2004-2011 Club Car Precedent Golf Cart Service & Repair Manual
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2005
Maintenance
And
Service
Manual No. 102680401 Edition Code 0205C0306B
IQ System
Electric Vehicles
2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page i
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.
This manual provides detailed information for the maintenance and repair of the electric Precedent vehicles,
and should be thoroughly reviewed prior to servicing the vehicle. The procedures provided herein must be
properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.
This manual was written for the trained technician who already possesses knowledge and skills in electrical
and mechanical repair. If the technician does not have such knowledge and skills, attempted service or
repairs to the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or
service be performed by an authorized Club Car distributor/dealer representative or by a Club Car factory-
trained technician.
It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.
This manual covers all aspects of typical vehicle service; unique situations, however, do sometimes occur
when servicing a vehicle. If it appears that a service question is not answered in this manual, you may write
to us at: Club Car, Inc.; P.O. Box 204658; Augusta, Georgia 30917; Attention: Technical Services, or contact
a Club Car Technical Service Representative at (706) 863-3000, ext. 3580.
Copyright © 2005 Club Car, Inc.
Club Car and PowerDrive are registered
trademarks of Club Car, Inc.
This manual effective August 2, 2004.
Page ii 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual
ý WARNING
• Read Section 1 – Safety before attempting any service on the vehicle.
• Before servicing vehicle, read complete section(s) and any referenced information that may
be relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is
continually working to further improve its vehicles and other products. These improvements may
affect servicing procedures. Any modification and/or significant change in specifications or proce-
dures will be forwarded to all Club Car dealers and will, when applicable, appear in future editions
of this manual.
Club Car, Inc. reserves the right to change specifications and designs at any time without notice
and without the obligation of making changes to units previously sold.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle owner’s manual or write to Club Car, Inc., P.O. BOX 204658, Augusta, Georgia 30917-
4658 USA, Attention: Warranty Department.
2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warnings ............................................................................................................................. 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
SECTION 3 – GENERAL INFORMATION
Serial Number Identification .............................................................................................................. 3-1
Safety Committee ............................................................................................................................. 3-2
Storage ............................................................................................................................................. 3-2
Preparing the Electric Vehicle for Extended Off-Season Storage ................................................ 3-3
Returning the Stored Electric Vehicle to Service .......................................................................... 3-3
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 4-1
Seat .............................................................................................................................................. 4-1
Front and Rear Body Repair ............................................................................................................. 4-2
Stress Lines or Streaks ................................................................................................................. 4-2
Minor Impact Damage/Deformations ............................................................................................ 4-2
Minor Scratches and Surface Blemishes ...................................................................................... 4-2
Gouges, Punctures, Tears, Large Scratches, and Abrasions ....................................................... 4-2
Front Body ........................................................................................................................................ 4-4
Front Body Removal ..................................................................................................................... 4-4
Front Body Installation .................................................................................................................. 4-4
Front Bumper .................................................................................................................................... 4-4
Instrument Panel ............................................................................................................................... 4-4
Instrument Panel Removal ........................................................................................................... 4-4
Instrument Panel Installation ........................................................................................................ 4-6
Floor Mat and Retainers ................................................................................................................... 4-6
Floor Mat Retainer Removal ......................................................................................................... 4-7
Floor Mat Retainer Installation ...................................................................................................... 4-7
Page iv 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual
Kick Plate and Charger Receptacle Bezel ....................................................................................... 4-7
Kick Plate and Charger Receptacle Bezel Removal .................................................................... 4-7
Kick Plate and Charger Receptacle Bezel Installation ................................................................. 4-7
Rear Body – Two-Passenger Vehicles ............................................................................................ 4-8
Universal Accessory Mounting ..................................................................................................... 4-8
Backrest and Structural Accessory Module (SAM) ...................................................................... 4-10
Rear Body Components (Two-Passenger) .................................................................................. 4-10
Rear Body – Four-Passenger Vehicles ............................................................................................ 4-12
Seat Backs ................................................................................................................................... 4-12
Seat Support ................................................................................................................................ 4-13
Foot Deck ..................................................................................................................................... 4-14
Rear Body Components (Four-Passenger) .................................................................................. 4-15
Canopy – Two-Passenger ................................................................................................................ 4-16
Two-Passenger Canopy Removal ................................................................................................ 4-16
Two-Passenger Canopy Installation ............................................................................................. 4-18
Canopy – Four-Passenger ............................................................................................................... 4-20
Four-Passenger Canopy Removal ............................................................................................... 4-20
Four-Passenger Canopy Installation ............................................................................................ 4-20
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Pedal Group ..................................................................................................................................... 5-1
Pedal Group Removal .................................................................................................................. 5-1
MCOR .......................................................................................................................................... 5-3
Debris Shields .............................................................................................................................. 5-3
Brake Return Spring ..................................................................................................................... 5-3
Pawl Assembly ............................................................................................................................. 5-4
Accelerator Return Spring ............................................................................................................ 5-4
Pedal Group Installation ............................................................................................................... 5-6
SECTION 6 – WHEEL BRAKE ASSEMBLIES
General Information ......................................................................................................................... 6-1
Brake Shoe Removal ....................................................................................................................... 6-1
Brake Assembly Cleaning ................................................................................................................ 6-5
Brake Shoe Installation .................................................................................................................... 6-6
Brake Cable Equalizer Adjustment .................................................................................................. 6-9
