

    ELECTRIC VEHICLE - ELECTRICAL Speed Controller COMPONENTS Set electronics module in place and secure with bolt (2) (Figure 13-11, Page 13-11). Tighten bolt to 40 in·lb (4.5 N·m). Install the batteries and battery cables in their original locations. See Battery Replacement on page 14-5. Place the Tow/Run switch (5) in the TOW position and connect the batteries.

  • Page 271: Solenoid

    Select Program, Vehicle ID, Vehicle Date of Manufacture and enter the number on the model year and week from the vehicle serial number. 7.7. Select Information, Software Version and verify the value is 13 or higher. If not, contact a Club Car Technical Representative. 7.8.

  • Page 272: Solenoid Installation

    ELECTRIC VEHICLE - ELECTRICAL Charger Receptacle COMPONENTS Disconnect the heavy gauge wires from the solenoid (4) by removing the nuts (7) and washers (10) (Figure 13-11, Page 13-11). Disconnect the spade connectors from the solenoid (4). Slide solenoid (4) up to disengage the mounting tabs and remove from mounting plate. SOLENOID INSTALLATION Slide solenoid (4) into mounting plate (Figure 13-11, Page 13-11).

  • Page 273: Charger Receptacle Installation

    ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Charger Receptacle CHARGER RECEPTACLE INSTALLATION Insert the wires through the hole in the bucket. Insert receptacle (2) into bucket. Install the three screws (1) that secure the receptacle to the bucket. Tighten screws to 16 in·lb (1.8 N·m). Connect 10-gauge red wire to solenoid.
  • Page 274 ELECTRIC VEHICLE - ELECTRICAL Charger Receptacle COMPONENTS Pagination Page Page 13-16 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 275: Section 14 - Electric Vehicle - Batteries

    SECTION 14 — ELECTRIC VEHICLE - BATTERIES DANGER Electric Vehicle - Batteries • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.

  • Page 276: Battery Testing Basics - 8 Volt

    Battery Testing Basics – 8 Volt ELECTRIC VEHICLE - BATTERIES BATTERY TESTING BASICS – 8 VOLT See General Warnings on page 1-2. OBSERVATION Inspect the battery compartment for the following items: • Rusted, corroded, or broken battery posts • Rusted, corroded, loose or broken wires •...

  • Page 277: Battery Testing - 8 Volt

    Regrouping is now Club Car’s standard battery replacement method. Regrouping is the practice of placing batteries of similar condition together in one vehicle. For example, if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car, after removing the failed batteries, there will be six good batteries remaining.
  • Page 278 Battery Regrouping ELECTRIC VEHICLE - BATTERIES 3104 Figure 14-2 Battery Regrouping Process Flow Page 14-4 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 279: Battery Replacement

    ELECTRIC VEHICLE - BATTERIES Battery Replacement BATTERY REPLACEMENT See General Warnings on page 1-2. WARNING • Wear steel-toe shoes when replacing batteries. • To prevent electrolyte leakage from the battery vents, batteries must be kept in an upright position. Tipping a battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak out the vent hole.

  • Page 280: Battery Care

    See General Warnings on page 1-2. WATER QUALITY Water purity is the most important factor in the performance and life span of the vehicle batteries. Club Car is, therefore, placing increased importance on battery water quality. Outlined below are four battery watering procedures, grouped into two categories: Preferred and Alternate methods.

  • Page 281: Deionizer

    Replace filter immediately if the red light comes ON indicating service is required. Replacement filters are available from Club Car Service Parts. • Inspect the condition of all tubing, connections, and couplers. Make sure that all parts are in good working condition, secure, leak free, and properly connected.

  • Page 282: Battery Care - Vehicles Equipped With The Single-Point Watering System

    Battery Care ELECTRIC VEHICLE - BATTERIES Single point watering systems will require seasonal maintenance if vehicles are taken out of service or put into storage for a period of 6 weeks or longer. To prepare the SPWS, ensure the feed tube and coupler are on top of battery. Then, use the following steps to bring vehicle back into service: After the batteries have been fully charged/equalized, connect the system to its water supply for 3 to 5 seconds, then disconnect regardless of whether or not the batteries are completely full.

  • Page 283: Battery Care - Vehicles Without The Single-Point Watering System

    • Do not overfill the batteries. NOTE: A battery watering gun or bottle is available from your authorized Club Car dealer. The battery hold-downs should be tight enough so that the batteries do not move while the vehicle is in motion, but not so tight as to crack or buckle the battery case.

  • Page 284: Electrolyte Level

    Battery Care ELECTRIC VEHICLE - BATTERIES Hot weather also has an effect on a battery’s self-discharge rate. The higher the temperature, the quicker a set of batteries will discharge. In hotter climates, batteries should be checked more often. When storing batteries, keep in a cool place.

  • Page 285: Single Point Watering System (Spws)

    A deionizer for vehicles with SPWS, Club Car Part Number 105166801 is available from Service Parts (DC powered water quality indicator light). Replacement cartridge: 104005901. Bottled distilled water, with hand pump, Club Car Part Number 104006101, is recommended for private consumer applications.
  • Page 286 Single Point Watering System (SPWS) ELECTRIC VEHICLE - BATTERIES 3083 Figure 14-4 Connecting Hose with Filter to Water Source Figure 14-5 Checking the Water Flow Rate Completely open the water faucet until the water flows out of the hose-end assembly (3), and note the movement of the red flow indicator balls (6).

  • Page 287: Battery Storage

    ELECTRIC VEHICLE - BATTERIES Battery Storage CAUTION • If at any time water overflows from the batteries, immediately stop the refill process, disconnect the pressure regulator from the battery fill coupling, and call for service. When the red flow indicator balls stop moving, immediately press the grey button to disconnect the hose-end assembly from the battery fill coupling (9), and squeeze the dust cover (10) to lightly secure it to the male connector of the battery fill coupling (Figure 14-6).
  • Page 288 Early Excessive Discharging ELECTRIC VEHICLE - BATTERIES Pagination Page Page 14-14 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 289: Section 15 - Electric Vehicle - Battery Charger

    2%. Make sure proper ventilation is used when charging batteries. WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • This vehicle is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the vehicle by a person responsible for their safety.

  • Page 290: General Information

    Club Car only recommends OEM replacement batteries. Contact your authorized Club Car dealer/distributor with any questions about battery and charger compatibility or algorithm updates.

  • Page 291: Ic 650 Battery Charger Specifications

    ELECTRIC VEHICLE - BATTERY CHARGER IC 650 Battery Charger Specifications The battery should never be left in a discharged state, as this too affects the internal components and can reduce the capacity of the battery. The battery should be charged every day they are used. However, the battery should not be charged if they have not been used.

  • Page 292: Federal Communications Commission

    Governmental And Industry Certifications ELECTRIC VEHICLE - BATTERY CHARGER • EMC Directives EN 61000-3-2: 2014, EN 61000-3-3: 2013, EN 61000-6-2: 2005, EN 61000-6-4: 2007 FEDERAL COMMUNICATIONS COMMISSION The battery charger is Federal Communications Commission (FCC) certified. NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules.

  • Page 293: Features

    ELECTRIC VEHICLE - BATTERY CHARGER Features FEATURES AC ELECTRICAL CORD AND PLUG The AC electric cord has an equipment-grounding conductor and grounding type plug. The AC plug must be connected to a correctly rated ground fault circuit interrupter (GFCI) receptacle with arc flash protection. The receptacle must be installed and grounded in accordance with the National Electrical Code, local codes, and local ordinances.

  • Page 294: Status Indicator Lights

    Features ELECTRIC VEHICLE - BATTERY CHARGER STATUS INDICATOR LIGHTS LIGHT STATUS STATUS EXPLANATION Charger fault condition. See Charger Troubleshooting. (Constant) Orange External error condition - caution. See Charger Troubleshooting. (Flash On and Off) Green USB port is active. (Flash On and Off) Green Safe to remove the USB flash drive.

  • Page 295: Battery Charging Interlock

    ELECTRIC VEHICLE - BATTERY CHARGER Features The following table is for battery chargers with a display panel. LIGHT STATUS STATUS EXPLANATION Yellow The charger output is active. There is a potential risk of electric shock. (Constant) Internal fault condition has caused the charging to stop. See the Battery Charger F code Fault Codes for more information.

  • Page 296: How To Make A Strain Relief And Drip Loop

    Features ELECTRIC VEHICLE - BATTERY CHARGER HOW TO MAKE A STRAIN RELIEF AND DRIP LOOP A strain relief and drip loop is necessary to prevent damage to the charger. The strain relief prevents tension on the AC plug. The drip loop prevents water damage to the AC plug. Connect the AC cord (1) into the AC plug (Figure 15-2, Page 15-8).

  • Page 297: The Charge Circuit

    ELECTRIC VEHICLE - BATTERY CHARGER The Charge Circuit THE CHARGE CIRCUIT EXTERNAL CHARGE CIRCUIT The external charge circuit consists of the: • Charger receptacle • Interlock wire • Controller • Solenoid • Battery pack 2788 Figure 15-3 Charge Circuit – External High-Frequency Charger Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 15-9...

  • Page 298: Onboard Charge Circuit

    The Charge Circuit ELECTRIC VEHICLE - BATTERY CHARGER ONBOARD CHARGE CIRCUIT The onboard charge circuit consists of the: • Interlock wire • Controller • Solenoid • Battery pack 2789 Figure 15-4 Charge Circuit – Onboard High-Frequency Charger Page 15-10 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 299: Battery Charger Operation

    ELECTRIC VEHICLE - BATTERY CHARGER Battery Charger Operation BATTERY CHARGER OPERATION CHARGING WITH EXTERNAL CHARGER Turn the key to OFF. Turn off all accessories. Connect the AC cord to the charger. Connect the AC cord to the power source. CAUTION •...

  • Page 300: Charging With Onboard Charger

    Battery Charger Operation ELECTRIC VEHICLE - BATTERY CHARGER CHARGING WITH ONBOARD CHARGER Turn the key to OFF. Turn off all accessories. Connect the AC cord (1) to the power source. NOTE: The vehicle will start to charge in 2 to 10 seconds. The charge indicator light will flash and the multi-purpose buzzer will operate when the vehicle starts to charge.

  • Page 301: Algorithm

    Club Car only recommends OEM replacement batteries. Contact your authorized Club Car dealer/distributor with any questions about battery and charger compatibility or algorithm updates.
  • Page 302 Algorithm ELECTRIC VEHICLE - BATTERY CHARGER Go to CHARGER/RESP/Battery charger serial number/SETTING (Figure 15-8). G-130898-000051 Figure 15-8 Setting.txt File Location Open the Setting.txt file (Figure 15-9). G-130898-000052 Figure 15-9 Setting.txt File The Active Charging Profile (1) displays the active algorithm. The Available Charging Profile(s) (2) displays the algorithms that are loaded on the battery charger.

  • Page 303: How To Install Trojan Algorithm - External Charger

    The Trojan battery algorithm is for Trojan T875 and T890 8-Volt batteries. Format a USB 2.0 flash drive as FAT16 or FAT32. Make sure the USB is blank. Login to Club Car Links via https://www.clubcar.com. Click on the Tech/Warranty drop-down menu and select Service and Warranty Bulletins (Figure 15-10).
  • Page 304 Algorithm ELECTRIC VEHICLE - BATTERY CHARGER Click on the Trojan - ERIC Shelf Charger Algorithm link (Figure 15-11). G-130898-000053 Figure 15-11 Trojan - ERIC Shelf Charger Algorithm Open the Trojan - ERIC Shelf Charger Algorithm.zip file. Copy the CHARGER folder to the USB flash drive (Figure 15-12). G-130898-000049 Figure 15-12 CHARGER Folder Safely eject the USB flash drive from the computer.
  • Page 305 ELECTRIC VEHICLE - BATTERY CHARGER Algorithm Wait until only the blue light (1) is on (Figure 15-13). Figure 15-13 USB Dust Cover Remove the USB dust cover (2). Connect the USB flash drive to the battery charger. The blue light and green triangle light (3) will turn off and on for approximately three minutes.

  • Page 306: How To Change Onboard Charger Algorithm

    Algorithm ELECTRIC VEHICLE - BATTERY CHARGER HOW TO CHANGE ONBOARD CHARGER ALGORITHM Disconnect the AC cord from the battery charger. Wait 30 seconds. Push and hold the Select Charge Profile button (1) (Figure 15-14, Page 15-18). Figure 15-14 Algorithm Change While pushing the Select Charge Profile button, connect the AC cord to the battery charger.

  • Page 307: Update Battery Charger With Usb

    Algorithm UPDATE BATTERY CHARGER WITH USB Contact Club Car to obtain the required algorithm, software, and settings files for the correct battery charger and vehicle model. Copy the files to a blank USB 2.0 flash drive formatted as FAT16 or FAT32. See the instructions that were included with the file.

  • Page 308: Inspection And Maintenance

    Inspection And Maintenance ELECTRIC VEHICLE - BATTERY CHARGER INSPECTION AND MAINTENANCE To ensure trouble-free performance, it is very important to follow an established preventive maintenance program. Regular and consistent maintenance can prevent vehicle downtime and expensive repairs that can result from neglect. Any charger not functioning correctly should be removed from use until it is properly repaired.

  • Page 309: Electrical Plugs And Receptacles

    ELECTRIC VEHICLE - BATTERY CHARGER Inspection And Maintenance ELECTRICAL PLUGS AND RECEPTACLES Examine electrical plugs for wear and damage before use. Immediately replace electrical plugs for: • Bent pins • Corrosion • Cracks • Loose connections • Missing pins • Worn pins CLEAN THE ELECTRICAL PLUGS AND RECEPTACLES DANGER •...

  • Page 310: Battery Charger Troubleshooting

    Battery Charger Troubleshooting ELECTRIC VEHICLE - BATTERY CHARGER BATTERY CHARGER TROUBLESHOOTING DANGER • Do not touch any wire or component in the battery charger while AC power is present. Failure to heed this warning will result in an electric shock. WARNING •...

  • Page 311: Reset Power - External Charger

    ELECTRIC VEHICLE - BATTERY CHARGER Battery Charger Troubleshooting RESET POWER – EXTERNAL CHARGER Before replacing the charger, reset the charger in case the failure was caused by a temporary situation. Disconnect the DC cord from the vehicle. Disconnect the AC cord from the AC power source. When the red triangle status indicator light turns off, wait 30 seconds.

  • Page 312: External Charger Troubleshooting Indicators

    Battery Charger Troubleshooting ELECTRIC VEHICLE - BATTERY CHARGER EXTERNAL CHARGER TROUBLESHOOTING INDICATORS If a fault occurs, count the number of red flashes (on the charger or dash) between pauses and refer to the table below: EXTERNAL CHARGER TROUBLESHOOTING GUIDE CHECK STATUS STATUS POSSIBLE CAUSES STATUS...
  • Page 313 ELECTRIC VEHICLE - BATTERY CHARGER Battery Charger Troubleshooting EXTERNAL CHARGER TROUBLESHOOTING GUIDE 1. Erroneous event (an unknown variable; Reset charger power. See Reset Power – External something occurred to Charger on page 15-23. Reconnect DC cord to vehicle. the charger or vehicle that If status goes away, continue using charger.

  • Page 314: Onboard Battery Charger Error Codes

    Reset the battery charger power. rent If problem continues, contact Club Car. • Error in the BMS/VCM software configuration This error will automatically clear once the battery charger USB operation failed (software) power is reset.

  • Page 315: Onboard Battery Charger Fault Codes

    • A battery or some other source has been connected to the Make sure the correct battery is installed. charger that exceeds the hardware’s design limits If the problem continues, contact Club Car. • VCM/BMS issue ONBOARD BATTERY CHARGER FAULT CODES The “F”...

  • Page 316: Test Procedures

    Test Procedures ELECTRIC VEHICLE - BATTERY CHARGER TEST PROCEDURES See General Warnings on page 1-2. When the upper green light is flashing, indicating the charger is in finish charge, it is okay to begin a battery discharge test if so desired. Index of Test Procedures 1 –...
  • Page 317 ELECTRIC VEHICLE - BATTERY CHARGER Test Procedures NOTE: Batteries near the end of their useful lives may not allow the battery charge current to taper and the upper half of the battery-shaped status indicator will continue to flash. Section 14 — Electric Vehicle - Batteries Continued poor performance may indicate a problem in the vehicle electrical system, brakes or battery charger.
  • Page 318 Test Procedures ELECTRIC VEHICLE - BATTERY CHARGER TEST PROCEDURE 7 – Charger Output Test Without a Meter: Connect DC cord and start a charge cycle. If buzzer sounds three times, then charger is functioning. Both a confirmed connection with the charger and a rise in battery pack voltage are required for buzzer to sound three times.

  • Page 319: External Charger Repairs

    ELECTRIC VEHICLE - BATTERY CHARGER External Charger Repairs EXTERNAL CHARGER REPAIRS WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair. • Prior to servicing the charger, disconnect the DC cord from the vehicle charge receptacle and the AC cord from the AC outlet.

  • Page 320: Dc Cord Removal

    External Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER DC CORD REMOVAL Disconnect the DC cord from the vehicle charge receptacle. Disconnect the AC cord from the AC power source. Remove the terminal block cover. Remove the screws (1) (Figure 15-16, Page 15-32). Figure 15-16 DC Cord Remove the clamp (2).

  • Page 321: Dc Cord Installation

    ELECTRIC VEHICLE - BATTERY CHARGER External Charger Repairs DC CORD INSTALLATION Attach the white DC cord wire to the positive (+) terminal (5) (Figure 15-17, Page 15-33). NOTE: The positive symbol (+) and negative symbol (–) are molded into the terminal block. Figure 15-17 Wire Installation Attach the black and green DC cord wires to the negative (-) terminal (6).

  • Page 322: Handle Removal

    External Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER HANDLE REMOVAL Remove the screws (1) (Figure 15-19, Page 15-34). Figure 15-19 Handle Remove the handle (2). HANDLE INSTALLATION Install the handle (2) on the battery charger (Figure 15-19, Page 15-34). Install the screws (1). Tighten the screws to 39.8 lb·in (4.5 N·m). Page 15-34 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 323: Foot Removal

    ELECTRIC VEHICLE - BATTERY CHARGER External Charger Repairs FOOT REMOVAL Disconnect the DC cord from the vehicle charge receptacle. Disconnect the AC cord from the AC power source. If the battery charge is mounted, remove the battery charger. Squeeze the barbs (1) on the foot (2) and push the foot out of charger mounting tab (Figure 15-20, Page 15-35). Figure 15-20 Foot FOOT INSTALLATION Push the foot (2) into hole in charger mounting tab until the barbs (1) come through and secure foot in place...

  • Page 324: Onboard Charger Repairs

    Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER ONBOARD CHARGER REPAIRS WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair. • Prior to servicing the charger, disconnect the AC cord from the AC outlet. NOTE: This charger has no internal components to service or repair.
  • Page 325 ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger Repairs Two-Passenger Onboard Charger Installation Connect the DC cord to the onboard charger harness (1) (Figure 15-22). Figure 15-22 Onboard Charger Connect the connector (2). Put the onboard charger (5) on the bracket (6). Install the bolts (5), washers (4), and nuts (3).
  • Page 326 Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER Two-Passenger AC Cord Reel Removal Disable the vehicle. Disconnect the batteries. Disconnect the AC cord from AC power source. Disconnect the AC cord (1) from the battery charger (Figure 15-23, Page 15-38). Figure 15-23 Disconnect From Battery Charger Remove the screws (2) (Figure 15-24, Page 15-38).
  • Page 327 ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger Repairs Remove the nuts (6), washers (7), and bolts (8) (Figure 15-25, Page 15-39). Figure 15-25 AC Cord Reel Removal Remove the AC cord reel (9). Two-Passenger AC Cord Reel Installation Install the AC cord reel (9) on the cord reel plate (Figure 15-26, Page 15-39). Figure 15-26 AC Cord Reel Installation Install the bolts (8), washers (7), and nuts (6).
  • Page 328 Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER Install the backing plate (5) on the AC cord (4) (Figure 15-27, Page 15-40). Figure 15-27 Cord Housing Installation Put the AC cord through the cord housing (3). Install the cord housing on the underbody. Install the screws (2).

  • Page 329: Fixed Rear Seat Onboard Charger

    ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger Repairs FIXED REAR SEAT ONBOARD CHARGER Fixed Rear Seat Onboard Charger Removal Disable the vehicle. Set the Run/Tow switch to TOW. Disconnect the batteries and discharge the controller. Disconnect the AC cord from the AC power source. Lift rear-facing seat bottom and support in the raised position.
  • Page 330 Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER Disconnect the charger harness (5) from the charger power harness (6) (Figure 15-31). Figure 15-31 Charger Harness Connections Disconnect the 14-pin connector (7) from battery charger. Remove the screws (8). Retain the insulator (9) (Figure 15-32). Figure 15-32 Charger Power Harness Connector Screws Page 15-42 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...
  • Page 331 ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger Repairs Remove the bolts (10) and the battery charger (Figure 15-33). Figure 15-33 Battery Charger Removal Fixed Rear Seat Onboard Charger Installation Install the battery charger (1) and the bolts (2) (Figure 15-34). Tighten the bolts to 53 in·lb (6 N·m). Figure 15-34 Battery Charger Installation Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 15-43...
  • Page 332 Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER Install the insulator (3) and the screws (4) (Figure 15-35). Tighten the screws to 11 in·lb (1.25 N·m). Figure 15-35 Charger Power Harness Connector Screws Connect the charger harness (5) from the charger power harness (6) (Figure 15-36). Figure 15-36 Charger Harness Connections Connect the 14-pin connector (7) to the battery charger.
  • Page 333 ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger Repairs Connect the AC cord (8) to battery charger (Figure 15-37). Figure 15-37 AC Cord Installation Install the charger shield (9) and the screws (10) (Figure 15-38). Tighten the screws to 17 in·lb (2 N·m). Figure 15-38 Charger Shield Installation Lower rear-facing seat bottom.
  • Page 334 Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER Fixed Rear Seat AC Cord Reel Removal Figure 15-39 AC Cord Disable the vehicle. Set the Run/Tow switch to TOW. Disconnect the batteries and discharge the controller. Disconnect the AC cord from the AC power source. Lift rear-facing seat bottom and support in the raised position.

  • Page 335: Fold-Down Rear Seat Onboard Charger

    ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger Repairs FOLD-DOWN REAR SEAT ONBOARD CHARGER Fold-Down Rear Seat Onboard Charger Removal Disable the vehicle. Set the Run/Tow switch to TOW. Disconnect the batteries and discharge the controller. Disconnect the AC cord from the AC power source. Remove the screws (1) and the charger shield (2) (Figure 15-29).
  • Page 336 Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER Remove the nuts (8), screws (9), and insulator (10) (Figure 15-32). Retain the insulator. Figure 15-42 Battery Charger Removal Remove the nuts (11), bolts (12), and the battery charger. Fold-Down Rear Seat Onboard Charger Installation Install the battery charger (1), bolts (2), and nuts (3) (Figure 15-43).
  • Page 337 ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger Repairs Connect the charger harness (7) from the charger power harness (8) (Figure 15-44). Figure 15-44 Harness Connections Connect the 14-pin connector (9) to the battery charger. Connect the AC cord (10) to battery charger. Install the charger shield (11) and the screws (12) (Figure 15-45).
  • Page 338 Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER Fold-Down Rear Seat AC Cord Reel Removal Figure 15-46 AC Cord Disable the vehicle. Set the Run/Tow switch to TOW. Disconnect the batteries and discharge the controller. Disconnect the AC cord from the AC power source. Lift rear-facing seat bottom and support in the raised position.

  • Page 339: Terminal Block Cover Removal

    ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger Repairs TERMINAL BLOCK COVER REMOVAL Disconnect the AC cord from AC power source. Disconnect the DC cord from the charger harness. Push the tabs (1) in and remove the terminal block cover (2) (Figure 15-47, Page 15-51). Figure 15-47 Onboard Charger Terminal Block Cover TERMINAL BLOCK COVER INSTALLATION WARNING...

  • Page 340: Dc Cord Removal

    Onboard Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER DC CORD REMOVAL Disable the vehicle. Disconnect the batteries. Disconnect the AC cord from AC power source. Disconnect the DC cord from the onboard charger harness. Remove the terminal block cover. Remove the screws (1) (Figure 15-48, Page 15-52). Figure 15-48 Onboard Charger DC Cord Remove the clamp (2).

  • Page 341: Section 16 - Electric Vehicle - Motor

    The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use in Excel System vehicles. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.
  • Page 342 External Motor Testing ELECTRIC VEHICLE - MOTOR MOTOR TERMINALS CONTINUITY TEST RESULT A1 to A2 Continuity F1 to F2 A1 to F1 No Continuity A1 to F2 A2 to F1 No Continuity A2 to F2 A1 to Ground No Continuity A2 to Ground F1 to Ground No Continuity...
  • Page 343 ELECTRIC VEHICLE - MOTOR External Motor Testing TEST PROCEDURE 4 – Field Circuit Open See General Warnings on page 1-2. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-4. Disconnect wires from the F1 and F2 terminals on the motor using two wrenches to prevent posts from turning. Set a multimeter to 200 ohms and place the red (+) probe on the F1 terminal and the black (–) probe on the F2 terminal.

  • Page 344: Motor

    Motor ELECTRIC VEHICLE - MOTOR MOTOR See General Warnings on page 1-2. MOTOR REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-4. Disconnect wires from the terminals on the motor using two wrenches to prevent posts from turning. Label the wires to ensure proper reconnection.

  • Page 345: Motor Disassembly

    ELECTRIC VEHICLE - MOTOR Motor Figure 16-3 Lower Axle Remove the bolts and lock washers that secure the motor to the transaxle (Figure 16-24, Page 16-17). See following CAUTION. CAUTION • Do not position fingers under motor when sliding motor off of the input shaft in step 9. Fingers may get pinched when motor disengages.
  • Page 346 Motor ELECTRIC VEHICLE - MOTOR 2.1. Remove the two screws (25) that secure the speed sensor (10) to the end cap (11) (Figure 16-15, Page 16-12). 2.2. Remove the screw securing the magnet to the armature shaft (Figure 16-4, Page 16-5). 2.3.
  • Page 347 ELECTRIC VEHICLE - MOTOR Motor CAUTION • Removing the armature from the end cap requires two people: one to operate the press, and another to hold the armature. Failure to heed this CAUTION could result in personal injury and/or damage to the armature resulting from an unsupported armature falling after it becomes disengaged from the end cap bearing.

  • Page 348: Motor Component Testing And Inspection

    Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR Figure 16-10 Brush Rigging Figure 16-11 Bearing Retaining Ring MOTOR COMPONENT TESTING AND INSPECTION See General Warnings on page 1-2. ARMATURE INSPECTION AND TESTING Remove the motor from the vehicle. See Motor Removal on page 16-4. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-5.
  • Page 349 ELECTRIC VEHICLE - MOTOR Motor Component Testing and Inspection CAUTION • Do not use emery cloth to polish the commutator. Particles of emery are conductive and may short-circuit the commutator bars. Do not use oil or lubricants on the commutator or brushes. NOTE: Oil on the commutator may indicate a faulty transaxle input shaft oil seal.

  • Page 350: Motor Frame And Field Windings Inspection

    Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal on page 16-4. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-5. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
  • Page 351 ELECTRIC VEHICLE - MOTOR Motor Component Testing and Inspection Bearing Inspection NOTE: Replacement of the end cap bearing is highly-recommended if the end cap is removed from the motor. The following procedure is provided as a guideline for determining general bearing failure. Remove the motor from the vehicle.
  • Page 352 Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR 2613 Figure 16-15 Electric Motor (EJ8-4001A) Page 16-12 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 353: Reconditioning The Motor

    ELECTRIC VEHICLE - MOTOR Reconditioning the Motor RECONDITIONING THE MOTOR See General Warnings on page 1-2. Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures is absolutely essential for successful motor reconditioning. MOTOR SPECIFICATIONS Any rework must be performed by a qualified technician.
  • Page 354 Motor Assembly ELECTRIC VEHICLE - MOTOR Figure 16-16 Brush Rigging Figure 16-17 Retracted Brushes Figure 16-18 Armature Installation Figure 16-19 Brush Setting With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 16-18, Page 16-14).

  • Page 355: Motor Installation

    ELECTRIC VEHICLE - MOTOR Motor Installation Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem. MOTOR INSTALLATION See General Warnings on page 1-2. Clean the transaxle input shaft. 1.1. Spray the input shaft thoroughly with CRC ®...
  • Page 356 Motor Installation ELECTRIC VEHICLE - MOTOR Install motor on transaxle. 4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE. NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle. When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle housing (Figure 16-15, Page 16-12).
  • Page 357 ELECTRIC VEHICLE - MOTOR Motor Installation nuts. For 5/16 inch (8mm) diameter studs, tighten the nuts to 100 in·lb (11 N·m). For 1/4 inch (6.3mm) diameter studs, tighten the nuts to 45 in·lb (5.0 N·m). 4.8. Secure the white, orange, green, and blue wires with a wire tie so that none of the motor wires will scrub the motor or transaxle when the vehicle is in operation.
  • Page 358 Motor Installation ELECTRIC VEHICLE - MOTOR Pagination Page Page 16-18 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 359: Section 17 - Electric Vehicle - Transaxle

    SECTION 17 — ELECTRIC VEHICLE - TRANSAXLE DANGER Electric Vehicle - Transaxle • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. LUBRICATION See General Warnings on page 1-2. There are two plugs located on the lower half of the transaxle housing. The upper plug (21) (as viewed when the vehicle is on a level surface) is used as a lubricant level indicator (Figure 17-5, Page 17-3).
  • Page 360 Axle Bearing and Shaft ELECTRIC VEHICLE - TRANSAXLE 6.2. Use a press to separate the axle oil seal (15) from the adapter ring (39) (Figure 17-3, Page 17-2). Retain the adapter ring and discard the oil seal. Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft.
  • Page 361 ELECTRIC VEHICLE - TRANSAXLE Axle Bearing and Shaft Figure 17-5 Transaxle – Type G Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 17-3...

  • Page 362: Axle Bearing

    Axle Bearing and Shaft ELECTRIC VEHICLE - TRANSAXLE Axle Shaft and Oil Seal Installation If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 17-3, Page 17-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 17-3, Page 17-2).

  • Page 363: Transaxle Removal

    ELECTRIC VEHICLE - TRANSAXLE Transaxle Removal TRANSAXLE REMOVAL See General Warnings on page 1-2. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles on page 1-4. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. See WARNING “Lift only one end...”...
  • Page 364 Transaxle Removal ELECTRIC VEHICLE - TRANSAXLE 2700 Figure 17-8 Disconnect Shocks Figure 17-9 Shackles If a floor jack was used, pull floor jack from beneath the transaxle and allow the springs to rest on the floor. Remove the U-bolts attaching the transaxle to the leaf springs (Figure 17-10, Page 17-6). Carefully lift each end of the transaxle off its positioning pin (on the leaf spring) and slide the transaxle to the rear and out of the vehicle.

  • Page 365: Transaxle Disassembly, Inspection, And Assembly

    ELECTRIC VEHICLE - TRANSAXLE Transaxle Disassembly, Inspection, and Assembly TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warnings on page 1-2. TRANSAXLE DISASSEMBLY AND INSPECTION To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts (8) (Figure 17-5, Page 17-3). Remove 11 bolts (24) that hold housing together.
  • Page 366 Transaxle Disassembly, Inspection, and Assembly ELECTRIC VEHICLE - TRANSAXLE Disassemble the differential gear case: 8.1. Remove the hex bolts (33) and the ring gear (32) from the differential case (Figure 17-5, Page 17-3). 8.2. Remove the ring gear. 8.3. Separate the differential gear case housing. If necessary, install two of the hex bolts (removed previously in step 8.1.) into the differential gear unit and, while holding the unit slightly above the work area, lightly tap the bolt heads (Figure 17-13, Page 17-8).

  • Page 367: Transaxle Assembly

    ELECTRIC VEHICLE - TRANSAXLE Transaxle Disassembly, Inspection, and Assembly NOTE: Damaged or worn gears should be replaced as sets. TRANSAXLE ASSEMBLY CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 17-5, Page 17-3).