Brake Cluster Removal and Installation ........................................................................................... 6-9
Brake Cluster Installation ............................................................................................................. 6-10
Brake Cable Removal and Installation ............................................................................................. 6-11
2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page v
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information .......................................................................................................................... 7-1
Steering Wheel ................................................................................................................................. 7-1
Steering Wheel Removal .............................................................................................................. 7-1
Steering Wheel Installation ........................................................................................................... 7-2
Steering Column ............................................................................................................................... 7-2
Steering Column Removal ............................................................................................................ 7-2
Steering Column Installation ......................................................................................................... 7-4
Rack and Pinion ................................................................................................................................ 7-4
Rack and Pinion Removal ............................................................................................................ 7-4
Rack and Pinion Disassembly ...................................................................................................... 7-5
Rack and Pinion Assembly ........................................................................................................... 7-8
Rack and Pinion Installation ......................................................................................................... 7-9
Front Suspension .............................................................................................................................. 7-10
Lubrication .................................................................................................................................... 7-10
Wheel Alignment ........................................................................................................................... 7-10
Front Suspension Components ........................................................................................................ 7-12
Tie Rod End Removal ................................................................................................................... 7-12
Tie Rod Installation ....................................................................................................................... 7-12
Leaf Spring Removal .................................................................................................................... 7-13
Leaf Spring Installation ................................................................................................................. 7-13
Kingpin and Steering Spindle Removal ........................................................................................ 7-13
Kingpin and Steering Spindle Installation ..................................................................................... 7-13
Control Arm Removal ................................................................................................................... 7-14
Control Arm Installation ................................................................................................................ 7-14
Shock Absorber Removal ............................................................................................................. 7-14
Shock Absorber Installation .......................................................................................................... 7-14
Front Wheel Bearings and Hubs ....................................................................................................... 7-17
Front Wheel Free Play Inspection ................................................................................................ 7-17
Front Hub Removal ....................................................................................................................... 7-17
Hub Installation ............................................................................................................................. 7-17
SECTION 8 – WHEELS AND TIRES
General Information .......................................................................................................................... 8-1
Wheels .............................................................................................................................................. 8-1
Wheel Removal ............................................................................................................................ 8-1
Wheel Installation ......................................................................................................................... 8-1
Page vi 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual
Tires ................................................................................................................................................. 8-2
Tire Removal ................................................................................................................................ 8-2
Tire Repair .................................................................................................................................... 8-2
Tire Installation ............................................................................................................................. 8-3
SECTION 9 – REAR SUSPENSION
General Information ......................................................................................................................... 9-1
Shock Absorbers .............................................................................................................................. 9-1
Shock Absorber Removal and Inspection .................................................................................... 9-1
Shock Absorber Installation .......................................................................................................... 9-1
Leaf Springs (Two-Passenger Vehicles) .......................................................................................... 9-1
Leaf Spring Removal (Two-Passenger Vehicles) ......................................................................... 9-1
Leaf Spring Installation (Two-Passenger Vehicles) ...................................................................... 9-4
Leaf Springs (Four-Passenger Vehicles) ......................................................................................... 9-4
Leaf Spring Removal (Four-Passenger Vehicles) ........................................................................ 9-4
Leaf Spring Installation (Four-Passenger Vehicles) ..................................................................... 9-6
SECTION 10 – PERIODIC MAINTENANCE
General Information ......................................................................................................................... 10-1
Periodic Service Schedule ............................................................................................................... 10-1
Periodic Lubrication Schedule .......................................................................................................... 10-3
SECTION 11 – ELECTRICAL SYSTEM AND TESTING
General Information ......................................................................................................................... 11-1
Wiring Diagrams ............................................................................................................................... 11-2
Troubleshooting ............................................................................................................................... 11-7
Troubleshooting the Vehicle with the IQDM ................................................................................. 11-7
Troubleshooting Guide 1 .............................................................................................................. 11-8
Troubleshooting Guide 2 .............................................................................................................. 11-11
Test Procedures ............................................................................................................................... 11-13
Index of Test Procedures ............................................................................................................. 11-14
Communication Display Module (CDM) ........................................................................................... 11-38
Using the CDM to Retrieve Data from the Onboard Computer .................................................... 11-39
CDM Troubleshooting Guide ............................................................................................................ 11-40
2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page vii
SECTION 12 – ELECTRICAL COMPONENTS
Key Switch ........................................................................................................................................ 12-1
Battery Warning Light ....................................................................................................................... 12-3
Forward/Reverse Rocker Switch ...................................................................................................... 12-3
Electronics Module Cover ................................................................................................................. 12-5
Tow/Run Switch ................................................................................................................................ 12-6