  • Page 368: Transaxle Installation

    Transaxle Installation ELECTRIC VEHICLE - TRANSAXLE WARNING • Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
  • Page 369 ELECTRIC VEHICLE - TRANSAXLE Transaxle Installation WARNING • Make sure that the vehicle operates in the reverse direction when the Forward/Neutral/Reverse switch is in the REVERSE position. The reverse buzzer will sound as a warning when the Forward/Neutral/Reverse switch is in REVERSE. •...
  • Page 370 Transaxle Installation ELECTRIC VEHICLE - TRANSAXLE Pagination Page Page 17-12 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 371: Section 18 - Gasoline Vehicle - Transaxle

    SECTION 18 — GASOLINE VEHICLE - TRANSAXLE DANGER Gasoline Vehicle - Transaxle • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The vehicles addressed in this manual are equipped with heavy-duty transaxles. The transaxle utilizes internal gearing to change vehicle direction.

  • Page 372: Governor System

    General Information GASOLINE VEHICLE - TRANSAXLE POSITION DESCRIPTION Normal Operation OPERATE The engine will not operate in neutral. The engine will operate in neutral (N). MAINTENANCE The vehicle will not operate in the forward (F) or reverse (R) position. GOVERNOR SYSTEM The governor system regulates vehicle ground speed.

  • Page 373: Tools Required For This Section

    GASOLINE VEHICLE - TRANSAXLE General Information 3055 Figure 18-2 Lubricant Level Plug and Drain Plug TOOLS REQUIRED FOR THIS SECTION Hydraulic floor jack (or chain hoist) Torque wrench, 3/8-in. drive 1/2-in. combination wrench Jack stands (2) (one ton capacity) 3/8-in. socket, 3/8-in. drive 9/16-in.

  • Page 374: Rear Hubs

    Rear Hubs GASOLINE VEHICLE - TRANSAXLE REAR HUBS REAR HUB REMOVAL Turn the key switch to the OFF position and remove the key, and place the Forward/Neutral/Reverse handle in the NEUTRAL position. Disconnect battery and spark plug wire. See Disconnect the Battery - Gasoline Vehicles on page 1-3. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
  • Page 375 GASOLINE VEHICLE - TRANSAXLE Rear Hubs CAUTION • Do not allow anti-seize compound to contact the brake drum or shoes. Slide hub (6) onto axle shaft (Figure 18-3, Page 18-4). Install the large flat washer (5) onto the threaded portion of the axle. Install hub nut (4) and advance the nut to the large flat washer.

  • Page 376: Axle Tubes, Axle Shafts And Wheel Bearings

    Axle Tubes, Axle Shafts and Wheel Bearings GASOLINE VEHICLE - TRANSAXLE AXLE TUBES, AXLE SHAFTS AND WHEEL BEARINGS Removal of the transaxle is not required for servicing or replacing axle shafts, axle bearings, or axle shaft oil seals. If the transaxle is to be removed from the vehicle, do not remove the wheels, axle shafts, or axle tubes first. Instructions for removing the transaxle from the vehicle begin on page 18-9.

  • Page 377: Axle Tube And Axle Shaft Installation

    GASOLINE VEHICLE - TRANSAXLE Axle Tubes, Axle Shafts and Wheel Bearings AXLE TUBE AND AXLE SHAFT INSTALLATION Clean mating surfaces of axle tube (2) flange and transaxle gearcase (4). Also clean the threads of the five axle tube mounting holes in the gearcase. See following CAUTION. CAUTION •...

  • Page 378: Axle Shaft Oil Seal Installation

    Axle Tubes, Axle Shafts and Wheel Bearings GASOLINE VEHICLE - TRANSAXLE Remove axle tube (2) from gearcase (4) (Figure 18-5, Page 18-6). See Axle Tube and Axle Shaft Removal on page 18-6. Pull oil seal (7) from gearcase (4). AXLE SHAFT OIL SEAL INSTALLATION Clean bore in gearcase (4) where new oil seal (7) will sit (Figure 18-5, Page 18-6).

  • Page 379: Transaxle Removal

    GASOLINE VEHICLE - TRANSAXLE Transaxle Removal TRANSAXLE REMOVAL See General Warnings on page 1-2. Turn the key switch to the OFF position and remove the key, and place the Forward/Neutral/Reverse handle in the NEUTRAL position. Disconnect battery and spark plug wire. See Disconnect the Battery - Gasoline Vehicles on page 1-3. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
  • Page 380 Transaxle Removal GASOLINE VEHICLE - TRANSAXLE 2700 2401 Figure 18-8 Disconnect Rear Shackles Figure 18-9 Disconnect Front of Leaf Spring Position floor jack under rear crossmember of chassis or trailer hitch mount (if equipped) (Figure 18-10, Page 18-10). See WARNING “Lift only one end of the vehicle...” in General Warnings on page 1-2. Raise vehicle just enough to relieve weight on leaf springs, then remove bolts securing leaf springs to shackles (Figure 18-8, Page 18-10).
  • Page 381 GASOLINE VEHICLE - TRANSAXLE Transaxle Removal Roll powertrain out from under vehicle. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor (Figure 18-12, Page 18-11). See following NOTE. NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from the powertrain.

  • Page 382: Transaxle Installation

    Transaxle Installation GASOLINE VEHICLE - TRANSAXLE 3063 Figure 18-13 Transaxle Mounting Bolts TRANSAXLE INSTALLATION See General Warnings on page 1-2. Installation is reverse of removal procedure. When attaching transaxle to powertrain, initially install the eight bolts (1) finger-tight (Figure 18-13, Page 18-12). Then, tighten fasteners in the following order: 1.1.

  • Page 383: Forward/Neutral/Reverse Handle

    GASOLINE VEHICLE - TRANSAXLE Forward/Neutral/Reverse Handle FORWARD/NEUTRAL/REVERSE HANDLE FORWARD/NEUTRAL/REVERSE HANDLE REMOVAL Remove the bolt (1) from the Forward/Neutral/Reverse handle (2) (Figure 18-14, Page 18-13). Remove the bolts (3) from the bezel (4). Remove the bezel. FORWARD/NEUTRAL/REVERSE HANDLE INSTALLATION Install the bezel (4) and the bolts (3). Tighten the bolts to 22 lb·in (2.5 N·m) (Figure 18-14, Page 18-13). Install the Forward/Neutral/Reverse handle (2).

  • Page 384: Shifter Cable Installation

    Shifter Cable GASOLINE VEHICLE - TRANSAXLE Push the cable end socket (1) off the stud (3) on the Forward/Neutral/Reverse shifter handle (Figure 18-15, Page 18-14). Press in tangs (4) anchoring shifter cable (2) to chassis and push out of mounting hole. Loosen jam nuts (1) securing shifter cable (2) to FNR/accelerator cable bracket (3) (Figure 18-16, Page 18-14).
  • Page 385 GASOLINE VEHICLE - TRANSAXLE Shifter Cable To adjust, the jam nuts (6) at the FNR/accelerator cable bracket must be loosened and moved forward or backward as required (Figure 18-16, Page 18-14). Tighten jam nuts (6) to 22 lb·ft (29.8 N·m). Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 18-15...
  • Page 386 Shifter Cable GASOLINE VEHICLE - TRANSAXLE Pagination Page Page 18-16 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 387: Section 19 - Kohler Ech400 - Troubleshooting And Electrical System

    SECTION 19 — KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM DANGER Kohler ECH400 - Troubleshooting and Electrical System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help avoid installing it in the gray port.

  • Page 388: Low Oil Warning Light

    KOHLER ECH400 - TROUBLESHOOTING Troubleshooting Guide AND ELECTRICAL SYSTEM LOW OIL WARNING LIGHT CAUTION • Failure to add oil immediately when the low oil warning light stays on may result in permanent engine damage. The low oil warning light gives a visual indication of an oil level problem. Figure 19-1 Low Oil Warning Light STATUS CONDITION...

  • Page 389: Gasoline Powertrain

    KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide GASOLINE POWERTRAIN TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Maintenance/Operate switch is in the Set the Maintenance/Operate switch to MAINTENANCE position OPERATE Fuse is blown See the Fuses Test Procedure Battery is dead See the Battery Test Procedure See the Key Switch (Start Circuit) Test Starter control circuit is not operating...
  • Page 390 KOHLER ECH400 - TROUBLESHOOTING Troubleshooting Guide AND ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Engine mounting nuts or bolts are loose See the Engine (Kohler ECH440) Section Snubber on frame is worn or damaged See the Engine (Kohler ECH440) Section See the Exhaust System: Gasoline Vehicles Loose muffler mounting hardware Section...

  • Page 391: Fuse And Relay Locations

    KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Fuse And Relay Locations FUSE AND RELAY LOCATIONS Figure 19-2 Fuse and Relay Locations Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 19-5...

  • Page 392: Electrical System

    KOHLER ECH400 - TROUBLESHOOTING Electrical System AND ELECTRICAL SYSTEM See Fuse and Relay Locations on page 19-5. CALLOUT NUMBER DESCRIPTION Fuse Holder • 10A Fuse • 5A Fuse • 20A Fuse 2A Fuse 15A Fuse Fuel Pump Relay Fuse Holder •...

  • Page 393: Test Procedures

    KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 394 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Index of Test Procedures 1 – Battery 2 – Fuse Inspection 3 – Ground Cables 4 – Key Switch (Start Circuit) 5 – Key Switch (Engine Kill Circuit) 6 – Throttle Position Sensor (TPS) 7 –...
  • Page 395 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 1 – Battery DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working near a battery. • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
  • Page 396 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM IF TEMPERATURE IS MINIMUM CRANKING VOLTAGE 70 °F (20 °C and above) 9.6 V 60 °F (16 °C) 9.5 V 50 °F (10 °C) 9.4 V 40 °F (4 °C) 9.3 V 30 °F (-1 °C) 9.1 V 20 °F (-7 °C)
  • Page 397 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 3 – Ground Cables See General Warnings on page 1-2. NOTE: This is a continuity test for the main ground wire of the vehicle. An additional ground wire is located on top of the fuel tank.
  • Page 398 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM –M WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohm Setting 1337 Figure 19-3 Key Switch Test – Engine Kill Circuit Put the red (+) probe on the (+M) terminal. Put the black (–) probe on the (–M) terminal.
  • Page 399 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures NOTE: It may be necessary to partially pull the green wire from the switch terminal to attach the black lead. Turn the key switch to the ON position. With accelerator pedal in the up position: The meter should indicate an over limit (no continuity) condition. If the reading is incorrect, replace the accelerator pedal assembly.
  • Page 400 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 7 – Solenoid See General Warnings on page 1-2. NOTE: This is a resistance and voltage test. If necessary, see Testing Basics. Make sure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Coil Side: Check the resistance across the small posts of the solenoid.
  • Page 401 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures – With accelerator pedal pressed: The solenoid should click and the meter should read battery voltage. If the reading is incorrect, replace the solenoid. TEST PROCEDURE 8 – Maintenance/Operate Switch NOTE: This is a continuity test. The Maintenance/Operate Switch is also known as the Neutral Lockout Switch.
  • Page 402 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 9 – Transaxle Limit Switch See General Warnings on page 1-2. NOTE: This is a continuity test. This switch is located on the transaxle. A black/pink wire, a red wire, and a gray wire are connected to this limit switch with a 3-pin connector.
  • Page 403 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 10 – Starter/Generator (Generator Function) NOTE: This is a voltage test. If necessary, see Testing Basics. Disable the vehicle. Set the Maintenance/Operate switch to MAINTENANCE. Make sure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Disconnect the yellow wire (1) from the DF terminal (2) on starter/generator (Figure 19-8).
  • Page 404 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 11 – Starter/Generator (Starter Function) NOTE: Observe the following before testing the starter/generator: • This is only testing continuity. • Tag the starter/generator wires for identification before disconnecting. • Remove starter/generator wire from one of the “A” terminals and one of the “F” terminals if testing while starter/generator is in vehicle.
  • Page 405 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 3030B Figure 19-9 Check Starter Terminal Continuity Put the red (+) probe (one at a time) on the A1, A2, F1, F2 and DF terminals. The readings should be no continuity. 6.1.
  • Page 406 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 12 – Voltage Regulator NOTE: This is a voltage test. Keep the battery connected while performing this test procedure. If necessary, see Testing Basics. Disable the vehicle. Set the Maintenance/Operate switch to MAINTENANCE. Make sure that the wires are connected correctly and are tight.
  • Page 407 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 13 – Ignition Spark NOTE: Keep the battery connected while performing this test procedure. ® Use an spark gap test tool (Thexton 404 or equivalent) If necessary, see Testing Basics. Disable the vehicle.
  • Page 408 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 14 – Multi-Purpose Buzzer and Multi-Purpose Buzzer Limit Switch NOTE: Multi-purpose Buzzer: This is a voltage test. A multi-purpose buzzer is mounted on the back side of the instrument panel. On some models, another multi-purpose buzzer is also mounted on a bracket at the left rear of the vehicle.
  • Page 409 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 15 – Malfunction Indicator Light (MIL) NOTE: This is a voltage test. If necessary, see Testing Basics. Remove the instrument panel. Make sure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Turn the key switch to ON.
  • Page 410 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 17 – Battery Test (Under Load) NOTE: Keep the battery connected while performing this test procedure. The voltage reading listed is for electrolyte at 70 °F (21 °C). At lower electrolyte temperatures the voltage reading will be lower.
  • Page 411 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 18 – Fuel Pump WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure. NOTE: This is a voltage and resistance test.
  • Page 412 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Fuel Pump Resistance Procedure If necessary, see Testing Basics. Disconnect the battery. Disconnect the fuel pump connector from the top of the fuel pump module. Set the multimeter to 200 Ohms. Check for approximately 2 to 5 ohms between pin (1) and pin (2) terminals in fuel pump module.
  • Page 413 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 5.2. If the reading is correct and the fuel pump does not function correctly, go to step 5.2.1. Leave the battery disconnected while checking continuity. 5.2.1. Check the continuity from the black/white wire of the fuel pump relay to pin (G) of the ECU connector. Wire Color Description Switched 12V Power...
  • Page 414 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Check the resistance between pin (3) and pin (4) terminals in module. Description Wire Color 1. Fuel Pump Positive (+) Red/White 2. Fuel Pump Negative (–) Black/White 3. Sending Unit Positive (+) Orange 4.
  • Page 415 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 20 – Fuel Gauge NOTE: This is a voltage test. Pin Description Wire Color 1. Fuel (-) Black 2. Fuel (+) Blue 4. Fuel Input Orange 6. Hour (-) Black/White 7.
  • Page 416 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Put the red (+) probe of the multimeter on the positive post of the battery. Put the black (–) probe on the negative post of the battery. Record the voltage reading. Put the red (+) probe on terminal 2 of the fuel gauge/hour meter with the blue wire (2) connected.
  • Page 417 KOHLER ECH400 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 22 – 4-Pin Connector (to Visage) See General Warnings on page 1-2. NOTE: This is a voltage and continuity test. The Connected Car Device 4-pin connector is used for Guardian/Visage and is labeled “V3 circuit” on the main wire harness.
  • Page 418 KOHLER ECH400 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Pagination Page Page 19-32 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 419: Section 20 - Kohler Ech400 - Electrical Components

    SECTION 20 — KOHLER ECH400 - ELECTRICAL COMPONENTS DANGER Kohler ECH400 - Electrical Components • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. BATTERY DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working on or near batteries.

  • Page 420: Preventive Maintenance

    Battery KOHLER ECH400 - ELECTRICAL COMPONENTS PREVENTIVE MAINTENANCE To keep the battery in good operating condition, remove any corrosion immediately. Post connections should be clean and tight. Any frayed or worn wires should be replaced. After all cables have been connected and properly tightened to 41 lb·in (4.3 N·m), coat terminals with Battery Terminal Protector Spray to prevent future corrosion.

  • Page 421: Battery Removal

    KOHLER ECH400 - ELECTRICAL COMPONENTS Battery BATTERY REMOVAL Also see DANGER at beginning of Battery topic. Turn the key switch OFF and remove the key. Place the Forward/Neutral/Reverse handle in the NEUTRAL position. Chock the wheels. Disconnect battery and spark plug wire. See Disconnect the Battery - Gasoline Vehicles on page 1-3. Remove the battery hold-down clamp from the battery.

  • Page 422: Battery Storage

    Ground Cables KOHLER ECH400 - ELECTRICAL COMPONENTS BATTERY STORAGE Also see DANGER at beginning of Battery topic. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 20-2. The battery cables should be disconnected from the battery so the battery can be connected to the charger. The battery can be left in the vehicle.

  • Page 423: Disassembly Of The Starter/Generator To Service The Brushes

    KOHLER ECH400 - ELECTRICAL COMPONENTS Starter/Generator Loosen the pivot nuts (7) and bolts (5) (Figure 20-13, Page 20-15). Remove the adjustment nut (4), washer (6) and adjustment bolt (1) (Figure 20-13, Page 20-15). Lower the starter/generator and remove the belt (2) from the pulley. Support the starter/generator so that when the pivot bolts (5) are removed the starter/generator will not fall.

  • Page 424: Brush Spring Inspection And Replacement

    Starter/Generator KOHLER ECH400 - ELECTRICAL COMPONENTS Figure 20-3 Inspect Brushes and Measure Length BRUSH SPRING INSPECTION AND REPLACEMENT Visually inspect springs. Replace all four springs if any spring is discolored from heat (straw or bluish in color). Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 20-2, Page 20-5). Using a spring scale, test brush spring tension.

  • Page 425: Disassembly Of The Starter/Generator To Service The Armature/Commutator

    KOHLER ECH400 - ELECTRICAL COMPONENTS Starter/Generator To prevent contact between the brushes and commutator as the commutator is installed, and possible damage to the brushes, lift the brush springs and pull the brushes back from the center of the commutator end cover. The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover (Figure 20-5, Page 20-7).

  • Page 426: Bearing Cleaning And Inspection

    Starter/Generator KOHLER ECH400 - ELECTRICAL COMPONENTS 1342 Figure 20-6 Output End Cover Assembly, Armature and Housing BEARING CLEANING AND INSPECTION Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 20-7, Page 20-8).

  • Page 427: Bearing Removal

    KOHLER ECH400 - ELECTRICAL COMPONENTS Starter/Generator BEARING REMOVAL Place the wedge attachment tool between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller to the wedge attachment tool and pull the bearing off of the end of the armature shaft.

  • Page 428: Commutator Cleaning And Inspection

    Starter/Generator KOHLER ECH400 - ELECTRICAL COMPONENTS Figure 20-9 Field Coil Assembly COMMUTATOR CLEANING AND INSPECTION Clean the carbon dust, dirt and oil from the commutator. Visually inspect the commutator for worn, burned or glazed areas. Check for loose or raised commutator bars. Slight roughness of the commutator can be polished away with 400 grit (or finer) sandpaper.

  • Page 429: Armature Ground Test

    KOHLER ECH400 - ELECTRICAL COMPONENTS Starter/Generator 1. Measure each position in two places, 90 degrees apart Figure 20-10 Inspect Commutator ARMATURE GROUND TEST CAUTION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.

  • Page 430: Visual Inspection Of Field Coils

    Starter/Generator KOHLER ECH400 - ELECTRICAL COMPONENTS WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohms Setting 2. Commutator 3. Armature Shaft Figure 20-11 Armature Ground Test VISUAL INSPECTION OF FIELD COILS If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings.
  • Page 431 KOHLER ECH400 - ELECTRICAL COMPONENTS Starter/Generator Press a new ball bearing (35) onto the output end of the armature (Figure 20-6, Page 20-8). Press a new ball bearing onto the commutator end of the armature shaft. See following CAUTION. CAUTION •...
  • Page 432 Starter/Generator KOHLER ECH400 - ELECTRICAL COMPONENTS 90° 1. Jumper Wire 2. 1 inch (25.4 mm) Minimum Radius 3. Jumper Wire Not Allowed in this Area. 2687 Figure 20-12 A1 to F1 Terminal Jumper Wire Routing Page 20-14 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 433: Starter/Generator Installation

    KOHLER ECH400 - ELECTRICAL COMPONENTS Starter/Generator STARTER/GENERATOR INSTALLATION 2997 Figure 20-13 Starter/Generator Installation Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 20-14, Page 20-16). Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 lb·in (5.4 N·m). Position the starter/generator over the mounting bracket so that the bolts will go through the starter/generator before going through the bracket.

  • Page 434: Belt Tension Adjustment For Efi Engines

    Starter/Generator KOHLER ECH400 - ELECTRICAL COMPONENTS 3033 Figure 20-14 Starter/Generator Wiring BELT TENSION ADJUSTMENT FOR EFI ENGINES NOTE: To prevent belt slipping while starting an EFI engine, follow procedure outlined below which is best performed by two people to expedite the process, but can be performed by a single individual if required. The amount a starter/generator belt is tensioned varies between a used and new belt.
  • Page 435 KOHLER ECH400 - ELECTRICAL COMPONENTS Starter/Generator – Use combination of above methods. Mark a location on belt to repeat tension measurement each time. Use paint pen or permanent marker of light color. For Existing Belts Only: Verify current belt tension using Universal Belt Tension Gauge (OTC 6673 ®...

  • Page 436: Solenoid

    Solenoid KOHLER ECH400 - ELECTRICAL COMPONENTS 7.1. Tighten nut on belt tension tool 1/2 turn and check belt tension with gauge (Figure 20-15, Page 20-16). NOTE: To prevent errors in measurement caused by residual tension, ensure to loosen, then reapply, the Universal Belt Tension gauge between measurements.

  • Page 437: Solenoid Installation

    KOHLER ECH400 - ELECTRICAL COMPONENTS Solenoid Figure 20-18 Solenoid Removal Disconnect all the wires from the solenoid (2). Remove the two screws (3). Remove the solenoid. SOLENOID INSTALLATION Install the solenoid (1) in the vehicle (Figure 20-19, Page 20-19). Figure 20-19 Solenoid Installation Install the two screws (2).

  • Page 438: Voltage Regulator

    Voltage Regulator KOHLER ECH400 - ELECTRICAL COMPONENTS Figure 20-20 Solenoid Large Posts Connect the red wire to the large post (4) on the solenoid. Install the nuts (5). Tighten the nuts to 59 lb·in (6.7 N·m). Connect the blue wire to the small post (6) on the solenoid (Figure 20-21, Page 20-20). Figure 20-21 Solenoid Small Posts Connect the orange wire to the small post (7) on the solenoid.

  • Page 439: Voltage Regulator Installation

    KOHLER ECH400 - ELECTRICAL COMPONENTS Engine Control Unit (ECU) Disconnect the voltage regulator connector (3) from the wire harness (Figure 20-22, Page 20-21). Remove the voltage regulator mounting screw (2) and remove the voltage regulator (1). 2432 Figure 20-22 Voltage Regulator VOLTAGE REGULATOR INSTALLATION Position the voltage regulator (1) and install the mounting screw (2) (Figure 20-22, Page 20-21).

  • Page 440: Engine Control Unit Installation

    Fuel Level Sending Unit KOHLER ECH400 - ELECTRICAL COMPONENTS ENGINE CONTROL UNIT INSTALLATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help prevent accidentally installing it in the gray port.

  • Page 441: Maintenance/Operate Switch Installation

    KOHLER ECH400 - ELECTRICAL COMPONENTS Accelerator Pedal Limit Switch Disconnect the wires and remove Maintenance/Operate switch. MAINTENANCE/OPERATE SWITCH INSTALLATION Connect the wires to the Maintenance/Operate switch. Pedal-Start Terminal Wire Color Black / Pink Black Black / Yellow Make sure that the groove switch is aligned with tang on bracket (3) and install the Maintenance/Operate switch (2) (Figure 20-24, Page 20-23).

  • Page 442: Kill Limit Switch

    Kill Limit Switch KOHLER ECH400 - ELECTRICAL COMPONENTS KILL LIMIT SWITCH See General Warnings on page 1-2. The kill limit switch is housed inside the throttle position sensor. The throttle position sensor itself is not intended to be replaced. If sensor is determined to need replacing through test procedures found in this manual, the accelerator pedal assembly must be replaced.

  • Page 443: Multi-Purpose Buzzer Limit Switch Installation

    KOHLER ECH400 - ELECTRICAL COMPONENTS Neutral Lockout Limit Switch MULTI-PURPOSE BUZZER LIMIT SWITCH INSTALLATION Install the multi-purpose buzzer limit switch (5) on the two bolts (Figure 20-25, Page 20-24). Install washers (4) and neutral lockout limit switch (3). CAUTION • Do not overtighten the nuts. If the nuts are over tightened, the limit switches could be damaged. Install the washers (2) and nuts (1).

  • Page 444: Neutral Lockout Limit Switch Installation

    Neutral Lockout Limit Switch KOHLER ECH400 - ELECTRICAL COMPONENTS Remove the nuts (2) and washers (3). Remove the neutral lockout limit switch. NEUTRAL LOCKOUT LIMIT SWITCH INSTALLATION Install the neutral lockout limit switch (1) on the bolts (Figure 20-27, Page 20-26). Figure 20-27 Neutral Lockout Limit Switch Installation CAUTION •...

  • Page 445: Transaxle Limit Switch

    KOHLER ECH400 - ELECTRICAL COMPONENTS Transaxle Limit Switch Connect the battery and spark plug wire. Set the FNR to R. Make sure that the multi-purpose buzzer operates. TRANSAXLE LIMIT SWITCH See General Warnings on page 1-2. TRANSAXLE LIMIT SWITCH REMOVAL Disable the vehicle.

  • Page 446: Brake Light Relay

    Brake Light Relay KOHLER ECH400 - ELECTRICAL COMPONENTS 000999-003 Figure 20-30 Transaxle Limit Switch Move the Forward/Neutral/Reverse control (FNR) to make sure that the switch actuates. Connect the 3-wire connector to the transaxle limit switch lead. Connect the battery and spark plug wire. Test drive the vehicle in both forward and reverse for proper operation.

  • Page 447: Brake Light Relay Installation

    KOHLER ECH400 - ELECTRICAL COMPONENTS Fuel Gauge/Hour Meter Remove the screws (2). Remove the brake light relay. BRAKE LIGHT RELAY INSTALLATION Install the brake light relay (1) on the instrument panel (Figure 20-31, Page 20-28). Install the screws (2). Connect the wires to the brake light relay terminals (Figure 20-32, Page 20-29). Pin Description Wire Color Blue...

  • Page 448: Fuel Gauge/Hour Meter Removal

    Fuel Gauge/Hour Meter KOHLER ECH400 - ELECTRICAL COMPONENTS Figure 20-33 Fuel Gauge / Hour Meter FUEL GAUGE/HOUR METER REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Disconnect the wires from the fuel gauge/hour meter (1) (Figure 20-33, Page 20-30). Do not allow wires to touch. Alternate pulling the lower and upper tabs away from the gauge housing (2) to remove clip.

  • Page 449: Headlight Switch

    KOHLER ECH400 - ELECTRICAL COMPONENTS Headlight Switch 2. Fuel (+) Blue 4. Fuel Input Orange 6. Hour (-) Black/White 7. Hour Input Figure 20-34 Fuel Gauge/Hour Meter Install the instrument panel. Connect the battery and spark plug wire. HEADLIGHT SWITCH Figure 20-35 Headlight Switch HEADLIGHT SWITCH REMOVAL Disconnect the battery and spark plug wire.

  • Page 450: Key Switch

    Key Switch KOHLER ECH400 - ELECTRICAL COMPONENTS Connect the blue and yellow wires to the headlight switch terminals. Install the instrument panel. Connect the battery and spark plug wire. KEY SWITCH See General Warnings on page 1-2. Figure 20-36 Key Switch KEY SWITCH REMOVAL Disconnect the battery and spark plug wire.

  • Page 451: Low Oil Warning Light

    KOHLER ECH400 - ELECTRICAL COMPONENTS Low Oil Warning Light Black White / Black Install the instrument panel. Connect the battery and spark plug wire. LOW OIL WARNING LIGHT See General Warnings on page 1-2. Figure 20-37 Low Oil Warning Light LOW OIL WARNING LIGHT REMOVAL Disconnect the battery and spark plug wire.

  • Page 452: Malfunction Indicator Light (Mil)

    Malfunction Indicator Light (MIL) KOHLER ECH400 - ELECTRICAL COMPONENTS MALFUNCTION INDICATOR LIGHT (MIL) Figure 20-38 Malfunction Indicator Light (MIL) MALFUNCTION INDICATOR LIGHT REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Disconnect the wires (1) (Figure 20-38, Page 20-34). Do not allow wires to touch. Push the retaining tabs (2) and remove the malfunction indicator light (3) from the instrument panel.

  • Page 453: Multi-Purpose Buzzer

    KOHLER ECH400 - ELECTRICAL COMPONENTS Multi–Purpose Buzzer MULTI–PURPOSE BUZZER See General Warnings on page 1-2. Figure 20-39 Multi-Purpose Buzzer MULTI–PURPOSE BUZZER REMOVAL Disconnect battery and spark plug wire. Remove the instrument panel. Disconnect the wires from the multi-purpose buzzer (1) (Figure 20-39, Page 20-35). Remove the two mounting screws (2).

  • Page 454: Usb Receptacle

    USB Receptacle KOHLER ECH400 - ELECTRICAL COMPONENTS USB RECEPTACLE The 5-volt, 2.1 amp USB receptacle supplies electricity to power and charge portable devices. The USB receptacle is not for movement of data. The USB receptacle will only operate when a shielded USB cord is connected. When the USB receptacle is not in use, remove the shielded USB cord to prevent battery drain.

  • Page 455: Oxygen Sensor

    KOHLER ECH400 - ELECTRICAL COMPONENTS Oxygen Sensor OXYGEN SENSOR OXYGEN SENSOR REMOVAL Disconnect the battery. Disconnect the oxygen sensor connector from the engine wire harness (1) (Figure 20-41, Page 20-37). Figure 20-41 Oxygen Sensor Remove the oxygen sensor (2). OXYGEN SENSOR INSTALLATION Install the oxygen sensor (2) into the muffler tube (Figure 20-41, Page 20-37).
  • Page 456 Oxygen Sensor KOHLER ECH400 - ELECTRICAL COMPONENTS Pagination Page Page 20-38 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 457: Section 21 - Kohler Ech400 - Engine

    SECTION 21 — KOHLER ECH400 - ENGINE DANGER Kohler ECH400 - Engine • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION This vehicle is powered by a Kohler, high-compression, chain driven, overhead valve engine (OHV). See following NOTE.

  • Page 458: Engine Removal

    Engine Removal KOHLER ECH400 - ENGINE ENGINE REMOVAL CAUTION • Before removal and disassembly, clean the engine. Disconnect the battery. Disconnect the spark plug wire. For some vehicles, the engine can be removed by lifting it up and out of the chassis. For other vehicles, it is easier to remove the entire powertrain assembly first.
  • Page 459 KOHLER ECH400 - ENGINE Engine Removal Remove the bolts (5 and 6) (Figure 21-2, Page 21-3). Figure 21-2 Clutch Plate Removal Remove the clutch plate (7). Remove the bolts (8) (Figure 21-3, Page 21-3). Figure 21-3 Exhaust Weldment Removal Remove the exhaust weldment (9). Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 21-3...
  • Page 460 Engine Removal KOHLER ECH400 - ENGINE Remove the bolts (10), washers (11), and nuts (12) (Figure 21-4, Page 21-4). Figure 21-4 Engine Pan Removal Lift the engine from engine pan (13). See following NOTE. NOTE: The engine weighs approximately 54 lb (24.5 kg). Remove the oil drain plug and drain all oil from crankcase.

  • Page 461: Engine Installation

    KOHLER ECH400 - ENGINE Engine Installation ENGINE INSTALLATION If replacing engine, install starter/generator mounting weldment on engine with the screws. Tighten the screws to 17 ft·lb (23 N·m). Install oil drain plug and tighten to 13 ft·lb (18 N·m). Place the engine onto the engine pan (13) and secure with mounting hardware (10, 11, and 12) (Figure 21-5, Page 21-5).
  • Page 462 Engine Installation KOHLER ECH400 - ENGINE Install the clutch plate (7) with bolts (5 and 6) (Figure 21-7, Page 21-6). Tighten the bolts (5) to 27 ft·lb (36 N·m). Tighten the bolts (6) to 50 ft·lb (68 N·m). Figure 21-7 Clutch Plate Installation Install the drive clutch.
  • Page 463 KOHLER ECH400 - ENGINE Engine Installation Connect the ground cable to the engine (4) (Figure 21-8, Page 21-7). Figure 21-8 Governor Cover and Ground Cable Installation Route the vent line (3) through the governor cover (2). Connect the vent line. Install the governor cover with the screw (1).

  • Page 464: Snubber

    Snubber KOHLER ECH400 - ENGINE SNUBBER NOTE: The snubber is installed on the gasoline vehicle only. Figure 21-9 Snubber SNUBBER REMOVAL Support the powertrain with a floor jack under the engine pan (1) so that the snubber (2) is raised slightly and does not rest on the vehicle frame (Figure 21-9, Page 21-8).