Motor Controller Output Regulator (MCOR) ..................................................................................... 12-7
Reverse Buzzer ................................................................................................................................ 12-8
Electronics Module ........................................................................................................................... 12-10
Solid State Speed Controller ............................................................................................................ 12-11
Solenoid ............................................................................................................................................ 12-12
Onboard Computer (OBC) ................................................................................................................ 12-13
Charger Receptacle .......................................................................................................................... 12-13
SECTION 13 – BATTERIES
General Information .......................................................................................................................... 13-1
Battery Replacement ........................................................................................................................ 13-1
Battery Care ...................................................................................................................................... 13-2
Preventive Maintenance ............................................................................................................... 13-2
Self-Discharge .............................................................................................................................. 13-3
Electrolyte Level ........................................................................................................................... 13-3
Mineral Content ............................................................................................................................ 13-4
Vibration Damage ......................................................................................................................... 13-4
Battery Charging ............................................................................................................................... 13-4
Charger Shuts Off After 16 Hours ................................................................................................. 13-5
Deep-Discharge ............................................................................................................................ 13-5
Early Excessive Discharging ........................................................................................................ 13-5
Incoming AC Service .................................................................................................................... 13-5
Fleet Rotation ............................................................................................................................... 13-5
Numbering Vehicles and Chargers ............................................................................................... 13-5
Battery Troubleshooting Chart .......................................................................................................... 13-6
Battery Testing .................................................................................................................................. 13-7
Battery Charger Test .................................................................................................................... 13-7
On-Charge Voltage Test ............................................................................................................... 13-7
Hydrometer Test ........................................................................................................................... 13-7
Discharge Test .............................................................................................................................. 13-9
Battery Troubleshooting Examples ............................................................................................... 13-11
Battery Storage ................................................................................................................................. 13-12
Page viii 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual
Charging a Battery Pack that has Low Voltage ................................................................................ 13-12
SECTION 14 – BATTERY CHARGER
SECTION 15A – MOTOR (MODEL 5BC59JBS6365)
General Information ......................................................................................................................... 15a-1
Motor Identification ........................................................................................................................... 15a-1
External Motor Testing ..................................................................................................................... 15a-1
Motor ................................................................................................................................................ 15a-3
Motor Component Testing and Inspection ....................................................................................... 15a-5
Armature ...................................................................................................................................... 15a-5
Field Windings Inspection ............................................................................................................ 15a-6
Motor Components ....................................................................................................................... 15a-7
Bearing Inspection ....................................................................................................................... 15a-7
Bearing Removal .......................................................................................................................... 15a-9
Bearing Installation ....................................................................................................................... 15a-9
Speed Sensor Magnet Inspection ................................................................................................ 15a-9
Speed Sensor Magnet Removal .................................................................................................. 15a-9
Speed Sensor Magnet Installation ............................................................................................... 15a-9
Reconditioning the Motor ................................................................................................................. 15a-9
Motor Assembly ............................................................................................................................... 15a-10
Motor Installation .............................................................................................................................. 15a-12
Motor Speed Sensor ........................................................................................................................ 15a-15
SECTION 15B – MOTOR (MODEL EJ4-4001)
General Information ......................................................................................................................... 15b-1
Motor Identification ........................................................................................................................... 15b-1
External Motor Testing ..................................................................................................................... 15b-1
Motor ................................................................................................................................................ 15b-2
Motor Removal ............................................................................................................................. 15b-2
Motor Disassembly ....................................................................................................................... 15b-4
Motor Component Testing and Inspection ....................................................................................... 15b-6
Armature Inspection and Testing ................................................................................................. 15b-6
Motor Frame and Field Windings Inspection ................................................................................ 15b-8
Motor Brush, Spring, and Terminal Insulator Inspection .............................................................. 15b-8
Reconditioning the Motor ................................................................................................................. 15b-11
Motor Assembly ............................................................................................................................... 15b-11
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This service repair manual is specifically designed for the Club Car Precedent Golf Cart models manufactured between 2004 and 2011, covering both electric and gas variants. It provides comprehensive instructions, diagrams, illustrations, wiring schematics, and specifications for all repairs from A to Z.
Whether you are a professional mechanic or a DIY enthusiast, this vehicle-specific manual offers the exact same information used by dealership technicians to maintain, service, diagnose, and repair your cart. The step-by-step guidance ensures ease of use, allowing you to print only the necessary pages and diagrams, eliminating the hassle of searching through multiple books.
With printable pages, you can conveniently carry the required information to your vehicle or workshop. Additionally, the manual allows you to enlarge and print images as needed. It is a highly detailed resource with complete instructions, illustrations, wiring schematics, and diagrams for thorough vehicle servicing and repairs.
Compatible with Windows Vista 32 and 64, XP, ME, 98, NT, 2000, as well as Mac, this manual provides a versatile solution for all users. Whether you are looking to maintain, service, diagnose, or repair your Club Car Precedent Golf Cart, this manual equips you with the necessary tools to do so effectively.