  • Page 465: Section 22 - Kohler Ech400 - Fuel System

    SECTION 22 — KOHLER ECH400 - FUEL SYSTEM DANGER Kohler ECH400 - Fuel System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. WARNING • Fuel may be under pressure. Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine.

  • Page 466: Engine Control Linkages

    Engine Control Linkages KOHLER ECH400 - FUEL SYSTEM ENGINE CONTROL LINKAGES DANGER • To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push cable, do the following: – Turn key switch OFF and remove key, place Forward/Neutral/Reverse handle in the NEUTRAL position, and chock the wheels prior to servicing the vehicle.
  • Page 467 KOHLER ECH400 - FUEL SYSTEM Engine Control Linkages 3.2. Remove the governor cable fitting (1) from the linkage retainer (2) (Figure 22-1, Page 22-3). Figure 22-1 Governor Cable Removal - Throttle Body 3.3. Disconnect the governor cable fitting from throttle lever (3). 3.4.
  • Page 468 Engine Control Linkages KOHLER ECH400 - FUEL SYSTEM Figure 22-3 Governor Cable Installation - Throttle Body 1.2. Connect the governor cable fitting (1) to throttle lever (2). 1.3. Install the governor cable fitting into the linkage retainer (3). At transaxle: 2.1.

  • Page 469: Accelerator Cable

    KOHLER ECH400 - FUEL SYSTEM Engine Control Linkages Adjustment: 3.1. Connect the diagnostic tool. 3.2. Loosen the jam nuts (7 and 11) and back off the throttle stop screws (8 and 12) several turns (Figure 22-5, Page 22-5). Figure 22-5 Governor Cable Adjustment 3.3.
  • Page 470 Engine Control Linkages KOHLER ECH400 - FUEL SYSTEM 3130B Figure 22-6 Accelerator Cable At Transaxle 4.2. Remove the dust shield (4) from the end of the cable housing. 4.3. Unsnap the accelerator cable from FNR/accelerator cable bracket (5). At pedal group: 5.1.
  • Page 471 KOHLER ECH400 - FUEL SYSTEM Engine Control Linkages 5.4. Remove the debris shield (8). 5.5. Disconnect the accelerator cable clip (9) from the accelerator pedal (10). 5.6. Loosen the jam nuts (11) and remove accelerator cable from vehicle. Accelerator Cable Installation At transaxle: 1.1.

  • Page 472: Idle Adjustment

    Engine Control Linkages KOHLER ECH400 - FUEL SYSTEM Figure 22-9 Accelerator Cable At Pedal Group 2.3. Install the debris shield (8). 2.4. Separate the jam nuts (11) on cable and put the threaded end into slot in underbody. Tighten the jam nuts finger-tight.

  • Page 473: Engine Rpm Adjustment

    KOHLER ECH400 - FUEL SYSTEM Engine Control Linkages Drive vehicle and bring to maximum speed before reaching the first cone. Using a stopwatch, record the amount of time it takes to travel from the first cone to the second cone at maximum speed.

  • Page 474: Air Intake System

    Air Intake System KOHLER ECH400 - FUEL SYSTEM AIR INTAKE SYSTEM Figure 22-10 Air Intake System AIR CLEANER REMOVAL Disable the vehicle. Disconnect battery and spark plug wire. Loosen the clamp (1) and disconnect air intake hose from throttle body (Figure 22-10, Page 22-10). Remove the screws (2).

  • Page 475: Relieving Fuel Pressure

    KOHLER ECH400 - FUEL SYSTEM Relieving Fuel Pressure RELIEVING FUEL PRESSURE In the event that servicing the EFI fuel system necessitates removal of the fuel delivery hose, extreme caution must be exercised. The fuel system is under high pressure even with the engine not running. Disconnecting any part of the fuel delivery system, without first depressurizing the system, will result in a sudden release of pressurized gasoline at the connection.

  • Page 476: Carbon Canister

    Carbon Canister KOHLER ECH400 - FUEL SYSTEM CARBON CANISTER Figure 22-11 CARBON CANISTER REMOVAL Disable the vehicle. Relieve the fuel pressure. Disconnect the battery. Clean the area around the vent line (1) and purge line (2) on the carbon canister (3). Remove the clamps (4).

  • Page 477: Fuel Line

    CAUTION • This EFI gasoline vehicle is equipped with fuel hose rated for high-pressure systems. Always replace the fuel line on this vehicle with approved Club Car replacement part. Do not attempt to repair, patch or splice the fuel line.
  • Page 478 Fuel Line KOHLER ECH400 - FUEL SYSTEM At engine: 5.1. Remove the bolt (1), washer (2), and P-clamp (3) from the fuel line support bracket (4) (Figure 22-12, Page 22-14). Figure 22-12 5.2. Pull out the locking clip (4) (Figure 22-13, Page 22-14). Figure 22-13 5.3.

  • Page 479: Fuel Line Installation

    KOHLER ECH400 - FUEL SYSTEM Fuel Line FUEL LINE INSTALLATION Clean the nipple on the throttle body. DANGER • Make sure that the fuel line is connected properly to avoid a leak that can cause a fire. Push the fuel line (1) onto the nipple until it locks into place (Figure 22-14). Figure 22-14 Push in the locking clip (2) until it is fully seated.
  • Page 480 Fuel Line KOHLER ECH400 - FUEL SYSTEM Install the P-clamp (1), washer (2), and bolt (3) onto the fuel line support bracket (4) (Figure 22-16). Tighten the bolt to 93 to 111 in·lb (10.5 to 12.5 N·m). Figure 22-16 Clean the nipple on top of fuel pump module. Rotate the fuel line connector (1) 180 degrees and connect it to the nipple (Figure 22-17, Page 22-16).

  • Page 481: Fuel Pump Module

    KOHLER ECH400 - FUEL SYSTEM Fuel Pump Module Make sure that the fuel line is routed correctly (Figure 22-18). Figure 22-18 Clean spilled and remove any drained gasoline from the area. Connect the battery. Disable the vehicle. Set the Maintenance/Operate switch to MAINTENANCE. Turn the key switch to the ON position and check for fuel leaks.
  • Page 482 Fuel Pump Module KOHLER ECH400 - FUEL SYSTEM Disconnect the battery. Clean the top of the fuel tank and fuel pump module. With a marker pen, make a mark across the top of the fuel pump module and onto the tank to note orientation before removal.

  • Page 483: Fuel Pump Module Installation

    KOHLER ECH400 - FUEL SYSTEM Fuel Pump Module FUEL PUMP MODULE INSTALLATION Clean the groove on top of fuel tank. Install the new fuel module o-ring (9) into groove on top of fuel tank (Figure 22-20, Page 22-19). Figure 22-20 Fuel Pump Module Installation Lower the fuel pump module (8) into fuel tank noting correct orientation marked before removal.

  • Page 484: Fuel Tank

    SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses or equivalent. FUEL TANK REMOVAL Disable the vehicle.
  • Page 485 KOHLER ECH400 - FUEL SYSTEM Fuel Tank Remove gas cap and siphon all fuel from tank into an approved container. See following DANGER and WARNING. DANGER • Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area.

  • Page 486: Fuel Tank Disposal

    SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses or equivalent. Install the fuel tank (8) in vehicle (Figure 22-22, Page 22-23).
  • Page 487 KOHLER ECH400 - FUEL SYSTEM Fuel Tank Figure 22-22 Fuel Tank Installation Install the fuel tank retaining strap (7). 2.1. Insert the tabs on the rear of the fuel tank retaining strap into the slots on the back of the bucket. 2.2.

  • Page 488: Fuel Filter

    Fuel Filter KOHLER ECH400 - FUEL SYSTEM Turn key switch to the ON position and check for fuel leaks. Repeat as necessary to build fuel pressure. Any leaks found must be fixed. DANGER • Repair all fuel leaks before returning the vehicle to service. If no leaks are found, set the Maintenance/Operate switch to OPERATE.

  • Page 489: Fuel Filter Installation

    KOHLER ECH400 - FUEL SYSTEM Fuel Filter FUEL FILTER INSTALLATION CAUTION • Fuel filter flex hoses are keyed to aid proper installation into fuel pump module. NOTE: The fuel filter is keyed to the fuel pump module to prevent incorrect assembly. The inlet and outlet flex hoses are keyed to the fuel filter ports to prevent incorrect assembly.
  • Page 490 Fuel Filter KOHLER ECH400 - FUEL SYSTEM Pagination Page Page 22-26 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 491: Section 23 - Kohler Ech400 - Exhaust System

    SECTION 23 — KOHLER ECH400 - EXHAUST SYSTEM DANGER Kohler ECH400 - Exhaust System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. MUFFLER MUFFLER REMOVAL Disconnect the battery and spark plug wire. If necessary, remove the oxygen sensor (1) from the muffler (2) (Figure 23-1, Page 23-1). See Oxygen Sensor Removal.

  • Page 492: Muffler Installation

    Muffler KOHLER ECH400 - EXHAUST SYSTEM MUFFLER INSTALLATION Install the new exhaust gasket (7) on the exhaust port studs (Figure 23-2, Page 23-2). Figure 23-2 Muffler Installation Put the muffler (2) into position on the engine. Install the nuts (3), bolt (4), washer (5), and bolts (6). Tighten the hardware by hand. Tighten the hardware in the following order: 4.1.

  • Page 493: Section 24 - Kohler Ech400 - Clutches

    SECTION 24 — KOHLER ECH400 - CLUTCHES DANGER Kohler ECH400 - Clutches • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to the engine, is in the open position when the engine is at idle.
  • Page 494 Troubleshooting KOHLER ECH400 - CLUTCHES If the torque converter is not operating properly, perform the following steps: Check the governor and throttle settings. See Engine Control Linkages. Inspect the driven clutch for dirt and dust buildup on its component parts. Clean the driven clutch with water to remove any dust or dirt, then drive the vehicle and check for proper operation.

  • Page 495: Drive Belt

    KOHLER ECH400 - CLUTCHES Drive Belt DRIVE BELT The drive belt should be inspected semiannually for wear and (or) glazing. If it is excessively worn, frayed, or glazed, replace the belt. As the drive belt wears, the engine RPM will increase to compensate for the change in torque converter ratio. This will keep the vehicle’s maximum ground speed correct.

  • Page 496: Drive Clutch

    Drive Clutch KOHLER ECH400 - CLUTCHES DRIVE CLUTCH 1. Screw, 3/8-24 x 5.75, Patch 10. Retainer 2. Washer, Hard, M10 11. Ring, Spiral Backup 3. Washer, 3/8, Type A, Flat 12. Bushing, Split, Drive Clutch 4. Cap Plug 13. Sheave, Moveable, Drive 5.

  • Page 497: Drive Clutch Removal

    KOHLER ECH400 - CLUTCHES Drive Clutch CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. DRIVE CLUTCH REMOVAL Remove the drive belt as instructed.

  • Page 498: Drive Clutch Cleaning And Inspection

    Drive Clutch KOHLER ECH400 - CLUTCHES WARNING position. Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor. When not performing a test or service procedure that requires movement of the wheels, lock the brakes. Remove the drive clutch retaining bolt (1) and mounting washers (2 and 3) (Figure 24-2, Page 24-4).
  • Page 499 KOHLER ECH400 - CLUTCHES Drive Clutch Remove the drive clutch hub (5) (Figure 24-2, Page 24-4): 2.1. Remove the three plugs (4) from the clutch puller attachment holes. 2.2. Thread the center bolt of the Drive Clutch Hub Puller (1) into clutch until the stop nut touches the clutch, then back the bolt out one-half turn (Figure 24-6, Page 24-7).
  • Page 500 Drive Clutch KOHLER ECH400 - CLUTCHES 3053 Figure 24-7 Drive Button Mounting Figure 24-8 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 24-8, Page 24-8). 5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch.

  • Page 501: Inspection Of Drive Clutch Parts

    KOHLER ECH400 - CLUTCHES Drive Clutch Figure 24-9 Primary and Secondary Weights, Wave Washer and Pin Remove the retaining ring (6) from the shaft of the fixed sheave (18) and slide the moveable sheave (13) off the shaft (Figure 24-2, Page 24-4). See following NOTE. NOTE: If the moveable sheave is removed from the hub of the fixed sheave, the spiral back-up rings (11) must be replaced with new rings (Figure 24-2, Page 24-4).

  • Page 502: Drive Clutch Assembly

    Drive Clutch KOHLER ECH400 - CLUTCHES Inspect the primary weights (8) and the hub casting for wear. If the primary weights show signs they are touching the casting, the tips of the weights have worn beyond specification and they must be replaced. Inspect the pins on the primary weights (8).

  • Page 503: Drive Clutch Installation

    KOHLER ECH400 - CLUTCHES Drive Clutch NOTE: Make sure there is at least a (minimum) gap of 0.020 in. (0.51 mm) between each end of the mounting pin and the mounting bolt. Install three drive button take-up springs. 11.1. Install each spring on right-hand side of the three button mounting posts (when looking into the interior of the clutch drive hub, and with the rib at a twelve o’clock position) as shown (Figure 24-12, Page 24-11).

  • Page 504: Driven Clutch

    Driven Clutch KOHLER ECH400 - CLUTCHES DRIVEN CLUTCH 1. Screw, 5/16-18 X 3/4 Hex-Head with Patch 7. Screw, #8-32 X 3/4, Socket-Head Cap 2. Washer, Driven Clutch 8. Button, Drive 3. Ring, Retaining 9. Sheave, Movable, Driven 4. Key, Driven Clutch 10.

  • Page 505: Driven Clutch Removal

    KOHLER ECH400 - CLUTCHES Driven Clutch DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed. See Drive Belt Removal on page 24-3. Remove the bolt (1) and mounting washer (2) from the transaxle input shaft (Figure 24-13, Page 24-12). Discard the bolt. NOTE: The bolt (1) must be replaced with a new bolt containing a locking patch that will prevent the bolt from loosening.
  • Page 506 Driven Clutch KOHLER ECH400 - CLUTCHES WARNING • Do not place fingers under the cam when removing the cam. The moveable face may spin when the cam buttons release from the cam ramps, resulting in severe personal injury. Remove the retaining ring (10) (Figure 24-15, Page 24-14). 608B Figure 24-15 Remove Retaining Ring Insert a puller plug (11) into the shaft bore (Figure 24-16, Page 24-14).

  • Page 507: Driven Clutch Inspection

    KOHLER ECH400 - CLUTCHES Driven Clutch Remove the spring (14) (Figure 24-17, Page 24-15). 2961B Figure 24-17 Driven Clutch Disassembly Inspect the key (15) for damage. Replace as necessary. Slide the moveable sheave (16) off the fixed sheave (17). DRIVEN CLUTCH INSPECTION Inspect the cam for excessive wear.

  • Page 508: Driven Clutch Assembly

    Driven Clutch KOHLER ECH400 - CLUTCHES 2961C Figure 24-18 Drive Button Inspection Inspect the smooth surface on the fixed and moveable sheaves. Sheaves must be replaced if surfaces are worn more than 0.060 in. (1.5 mm). Inspect the bronze bearing in the moveable sheave. If the bearing bore diameter is more than 1.384 in. (35.15 mm), the entire moveable sheave must be replaced.
  • Page 509 KOHLER ECH400 - CLUTCHES Driven Clutch 2961D Figure 24-20 Driven Clutch Assembly Place the end of the spring (6) into the hole in the moveable sheave (9). Install the key (7) into the keyway of the fixed sheave shaft. Holding the cam (8) in position for assembly on the shaft, install the other end of the spring into the center spring hole of the cam.

  • Page 510: Driven Clutch Installation

    Driven Clutch KOHLER ECH400 - CLUTCHES Slide the threaded bolt assembly through the clutch body until the threaded bolt and thrust collar are against the fixed sheave. Hold the clutch assembly and cam installation tool together and place the fixed sheave down on spaced blocks. Install the cam press plate (13), thrust washer (14), thrust bearing (15), thrust washer (16), and nut (17) onto the threaded bolt.

  • Page 511: Section 25 - Kohler Engine Service Manual

    SECTION 25 — KOHLER ENGINE SERVICE MANUAL Kohler Engine Service Manual Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 25-1...
  • Page 512 Driven Clutch KOHLER ENGINE SERVICE MANUAL Pagination Page Page 25-2 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 513: Section 26 - Subaru Ex-40 - Troubleshooting And Electrical System

    SECTION 26 — SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM DANGER Subaru EX-40 - Troubleshooting and Electrical System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help avoid installing it in the gray port.

  • Page 514: Features Of The Electronic Fuel Injection (Efi) System

    SUBARU EX-40 - TROUBLESHOOTING Troubleshooting Guide AND ELECTRICAL SYSTEM • Top of Fuel Tank: The fuel tank has a lead that connects to the main wire harness and goes to the B– battery terminal. FEATURES OF THE ELECTRONIC FUEL INJECTION (EFI) SYSTEM •...
  • Page 515 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide Error Codes – ECU BLINK CODE CODE DESCRIPTION CORRECTIVE ACTION Check battery voltage. Charge/replace battery Low Battery Voltage as necessary. Check connector at ECU & Throttle module. MAP Sensor: Open or Shorted Connection If connection is made and no corrosion is present, replace ECU and Throttle Module.

  • Page 516: Gasoline Powertrain

    SUBARU EX-40 - TROUBLESHOOTING Troubleshooting Guide AND ELECTRICAL SYSTEM GASOLINE POWERTRAIN TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Spark plug is partially fouled or in poor Clean or replace condition Spark plug is damaged or loose Replace or tighten Incorrect spark plug gap Adjust gap Spark plug wire is damaged or loose Replace or reconnect...
  • Page 517 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Fuel tank is empty Section 22 — Kohler ECH400 - Fuel System Fuel line or filter clogged Section 22 — Kohler ECH400 - Fuel System Fouled spark plug Section 28 —...
  • Page 518 SUBARU EX-40 - TROUBLESHOOTING Troubleshooting Guide AND ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Incorrect plug Section 28 — Subaru EX-40 - Engine Spark plug wire is damaged Section 28 — Subaru EX-40 - Engine Unsuitable fuel, or incorrect (rich) fuel mixture Section 22 —...
  • Page 519 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Transmission shifter linkage is binding or is Section 18 — Gasoline Vehicle - Transaxle out of adjustment Insufficient (low) level of lubricant or wrong Transmission does not engage or disengage Section 18 —...

  • Page 520: Sonic Weld, Fuse, And Diode Locations

    SUBARU EX-40 - TROUBLESHOOTING Sonic Weld, Fuse, and Diode Locations AND ELECTRICAL SYSTEM SONIC WELD, FUSE, AND DIODE LOCATIONS Figure 26-1 Sonic Weld and Diode Locations (Approximate) – Gasoline Vehicle Page 26-8 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 521: Electrical System

    SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Electrical System ELECTRICAL SYSTEM The electrical system on the gasoline vehicle is 12 volts DC with negative (–) ground to frame, and consists of the following circuits that are easily identified: • Starter Circuit •...

  • Page 522: Test Procedures

    SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 523 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 2 – Fuses 3 – Ground Cables 4 – EFI System (ECU and Sensors) 5 – Key Switch (Start Circuit) 6 – Key Switch (Engine Kill Circuit) 7 – Throttle Position Sensor (TPS) 8 –...
  • Page 524 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 1 – Battery See General Warnings on page 1-2. DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working near a battery.
  • Page 525 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures IF TEMPERATURE IS MINIMUM CRANKING VOLTAGE 70 °F (20 °C and above) 9.6 V 60 °F (16 °C) 9.5 V 50 °F (10 °C) 9.4 V 40 °F (4 °C) 9.3 V 30 °F (-1 °C) 9.1 V 20 °F (-7 °C)
  • Page 526 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 2 – Fuses See General Warnings on page 1-2. WARNING • Failure to use properly rated fuse can result in a fire hazard. NOTE: This vehicle uses three ATM-style blade fuses. A single ABC-style glass fuse is used for the Guardian/Visage 4-pin connector that is labeled “V3 circuit”...
  • Page 527 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 5-amp ATM Fuse Only: With the key switch in the ON position: 4.1. Probe the two, small metal contacts on the top of the fuse (Figure 26-2, Page 26-14). 4.2. Each contact should show battery voltage. 4.3.
  • Page 528 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 4 – EFI System (ECU and Sensors) See General Warnings on page 1-2. WARNING • This procedure involves testing voltage, resistance and continuity. If necessary, see Testing Basics on page 19-7.
  • Page 529 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 18-PIN CONNECTOR (GRAY AND BLACK): A. ECU SIDE OF CONNECTOR B. WIRE ENTRY SIDE OF CONNECTOR CONNECTOR FUNCTION TEST TYPE & PROBE BETWEEN LOCATIONS TEST RESULT CONDITION I.D. COLOR Resistance: ECU Gray Pin 1 (Black/White) and ECU Approx.
  • Page 530 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM 18-PIN CONNECTOR (GRAY AND BLACK): A. ECU SIDE OF CONNECTOR B. WIRE ENTRY SIDE OF CONNECTOR CONNECTOR FUNCTION TEST TYPE & PROBE BETWEEN LOCATIONS TEST RESULT CONDITION I.D. COLOR Meter should beep Key OFF Black Ignition OFF Input...
  • Page 531 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 5 – Key Switch (Start Circuit) See General Warnings on page 1-2. NOTE: This is a voltage test. The key switch provides power and KEY INPUT to the ECU. If necessary, see Testing Basics on page 19-7.
  • Page 532 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM –M WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohm Setting 1337 Figure 26-3 Key Switch Test – Engine Kill Circuit TEST PROCEDURE 7 – Throttle Position Sensor (TPS) The throttle position sensor performs the function of two limit switches: the accelerator pedal limit switch and the kill limit switch.
  • Page 533 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Kill Limit Switch Function See General Warnings on page 1-2. The black and white/black wires connect to the kill limit switch function of the throttle position sensor. This is the normally closed (NC) portion of the circuit used to ground the ignition and shut the engine off when the pedal is released. NOTE: Keep the battery connected while performing this test procedure.
  • Page 534 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 8 – Solenoid See General Warnings on page 1-2. NOTE: This is a resistance and voltage test. WAVETEK 1000 2000 200k 200mA 1000 --- FUSED 750V 2424 2426 Figure 26-4 Solenoid Wire Removal Figure 26-5 Solenoid Ground Test If necessary, see Testing Basics on page 19-7.
  • Page 535 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 9 – Maintenance/Operate Switch – Pedal-Start Vehicles See General Warnings on page 1-2. NOTE: This is a continuity test. The Maintenance/Operate Switch is also known as the Neutral Lockout Switch. If necessary, see Testing Basics on page 19-7.
  • Page 536 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 10 – Neutral Lockout Limit Switch – Pedal-Start Vehicles Only See General Warnings on page 1-2. NOTE: This is a continuity test. This switch is located on the transaxle. A black/light blue wire, a red wire, and a blue wire are connected to this limit switch with a 3-pin connector.
  • Page 537 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 11 – Starter/Generator (Generator Function) See General Warnings on page 1-2. NOTE: This is a voltage test. If necessary, see Testing Basics on page 19-7. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
  • Page 538 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM • When disconnecting wires from starter/generator terminals, use a second wrench on the lower nut of the terminal post to hold post steady. • Scrape a small amount of paint from starter/generator housing (ground) and use this location when testing motor terminals to electrical ground.
  • Page 539 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 13 – Voltage Regulator See General Warnings on page 1-2. NOTE: This is a voltage test. Keep the battery connected while performing this test procedure. If necessary, see Testing Basics on page 19-7. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
  • Page 540 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 14 – Ignition Spark See General Warnings on page 1-2. NOTE: Keep the battery connected while performing this test procedure. If necessary, see Testing Basics on page 19-7. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
  • Page 541 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 15 – Ignition Coil See General Warnings on page 1-2. NOTE: This is a resistance test. The following test procedures will properly detect a coil that has failed in most cases; however, in rare cases, some ignition coils can fail to operate at normal (warmer) operating temperatures.
  • Page 542 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 16 – Reverse Buzzer and Reverse Buzzer Limit Switch See General Warnings on page 1-2. NOTE: Reverse Buzzer: This is a voltage test. Reverse Buzzer Limit Switch: This is a continuity test. A reverse buzzer is mounted on the back side of the instrument panel.
  • Page 543 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 18 – Oil Level Sensor See General Warnings on page 1-2. NOTE: Keep the battery connected while performing this test procedure. This procedure requires the oil to be drained from the engine. If necessary, see Testing Basics on page 19-7.
  • Page 544 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 20 – Fuel Pump See General Warnings on page 1-2. WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure.
  • Page 545 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Disconnect the 5-pin connector from the top of the fuel pump module. Probe between pin (1) and pin (2) terminals in module (Figure 19-14, Page 19-26). 4.1. The reading should be approximately 2 to 5 ohms. If the reading indicates no resistance, the fuel pump has failed and the fuel pump module must be replaced.
  • Page 546 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 22 – Fuel Gauge See General Warnings on page 1-2. NOTE: This is a voltage test. If necessary, see Testing Basics on page 19-7. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
  • Page 547 SUBARU EX-40 - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 23 – Hour Meter See General Warnings on page 1-2. NOTE: Keep the battery connected while performing this test procedure. Place the neutral lockout cam in the MAINTENANCE position, put the Forward/Reverse handle in the NEUTRAL position, and chock the wheels.
  • Page 548 SUBARU EX-40 - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 24 – 4-Pin Connector (for Connected Car Device) See General Warnings on page 1-2. NOTE: This is a voltage and continuity test. The Connected Car Device 4-pin connector is used for Guardian/Visage and is labeled “V3 circuit” on the main wire harness.

  • Page 549: Section 27 - Subaru Ex-40 - Electrical Components

    SECTION 27 — SUBARU EX-40 - ELECTRICAL COMPONENTS DANGER Subaru EX-40 - Electrical Components • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. STARTER/GENERATOR TESTING THE STARTER/GENERATOR See Test Procedure 11 – Starter/Generator (Starter Function) on page 19-18. See Test Procedure 10 –...

  • Page 550: Brush Inspection And Replacement

    Starter/Generator SUBARU EX-40 - ELECTRICAL COMPONENTS Figure 27-2 Brush Covers and Brushes Figure 27-1 Commutator End Cover BRUSH INSPECTION AND REPLACEMENT Visually inspect brushes. Replace brushes that are cracked or severely chipped. Measure the length of each brush. Replace the brush set if a brush is less than 0.375 inch (9.5 mm) (Figure 20-3, Page 20-6).

  • Page 551: Starter/Generator Assembly

    SUBARU EX-40 - ELECTRICAL COMPONENTS Starter/Generator CAUTION • When checking brush spring tension, do not push springs beyond the point they would normally be if there were new brushes installed. Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs. Figure 27-4 Brush Spring Tension Test STARTER/GENERATOR ASSEMBLY Install the brushes (27) into the holders.

  • Page 552: Disassembly Of The Starter/Generator To Service The Armature/Commutator

    Starter/Generator SUBARU EX-40 - ELECTRICAL COMPONENTS Figure 27-5 Pull Brushes Away From Center of the Commutator End Cover DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE ARMATURE/COMMUTATOR Remove the commutator end cover to prevent damage to the brushes and armature. See Commutator End Cover on page 20-5.

  • Page 553: Bearing Cleaning And Inspection

    SUBARU EX-40 - ELECTRICAL COMPONENTS Starter/Generator 1342 Figure 27-6 Output End Cover Assembly, Armature and Housing BEARING CLEANING AND INSPECTION Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 20-7, Page 20-8).

  • Page 554: Bearing Removal

    Starter/Generator SUBARU EX-40 - ELECTRICAL COMPONENTS BEARING REMOVAL Place the wedge attachment tool between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller to the wedge attachment tool and pull the bearing off of the end of the armature shaft.

  • Page 555: Commutator Cleaning And Inspection

    SUBARU EX-40 - ELECTRICAL COMPONENTS Starter/Generator Figure 27-9 Field Coil Assembly COMMUTATOR CLEANING AND INSPECTION Clean the carbon dust, dirt and oil from the commutator. Visually inspect the commutator for worn, burned or glazed areas. Check for loose or raised commutator bars. Slight roughness of the commutator can be polished away with 400 grit (or finer) sandpaper.

  • Page 556: Armature Ground Test

    Starter/Generator SUBARU EX-40 - ELECTRICAL COMPONENTS 1. Measure each position in two places, 90 degrees apart Figure 27-10 Inspect Commutator ARMATURE GROUND TEST CAUTION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.

  • Page 557: Visual Inspection Of Field Coils

    SUBARU EX-40 - ELECTRICAL COMPONENTS Starter/Generator WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohms Setting 2. Commutator 3. Armature Shaft Figure 27-11 Armature Ground Test VISUAL INSPECTION OF FIELD COILS If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings.
  • Page 558 Starter/Generator SUBARU EX-40 - ELECTRICAL COMPONENTS Press a new ball bearing (35) onto the output end of the armature (Figure 20-6, Page 20-8). Press a new ball bearing onto the commutator end of the armature shaft. See following CAUTION. CAUTION •...
  • Page 559 SUBARU EX-40 - ELECTRICAL COMPONENTS Starter/Generator 90° 1. Jumper Wire 2. 1 inch (25.4 mm) Minimum Radius 3. Jumper Wire Not Allowed in this Area. 2687 Figure 27-12 A1 to F1 Terminal Jumper Wire Routing Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 27-11...

  • Page 560: Starter/Generator Installation

    Starter/Generator SUBARU EX-40 - ELECTRICAL COMPONENTS STARTER/GENERATOR INSTALLATION 2997 Figure 27-13 Starter/Generator Installation Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 20-14, Page 20-16). Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 in·lb (5.4 N·m). Position the starter/generator over the mounting bracket so that the bolts will go through the starter/generator before going through the bracket.

  • Page 561: Belt Tension Adjustment For Efi Engines

    SUBARU EX-40 - ELECTRICAL COMPONENTS Starter/Generator 3033 Figure 27-14 Starter/Generator Wiring BELT TENSION ADJUSTMENT FOR EFI ENGINES NOTE: To prevent belt slipping while starting an EFI engine, follow procedure outlined below which is best performed by two people to expedite the process, but can be performed by a single individual if required. The amount a starter/generator belt is tensioned varies between a used and new belt.
  • Page 562 Starter/Generator SUBARU EX-40 - ELECTRICAL COMPONENTS – Use combination of above methods. Mark a location on belt to repeat tension measurement each time. Use paint pen or permanent marker of light color. For Existing Belts Only: Verify current belt tension using Universal Belt Tension Gauge (OTC 6673 ®...

  • Page 563: Voltage Regulator

    SUBARU EX-40 - ELECTRICAL COMPONENTS Voltage Regulator 7.1. Tighten nut on belt tension tool 1/2 turn and check belt tension with gauge (Figure 20-15, Page 20-16). NOTE: To prevent errors in measurement caused by residual tension, ensure to loosen, then reapply, the Universal Belt Tension gauge between measurements.

  • Page 564: Voltage Regulator Installation

    Voltage Regulator SUBARU EX-40 - ELECTRICAL COMPONENTS 2432 Figure 27-18 Voltage Regulator VOLTAGE REGULATOR INSTALLATION Position the voltage regulator (1) and install the mounting screw (2) (Figure 20-22, Page 20-21). Tighten screw to 23 in·lb (2.6 N·m). Connect the voltage regulator three-pin connector (3) to the wire harness. Connect battery and spark plug wire(s).

  • Page 565: Engine Control Unit (Ecu)

    SUBARU EX-40 - ELECTRICAL COMPONENTS Engine Control Unit (ECU) ENGINE CONTROL UNIT (ECU) CAUTION • The Engine Control Unit (ECU) and Throttle Body are to be purchased as one unit. They are matched pairs with matching serial numbers. Do not mix an ECU with another Throttle Body of a different serial number.

  • Page 566: Key Switch

    Key Switch SUBARU EX-40 - ELECTRICAL COMPONENTS KEY SWITCH See General Warnings on page 1-2. TESTING THE KEY SWITCH See Test Procedure 4 – Key Switch (Start Circuit) on page 19-11. See Test Procedure 5 – Key Switch (Engine Kill Circuit) on page 19-11. KEY SWITCH REMOVAL Disconnect battery and spark plug wire(s).

  • Page 567: Key Switch Installation

    SUBARU EX-40 - ELECTRICAL COMPONENTS Maintenance/Operate Switch KEY SWITCH INSTALLATION Reverse removal procedures to install key switch in the instrument panel. Connect wires to key switch. Install the instrument panel. 2.1. Connect the electrical connector (3) (Figure 27-19, Page 27-18). 2.2.

  • Page 568: Neutral Lockout Limit Switch

    Neutral Lockout Limit Switch SUBARU EX-40 - ELECTRICAL COMPONENTS NEUTRAL LOCKOUT LIMIT SWITCH See General Warnings on page 1-2. TESTING THE NEUTRAL LOCKOUT LIMIT SWITCH See Test Procedure 9 – Transaxle Limit Switch on page 19-16. NEUTRAL LOCKOUT LIMIT SWITCH REMOVAL Turn the key switch OFF and remove the key.

  • Page 569: Solenoid

    SUBARU EX-40 - ELECTRICAL COMPONENTS Solenoid SOLENOID See General Warnings on page 1-2. TESTING THE SOLENOID See Test Procedure 7 – Solenoid on page 19-14. SOLENOID REMOVAL Disconnect battery and spark plug wire(s). See Disconnect the Battery - Gasoline Vehicles on page 1-3. Disconnect all the wires from the solenoid.

  • Page 570: Fuse

    Fuse SUBARU EX-40 - ELECTRICAL COMPONENTS FUSE See General Warnings on page 1-2. ATM-style blade fuses are located on the main wire harness in front of the battery. The ABC-style glass fuse is located on the main wire harness adjacent to the ATM-fuse holder. TESTING THE FUSE See Test Procedure 2 –...

  • Page 571: Accelerator Pedal Limit Switch

    SUBARU EX-40 - ELECTRICAL COMPONENTS Accelerator Pedal Limit Switch ACCELERATOR PEDAL LIMIT SWITCH See General Warnings on page 1-2. TESTING THE ACCELERATOR PEDAL LIMIT SWITCH See Test Procedure 6 – Throttle Position Sensor (TPS) on page 19-12. The accelerator pedal limit switch is housed inside the throttle position sensor. The throttle position sensor itself is not intended to be replaced.

  • Page 572: Reverse Warning Buzzer Installation

    Reverse Warning Buzzer SUBARU EX-40 - ELECTRICAL COMPONENTS A, Red/White wire B. Black wire Figure 27-21 Reverse Buzzer REVERSE WARNING BUZZER INSTALLATION Install the screws (3) through the buzzer bracket tabs and tighten to 3.5 in·lb (0.40 N·m) (Figure 27-21, Page 27-24).

  • Page 573: Reverse Buzzer Limit Switch

    SUBARU EX-40 - ELECTRICAL COMPONENTS Reverse Buzzer Limit Switch REVERSE BUZZER LIMIT SWITCH See General Warnings on page 1-2. TESTING THE REVERSE BUZZER LIMIT SWITCH See Test Procedure 14 – Multi-Purpose Buzzer and Multi-Purpose Buzzer Limit Switch on page 19-22. REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).

  • Page 574: Low Oil Warning Light

    Low Oil Warning Light SUBARU EX-40 - ELECTRICAL COMPONENTS LOW OIL WARNING LIGHT See General Warnings on page 1-2. TESTING THE LOW OIL WARNING LIGHT See Test Procedure 16 – Low Oil Warning Light (LED) on page 19-23. LOW OIL WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s).

  • Page 575: Fuel Gauge

    SUBARU EX-40 - ELECTRICAL COMPONENTS Fuel Gauge FUEL GAUGE See General Warnings on page 1-2. With the key switch in the OFF position, the fuel gauge reads empty. When the key switch is turned to ON, the fuel gauge becomes active. TESTING THE FUEL GAUGE See Test Procedure 22 –...

  • Page 576: Fuel Level Sending Unit

    Fuel Level Sending Unit SUBARU EX-40 - ELECTRICAL COMPONENTS 4.2. Position the instrument panel (2) on the dash assembly. Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly. Ensure that there are no wires exposed or pinched during positioning.

  • Page 577: Oil Level Sensor

    SUBARU EX-40 - ELECTRICAL COMPONENTS Oil Level Sensor BLACK 2438 Figure 27-24 Hour Meter Installation OIL LEVEL SENSOR See General Warnings on page 1-2. TESTING THE OIL LEVEL SENSOR See Test Procedure 18 – Oil Level Sensor on page 26-31. OIL LEVEL SENSOR REMOVAL See Oil Level Sensor Removal on page 28-12.

  • Page 578: Battery

    Battery SUBARU EX-40 - ELECTRICAL COMPONENTS BATTERY DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working on or near batteries. • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.

  • Page 579: Self-Discharge

    SUBARU EX-40 - ELECTRICAL COMPONENTS Battery CAUTION • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in a fire, property damage, or personal injury.

  • Page 580: Battery Removal

    Battery SUBARU EX-40 - ELECTRICAL COMPONENTS BATTERY REMOVAL Also see DANGER at beginning of Battery topic. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. Disconnect battery and spark plug wire(s). See Disconnect the Battery - Gasoline Vehicles on page 1-3. Remove the battery hold-down clamp from the battery.

  • Page 581: Battery Storage

    SUBARU EX-40 - ELECTRICAL COMPONENTS Ground Cables BATTERY STORAGE Also see DANGER at beginning of Battery topic. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 20-2. The battery cables should be disconnected from the battery so the battery can be connected to the charger. The battery can be left in the vehicle.
  • Page 582 Ground Cables SUBARU EX-40 - ELECTRICAL COMPONENTS Pagination Page Page 27-34 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 583: Section 28 - Subaru Ex-40 - Engine

    SECTION 28 — SUBARU EX-40 - ENGINE DANGER Subaru EX-40 - Engine • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION See General Warnings on page 1-2. This vehicle is powered by a Subaru EX-40, high-compression, chain driven, overhead cam engine. The engine offers a heavy-duty construction featuring cast iron cylinder liner for longer life, dual ball bearing crankshaft support, low oil level sensor and heavy-duty air cleaner system, to name a few characteristics.

  • Page 584: Torque Specifications

    General Information SUBARU EX-40 - ENGINE TORQUE SPECIFICATIONS ITEM SIZE TORQUE Flywheel retaining nut 80 ft·lb (110 N·m) Crankcase cover to block bolts 250 in·lb (28.3 N·m) Step Step New head and bolts: New head and bolts: 159 in·lb (18 N·m) 336 in·lb (38 N·m) Cylinder head bolts Used head and bolts:...
  • Page 585 SUBARU EX-40 - ENGINE General Information Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it. If the oil level is at or below the low level mark on the dipstick gauge, add oil until the level is between low and full levels (safe level).
  • Page 586 General Information SUBARU EX-40 - ENGINE 1. Drain pan 2. Drain plug 2667 Figure 28-2 Engine Oil Drain Plug and Pan Use a 14 mm socket or wrench to remove the drain plug, turning it counterclockwise, and allow the engine oil to drain into the pan.

  • Page 587: Spark Plug

    SUBARU EX-40 - ENGINE General Information Figure 28-3 Oil Viscosity Chart Connect battery and spark plug wire. See Connect the Battery - Gasoline Vehicles on page 1-4. With the Forward/Reverse handle in the NEUTRAL position and the Maintenance/Operate switch in the OPERATE position, start and run the engine for a few minutes.

  • Page 588: Breather

    General Information SUBARU EX-40 - ENGINE Figure 28-4 Spark Plug Testing the Spark Plug Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible. Spark should be blue and strong and able to jump a 5/16-in. (8 mm) gap. Setting the Spark Gap Pass a contact point file between the electrodes to produce flat, parallel surfaces to facilitate accurate gauging.

  • Page 589: Valve Clearance Check And Adjustment

    SUBARU EX-40 - ENGINE General Information VALVE CLEARANCE CHECK AND ADJUSTMENT NOTE: Check and adjust clearance when the engine is cold. If equipped, remove air deflector from top of engine. Remove rocker cover. Turn the crankshaft until the piston is at top dead center of the compression stroke (Figure 28-5, Page 28-7). Using a feeler gauge (1), measure the clearance between the adjuster screw (3) and the top of the valve stem (Figure 28-6, Page 28-7).

  • Page 590: Engine Removal

    Engine Removal SUBARU EX-40 - ENGINE ENGINE REMOVAL ENGINE REMOVAL 3036a Figure 28-7 EX-40 Engine and Mounting Brackets Page 28-8 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 591: Engine Installation

    SUBARU EX-40 - ENGINE Engine Installation CAUTION • Before removal and disassembly, clean the engine. Disconnect battery and spark plug wire(s). See Disconnect the Battery - Gasoline Vehicles on page 1-3. For some vehicles, the engine (1) can be removed by lifting it up and out of the chassis. For other vehicles, it is easier to remove the entire powertrain assembly first.

  • Page 592: Flywheel

    Flywheel SUBARU EX-40 - ENGINE If necessary, install powertrain. See Transaxle Installation, Section 18, Page 18-12. Connect air intake hose, fuel line, wire harness connectors, ground cable and governor cable. See Kohler ECH400 - Fuel System, Section 22, Page 22-1. If equipped, install air deflector on top of engine.

  • Page 593: Flywheel Removal

    SUBARU EX-40 - ENGINE Flywheel 3037 Figure 28-8 Flywheel, Fan and Fan Housing – EX-40 FLYWHEEL REMOVAL Remove screws (1) and fan housing (2) (Figure 28-8, Page 28-11). Hold flywheel (4) only, not fan (7), with strap wrench (5) and use a 24 mm socket to remove flywheel nut (8) and flat washer (9) by turning it counterclockwise (Figure 28-9, Page 28-12).

  • Page 594: Flywheel Installation

    Oil Level Sensor SUBARU EX-40 - ENGINE Figure 28-9 Flywheel Nut Removal Figure 28-10 Fan and Flywheel Installation FLYWHEEL INSTALLATION Wipe off any oil on tapered portions of crankshaft and flywheel (4) (Figure 28-8, Page 28-11). Insert woodruff key (10) into keyway of crankshaft. Then align groove in flywheel (4) to woodruff key (10) and push flywheel onto crankshaft until it seats.

  • Page 595: Oil Level Sensor Installation

    SUBARU EX-40 - ENGINE Oil Level Sensor Pull oil level sensor (5) out of engine. OIL LEVEL SENSOR INSTALLATION Lubricate oil level sensor o-ring with oil and carefully insert sensor (5) into engine until fully seated. Secure sensor (5) to engine with two bolts (4) and tighten to 80 in·lb (9 N·m) (Figure 28-11, Page 28-13). Connect oil level sensor wire (3) to wire harness.

  • Page 596: Ignition Coil

    Ignition Coil SUBARU EX-40 - ENGINE IGNITION COIL See General Warnings on page 1-2. TESTING THE IGNITION COIL See Test Procedure 13 – Ignition Spark on page 19-21 and Test Procedure 15 – Ignition Coil on page 26-29. IGNITION COIL REMOVAL Remove screws (1) and fan housing (2) (Figure 28-8, Page 28-11).

  • Page 597: Snubber

    SUBARU EX-40 - ENGINE Snubber SNUBBER See General Warnings on page 1-2. NOTE: The snubber is installed on the gasoline vehicle only. SNUBBER REMOVAL Support the powertrain with a floor jack under the engine pan (1) so that the snubber (2) is raised slightly and does not rest on the vehicle frame (Figure 28-14, Page 28-15).
  • Page 598 Snubber SUBARU EX-40 - ENGINE Pagination Page Page 28-16 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 599: Section 29 - Subaru Ex-40 - Fuel System

    SECTION 29 — SUBARU EX-40 - FUEL SYSTEM DANGER Subaru EX-40 - Fuel System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. • Fuel may be under pressure. Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine.

  • Page 600: Relieving Fuel Pressure

    Relieving Fuel Pressure SUBARU EX-40 - FUEL SYSTEM 1. ECU 2. Fuel Pump 3. Fuel Tank 4. Fuel Injector 5. MAP Sensor 6. Engine Temperature Sensor 7. CDI Ignition Unit 3040 Figure 29-1 EFI System Components RELIEVING FUEL PRESSURE In the event that servicing the EFI fuel system necessitates removal of the fuel delivery hose, extreme caution must be exercised.

  • Page 601: Throttle Body

    SUBARU EX-40 - FUEL SYSTEM Throttle Body THROTTLE BODY See General Warnings on page 1-2. Before suspecting the throttle body as the cause of poor engine performance, make sure the fuel and ignition systems are in proper operating condition. Check the following items: •...
  • Page 602 Throttle Body SUBARU EX-40 - FUEL SYSTEM 3041 Figure 29-2 Throttle Body Page 29-4 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 603: Throttle Body Installation

    SUBARU EX-40 - FUEL SYSTEM Throttle Body THROTTLE BODY INSTALLATION See General Warnings on page 1-2. Install throttle body (1) and its related components onto threaded studs in order as shown (Figure 29-2, Page 29-4). Install two flange nuts (7) and tighten to 53 to 71 in·lb (6 to 8 N·m). Connect fuel line (6) and vent hose (5).

  • Page 604: Engine Control Linkages

    Engine Control Linkages SUBARU EX-40 - FUEL SYSTEM ENGINE CONTROL LINKAGES See General Warnings on page 1-2. DANGER • To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push rod, do the following: –...

  • Page 605: Ground Speed

    SUBARU EX-40 - FUEL SYSTEM Engine Control Linkages GROUND SPEED NOTE: If possible, the manufacturer recommends measuring ground speed when setting engine RPM. This vehicle should reach the forward ground speed specified in Section 2 – Vehicle Specifications. See How to Measure Ground Speed on page 22-8.

  • Page 606: Accelerator Cable

    Engine Control Linkages SUBARU EX-40 - FUEL SYSTEM 2.3. Push bellows back onto threaded end of cable housing. 2.4. Connect “Z” fitting of governor cable (1) to governor arm (4). Loosen adjustment screw jam nuts (6 and 10) and back off throttle stop screw (7) and power limiter screw (11) several turns (Figure 29-6, Page 29-8).
  • Page 607 SUBARU EX-40 - FUEL SYSTEM Engine Control Linkages Accelerator Cable Installation At transaxle: 1.1. Hook spring fitting of accelerator cable (8) to governor arm (4) (Figure 29-5, Page 29-8). 1.2. Snap accelerator cable (8) into FNR/accelerator cable bracket (9). 1.3. Push dust shield (13) onto end of cable housing.

  • Page 608: Closed Throttle Or Idle Adjustment - Pedal-Start Vehicles

    Engine Control Linkages SUBARU EX-40 - FUEL SYSTEM CLOSED THROTTLE OR IDLE ADJUSTMENT – PEDAL-START VEHICLES When the accelerator pedal is released, the engine will stop. Therefore, it is not possible to measure or set idling speed under normal vehicle operating conditions. Set throttle valve as follows: Loosen the throttle body idle screw so that it is not touching the throttle lever (Figure 29-7, Page 29-10).

  • Page 609: Engine Rpm Adjustment

    SUBARU EX-40 - FUEL SYSTEM Engine Control Linkages ENGINE RPM ADJUSTMENT DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. If governor is adjusted, proceed to step 2; otherwise, adjust governor. See Governor Cable Installation and Adjustment on page 22-3.

  • Page 610: Air Intake System

    Air Intake System SUBARU EX-40 - FUEL SYSTEM AIR INTAKE SYSTEM See General Warnings on page 1-2. GENERAL INFORMATION The air intake system is a simple mechanism requiring very little or no maintenance. The system consists of an air cleaner (1) and air hose (3) mounted under the seat (Figure 29-8, Page 29-12). The air cleaner draws clean, cool air from beneath the vehicle via an opening between the kick plate and the fuel bucket.

  • Page 611: Air Intake System Removal

    • If air cleaner is extremely dirty, clean thoroughly. • Use only Club Car replacement air filters or equivalent. The use of other air filters could result in engine damage. If the air filter is too small, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.

  • Page 612: Air Intake System Installation

    • Intake hose (3) is made from a special fire retardant neoprene material. Use of any hose that does not meet Club Car, LLC specifications could create a fire hazard. • Improper orientation of the hose clamp (5) may result in fuel tank damage (Figure 29-10, Page 29-14).

  • Page 613: Fuel Line

    NOTE: This EFI gasoline vehicle is equipped with SAEJ30R9 fuel hose rated for high-pressure systems. Always replace the fuel line on this vehicle with approved Club Car replacement part. Do not attempt to repair, patch or splice the fuel line.

  • Page 614: Fuel Line Installation

    Fuel Line SUBARU EX-40 - FUEL SYSTEM 1. Push fuel line onto nipple until it locks into place. 2. Push in locking clip until fully seated. 1. Pull out locking clip. 2. Push in on release tab. 3. While pushing in on release tab, pull fuel line off nipple. 3050 3051 Figure 29-11 Fuel Line Connector –...

  • Page 615: Fuel Pump Module

    SUBARU EX-40 - FUEL SYSTEM Fuel Pump Module 2.2. Make sure that the fuel line is routed correctly (Figure 29-13). Figure 29-13 Clean spilled and remove any drained gasoline from the area. Connect battery. See Connect the Battery - Gasoline Vehicles on page 1-4. Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout switch in the MAINTENANCE position (Figure 18-1, Page 18-1).

  • Page 616: Fuel Pump Module Removal

    Fuel Pump Module SUBARU EX-40 - FUEL SYSTEM FUEL PUMP MODULE REMOVAL Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. Disconnect battery. See Disconnect the Battery - Gasoline Vehicles on page 1-3. Clean the top of the fuel tank and fuel pump module (1) (Figure 29-14, Page 29-20).
  • Page 617 SUBARU EX-40 - FUEL SYSTEM Fuel Pump Module Connect fuel line (3) to fuel pump module (1). See Fuel Line Installation on page 22-15. See following DANGER. DANGER • Ensure line is connected properly to avoid a leak that can cause a fire. •...
  • Page 618 Fuel Pump Module SUBARU EX-40 - FUEL SYSTEM 3125a Figure 29-14 Fuel System Page 29-20 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 619: Fuel Tank

    SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses or equivalent. FUEL TANK REMOVAL Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout switch in the MAINTENANCE position.

  • Page 620: Fuel Tank Disposal

    SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses or equivalent. Place fuel tank (10) in vehicle.
  • Page 621 SUBARU EX-40 - FUEL SYSTEM Fuel Tank Connect fuel pump module ground wire (7) to main wire harness. See following WARNING. WARNING • Always install ground wires during reassembly. Connect fuel line (3) to fuel pump module (1). See Fuel Line Installation on page 22-15. See following DANGER.

  • Page 622: Fuel Filter

    Fuel Filter SUBARU EX-40 - FUEL SYSTEM FUEL FILTER See General Warnings on page 1-2. GENERAL INFORMATION The fuel filter is located in the fuel tank. It is part of the fuel pump module assembly and should last the life of the vehicle;...

  • Page 623: Carbon Canister

    CARBON CANISTER WARNING • If the carbon canister is damaged, only use an OEM (Club Car) replacement that is specifically designed and approved for use on this vehicle. Do not attempt to repair it. See the following canister removal procedure.
  • Page 624 Carbon Canister SUBARU EX-40 - FUEL SYSTEM Attach hoses (2, 3, and 4) to appropriate locations on carbon canister and secure with hose clamps (1). Install and/or lower seat bottom. Page 29-26 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 625: Section 30 - Subaru Ex-40 - Exhaust System

    SECTION 30 — SUBARU EX-40 - EXHAUST SYSTEM DANGER Subaru EX-40 - Exhaust System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. MUFFLER MUFFLER REMOVAL Disconnect battery and spark plug wire(s). See Disconnect the Battery - Gasoline Vehicles on page 1-3. If equipped, remove air deflector from top of engine.
  • Page 626 Muffler SUBARU EX-40 - EXHAUST SYSTEM 3112a Figure 30-1 Exhaust System Page 30-2 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 627: Section 31 - Subaru Ex-40 - Clutches

    SECTION 31 — SUBARU EX-40 - CLUTCHES DANGER Subaru EX-40 - Clutches • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to the engine, is in the open position when the engine is at idle.
  • Page 628 Troubleshooting SUBARU EX-40 - CLUTCHES If cleaning the driven clutch does not solve the problem, disassemble and thoroughly clean all parts of the drive clutch. Be sure to clean the plastic drive buttons (7) (Figure 24-2, Page 24-4). (CC P/N 101809101) (CC P/N 1014497) (CC P/N 1014508) (CC P/N 1014507)

  • Page 629: Drive Belt

    SUBARU EX-40 - CLUTCHES Drive Belt DRIVE BELT See General Warnings on page 1-2. The drive belt should be inspected semiannually for wear and (or) glazing. If it is excessively worn, frayed, or glazed, replace the belt. As the drive belt wears, the engine RPM will increase to compensate for the change in torque converter ratio. This will keep the vehicle’s maximum ground speed correct.

  • Page 630: Drive Clutch

    Drive Clutch SUBARU EX-40 - CLUTCHES DRIVE CLUTCH See General Warnings on page 1-2. 1. Screw, 3/8-24 x 5.75, Patch 10. Retainer 2. Washer, 3/8, Type A, Flat 11. Ring, Spiral Backup 3. Washer, Hard, M10 12. Bushing, Split, Drive Clutch 4.

  • Page 631: Drive Clutch Removal

    SUBARU EX-40 - CLUTCHES Drive Clutch CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. DRIVE CLUTCH REMOVAL Remove the drive belt as instructed.

  • Page 632: Drive Clutch Cleaning And Inspection

    Drive Clutch SUBARU EX-40 - CLUTCHES WARNING position. Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor. When not performing a test or service procedure that requires movement of the wheels, lock the brakes. Remove the drive clutch retaining bolt (1) and mounting washers (2 and 3) (Figure 24-2, Page 24-4).
  • Page 633 SUBARU EX-40 - CLUTCHES Drive Clutch 2.1. Remove the three plugs (4) from the clutch puller attachment holes. 2.2. Thread the center bolt of the Drive Clutch Hub Puller (1) into clutch until the stop nut touches the clutch, then back the bolt out one-half turn (Figure 24-6, Page 24-7). 2.3.
  • Page 634 Drive Clutch SUBARU EX-40 - CLUTCHES 3053 Figure 31-8 Drive Button Mounting Figure 31-9 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 24-8, Page 24-8). 5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch.

  • Page 635: Inspection Of Drive Clutch Parts

    SUBARU EX-40 - CLUTCHES Drive Clutch Figure 31-10 Primary and Secondary Weights, Wave Washer and Pin Remove the retaining ring (6) from the shaft of the fixed sheave (18) and slide the moveable sheave (13) off the shaft (Figure 24-2, Page 24-4). See following NOTE. NOTE: If the moveable sheave is removed from the hub of the fixed sheave, the spiral back-up rings (11) must be replaced with new rings (Figure 24-2, Page 24-4).

  • Page 636: Drive Clutch Assembly

    Drive Clutch SUBARU EX-40 - CLUTCHES Inspect the primary weights (8) and the hub casting for wear. If the primary weights show signs they are touching the casting, the tips of the weights have worn beyond specification and they must be replaced. Inspect the pins on the primary weights (8).

  • Page 637: Drive Clutch Installation

    SUBARU EX-40 - CLUTCHES Drive Clutch NOTE: Make sure there is at least a (minimum) gap of 0.020 in. (0.51 mm) between each end of the mounting pin and the mounting bolt. Install three drive button take-up springs. 11.1. Install each spring on right-hand side of the three button mounting posts (when looking into the interior of the clutch drive hub, and with the rib at a twelve o’clock position) as shown (Figure 24-12, Page 24-11).
  • Page 638 Drive Clutch SUBARU EX-40 - CLUTCHES Drive the vehicle and check for proper operation. Page 31-12 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 639: Driven Clutch

    SUBARU EX-40 - CLUTCHES Driven Clutch DRIVEN CLUTCH See General Warnings on page 1-2. 1. Screw, 5/16-18 X 3/4 Hex-Head with Patch 7. Screw, #8-32 X 3/4, Socket-Head Cap 2. Washer, Driven Clutch 8. Button, Drive 3. Ring, Retaining 9. Sheave, Movable, Driven 4.

  • Page 640: Driven Clutch Removal

    Driven Clutch SUBARU EX-40 - CLUTCHES DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed. See Drive Belt Removal on page 24-3. Remove the bolt (1) and mounting washer (2) from the transaxle input shaft (Figure 24-13, Page 24-12). Discard the bolt. NOTE: The bolt (1) must be replaced with a new bolt containing a locking patch that will prevent the bolt from loosening.
  • Page 641 SUBARU EX-40 - CLUTCHES Driven Clutch WARNING • Do not place fingers under the cam when removing the cam. The moveable face may spin when the cam buttons release from the cam ramps, resulting in severe personal injury. Remove the retaining ring (10) (Figure 24-15, Page 24-14). 608B Figure 31-16 Remove Retaining Ring Insert a puller plug (11) into the shaft bore (Figure 24-16, Page 24-14).

  • Page 642: Driven Clutch Inspection

    Driven Clutch SUBARU EX-40 - CLUTCHES Remove the spring (14) (Figure 24-17, Page 24-15). 2961B Figure 31-18 Driven Clutch Disassembly Inspect the key (15) for damage. Replace as necessary. Slide the moveable sheave (16) off the fixed sheave (17). DRIVEN CLUTCH INSPECTION Inspect the cam (5) for excessive wear (Figure 24-13, Page 24-12).
  • Page 643 SUBARU EX-40 - CLUTCHES Driven Clutch 5.1. Press Assembly Process: 5.1.1. Place the clutch assembly in a press and position the cam press tool on the cam (2) as shown (Figure 31-19, Page 31-17). 5.1.2. Hold the fixed sheave (3) and rotate the moveable sheave (1) one-third turn counterclockwise, then press the cam (2) onto the fixed sheave (Figure 31-19, Page 31-17).

  • Page 644: Driven Clutch Installation

    Driven Clutch SUBARU EX-40 - CLUTCHES 5.2.4. Hold the clutch assembly and cam installation tool together and place the fixed sheave down on spaced blocks (Figure 31-19, Page 31-17). 5.2.5. Place the cam press hub (6) onto the cam installation bolt and thread it down onto the cam hub, centering the press hub onto the cam hub.

  • Page 645: Section 32 - Wiring Diagrams

    SECTION 32 — WIRING DIAGRAMS GENERAL INFORMATION Wiring Diagrams Wire Description EXAMPLE: 18_GRN_RED • 18 = 18 gauge wire • GRN_RED = Green wire with red stripe Wire Colors NOTE: The following colors will represented as a black wire in the wiring diagrams: •...

  • Page 646: General Information

    General Information WIRING DIAGRAMS GRN_WHT Green with White Stripe ORG_BLK Orange with Black Stripe ORG_WHT Orange with White Stripe PUR_WHT Purple with White Stripe RED_GRN Red with Green Stripe RED_WHT Red with White Stripe RED_YEL Red with Yellow Stripe WHT_BLK White with Black Stripe Page 32-2 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 647: Kohler Ech440 Engine Harness Wiring Diagram Table

    WIRING DIAGRAMS Kohler ECH440 Engine Harness Wiring Diagram Table KOHLER ECH440 ENGINE HARNESS WIRING DIAGRAM TABLE Callout Description Red/Black Red/White Yellow Light Green Dark Green Dark Blue Purple Pink White Grey Black To Main Harness Oil Level Switch 10-amp Fuse (Ignition Switch) 10-amp Fuse (Battery Power) Black Connector Grey Connector...
  • Page 648 Kohler ECH440 Engine Harness Wiring Diagram Table WIRING DIAGRAMS Pagination Page Page 32-4 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...
  • Page 649 Wiring Diagrams Kohler ECH440: Engine Harness KOHLER ECH440: ENGINE HARNESS...
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  • Page 651 Wiring Diagrams Kohler ECH440: Main Harness KOHLER ECH440: MAIN HARNESS...
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  • Page 653 Wiring Diagrams Kohler ECH440: Instrument Panel Harness KOHLER ECH440: INSTRUMENT PANEL HARNESS...
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  • Page 655 Wiring Diagrams Gasoline: Instrument Panel Light Harness GASOLINE: INSTRUMENT PANEL LIGHT HARNESS...
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  • Page 657 Wiring Diagrams Subaru EX-40: Main Harness SUBARU EX-40: MAIN HARNESS...
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  • Page 659 Wiring Diagrams Subaru EX-40: Instrument Panel Dash Harness SUBARU EX-40: INSTRUMENT PANEL DASH HARNESS...
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  • Page 661 Wiring Diagrams Subaru EX-40: Engine Harness SUBARU EX-40: ENGINE HARNESS...
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  • Page 663 Wiring Diagrams Electric: Two Passenger Main Harness ELECTRIC: TWO PASSENGER MAIN HARNESS...
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  • Page 665 Wiring Diagrams Electric: Four Passenger Main Harness ELECTRIC: FOUR PASSENGER MAIN HARNESS...
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  • Page 667 Wiring Diagrams Electric: Instrument Panel Dash Harness ELECTRIC: INSTRUMENT PANEL DASH HARNESS...
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  • Page 669 Wiring Diagrams Electric: Instrument Panel Light Harness ELECTRIC: INSTRUMENT PANEL LIGHT HARNESS...
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  • Page 671 Wiring Diagrams Electric: Lighting Harness ELECTRIC: LIGHTING HARNESS...
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  • Page 673: Index

    Index Index storage ............ 20-4, 27-33 Index testing ............. 19-9, 26-12 AC power and circuit testing under load....19-9, 19-24, 26-12, 26-31 testing (ERIC charger) ........15-29 voltage test ..........19-9, 26-12 accelerator battery charger ............15-1 cable battery charger interface ........15-5 installation ..........22-7, 29-9 external charger repairs removal ..........22-5, 29-8...
  • Page 674 INDEX body repair.............. 4-2 diagnostics ............11-1 gouges, punctures, tears ........4-3 diagnostics menu ..........11-15 minor impact damage/deformations ....... 4-2 excel braking............11-8 minor scratches and surface blemishes ....4-3 fast accel ............11-6 stress lines or streaks ........... 4-2 fault history folder ..........11-15 brake light relay ...........
  • Page 675 INDEX commutator installation ..........20-22, 27-17 see starter/generator ........20-4, 27-1 removal ..........20-21, 27-17 connector, 16-pin testing ............. 26-16 see test procedures .......... 12-27 electric motor connector, 18-pin see motor ............16-4 see test procedures .......... 26-16 electrical system connector, 4-pin engine ignition circuit see test procedures ......12-31, 19-31, 26-36 see also ignition coil and ignition testing...
  • Page 676 INDEX removal ............13-4 fuse location - gas ..........26-8 testing ............12-17 fuses front body..............4-6 testing ........... 12-15, 26-14 installation ............4-7 removal ............... 4-7 front bumper............4-8 installation ............4-8 governor removal ............... 4-8 governor system..........18-2 front suspension governor cable front wheel hub ..........
  • Page 677 INDEX armature ..........20-9, 27-6 assembly ............16-13 bearing........20-8–20-9, 27-5–27-6 bearing brush spring ...........20-6, 27-2 inspection............16-11 brushes ..........20-5, 27-2 braking commutator .......... 20-10, 27-7 motor braking ..........12-2 field coils ..........20-12, 27-9 brush transaxle, type g..........17-7 inspection............. 16-10 instrument panel ............ 4-11 brush spring installation ............
  • Page 678 INDEX installation ............28-13 removal ..........4-58–4-59 removal ............28-12 seat back, 2+2 ........... 4-44 testing ............. 26-31 installation ............4-45 oil seal removal ............4-44 installation ............18-8 seat support............4-53 removal ............. 18-7 installation ............4-53 oxygen sensor............. 20-37 removal ............
  • Page 679 INDEX removal .............20-4, 27-1 rework ............. 20-12, 27-9 safety..............1-1 testing .........19-17–19-18, 26-25 seat bottom hinge ............ 4-4 steering column ............7-3 installation ............4-4 installation ............7-4 removal ............... 4-4 removal ............... 7-3 service tools steering wheel ............7-1 torque converter kit........24-1, 31-1 installation ............
  • Page 680 INDEX Forward/Neutral/Reverse rocker switch....12-17 fuel pump............26-32 index of ............12-11 fuses ............... 26-14 key switch............12-16 ground cables ..........26-15 MCOR ............. 12-22 ignition coil............26-29 MCOR limit switch ..........12-16 iignition spark........... 26-28 motor, A1 and A2 voltage........12-25 key switch pre-charge resistor ...........
  • Page 681 INDEX lubrication ............17-1 oil seal installation ............17-4 removal ............17-1 removal ............. 17-5 troubleshooting CDT handheld programmer........11-27 torque converter .........24-1, 31-1 troubleshooting guide 1........12-5 troubleshooting guide 2........12-8 troubleshooting guide gasoline vehicle .........19-2, 26-2 underbody bracket ........... 4-9 usb port installation ............
  • Page 682 NOTES...

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