Club Car Cafe Express Manual

2018CaféExpress
MaintenanceandService
Manual
GasolineVehiclewithSubaruEX40Engine
ManualNumber105344222
EditionCode0617A00000

FOREWORD
ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper
maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.
Thismanualprovidesdetailedinformationforthemaintenanceandrepairofthe2018CaféExpressvehicle,and
shouldbethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedmustbeproperlyimplemented,
andtheDANGER,WARNING,andCAUTIONstatementsmustbeheeded.
Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland
mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe
vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed
byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.
ItisthepolicyofClubCartoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledgeand
facilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,
vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications
alsorepresentClubCar’scontinuingcommitmenttocustomersupport.
ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout
ourproducts.Formoreinformation,contactyourlocaldealerorClubCar'sT echnicalServicesdepartmentfora
listofupcomingclasses.
Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga
vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized
ClubCardealerordistributorforassistance.
TondyourlocalauthorizedClubCardealer,visitwww.clubcardealer.com,call1-800-ClubCar(258–2227),orscan
thisQuickResponse(QR)codetobetakentotheClubCardealerlocator.RefertoFigure1.DownloadaQRcode
readersuchasRedLaserorBarcodeScannertoyourcellphoneortablet.
Ifyouwouldprefertowritetous,directyourletterto:ClubCarLLC,Attention:MarketingServices,P .O.Box204658,
Augusta,Georgia30917-4658USA.
_
DealerLocatorQRCode
Copyright©2017
ClubCarisaregisteredtrademarkofClubCar,LLC
ThismanualeffectiveJuly,2017
2018CaféExpressMaintenanceandServiceManualPagei

FOREWORD
TECHNICALPUBLICATIONCUSTOMERSATISFACTIONONLINESURVEY
Letyourvoicebeheard!
PleaseparticipateintheTechnicalPublicationcustomersatisfactiononlinesurvey.
Thissurveytakeslessthanveminutestocompleteandyourresponseswillhelpexaminecurrentperformance
andidentifyareasforfutureimprovement.
Ourtoppriorityistoprovidetimely,accurate,anduserfriendlymanuals.
Theonlinesurveycanbefoundathttp://bit.ly/1w9uFMhorusingtheQRCodebelow.
_
OnlineSurveyQRCode
WARNING
•ReadSafetyonpage1-1beforeattemptinganyserviceonthevehicle.
•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe
relevanttotheserviceorrepairtobeperformed.
_
MAINTENANCEITEMS
BatteryTerminalProtectorSpray
CCPN1014305
DryMolyLube
CCPN1012151
ChassisLube
EPNLGIGrade2(commerciallyavailable)
EngineAirFilter(404cc)
CCPN102558201
DeionizerFilterReplacementCartridge(SPWS)
CCPN104005901
SparkPlugO.H.C.(404cc)
CCPN105017801
DeionizerFilterReplacementCartridge(non-SPWS)
CCPNAM10975
NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCariscontinuallyworking
tofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicingprocedures.
Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoallClubCar
dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.
ClubCarreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithoutthe
obligationofmakingchangestounitspreviouslysold.
Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle
Owner’sManual.

CONTENTS
SECTION1—Safety.........................................................................................................................................1-1
SafetyDetails................................................................................................................................................1-1
PersonalSafety.........................................................................................................................................1-1
MachineSafety..........................................................................................................................................1-1
Information................................................................................................................................................1-1
GeneralWarnings..........................................................................................................................................1-1
DisablingtheVehicle..................................................................................................................................1-3
DisconnectingtheBattery-GasolineVehicles...............................................................................................1-3
ConnectingtheBattery-GasolineVehicles...................................................................................................1-3
RecyclingLead-AcidBatteries....................................................................................................................1-4
Internationalsafetysymbolsonbatteries.....................................................................................................1-5
SECTION2—VehicleSpecications..................................................................................................................2-1
VehicleSpecications....................................................................................................................................2-1
SECTION3—GeneralInformation.....................................................................................................................3-1
ModelIdentication........................................................................................................................................3-1
Storage.........................................................................................................................................................3-2
PreparingtheGasolineVehicleforExtendedStorage..................................................................................3-3
ReturningtheStoredGasolineVehicletoService........................................................................................3-3
SECTION4—BodyandTrim............................................................................................................................4-1
CleaningtheVehicle......................................................................................................................................4-1
SeatCleaning............................................................................................................................................4-1
FrontBodyRepair.........................................................................................................................................4-2
LightScratches..........................................................................................................................................4-2
AbrasionsandHaze..................................................................................................................................4-2
LargeScratchesandAbrasions..................................................................................................................4-2
Touch-UpPaintColorChart........................................................................................................................4-2
FrontBody....................................................................................................................................................4-3
HeavyDutyBumperRemoval.....................................................................................................................4-3
HeavyDutyBumperInstallation..................................................................................................................4-3
CowlRemoval...........................................................................................................................................4-5
CowlInstallation........................................................................................................................................4-5
GrilleRemoval...........................................................................................................................................4-6
GrilleInstallation........................................................................................................................................4-7
FrontBumperandSideFenderRemoval....................................................................................................4-9
FrontBumperandSideFenderInstallation..................................................................................................4-9
InstrumentPanelRemoval.......................................................................................................................4-10
InstrumentPanelInstallation....................................................................................................................4-10
DashRemoval..........................................................................................................................................4-11
DashInstallation.......................................................................................................................................4-11
TiltBed.......................................................................................................................................................4-13
TiltBedRemoval.....................................................................................................................................4-13
TiltBedInstallation..................................................................................................................................4-13
BedLatchAssemblyRemoval..................................................................................................................4-15
BedLatchAssemblyInstallation...............................................................................................................4-15
RearFendersandTailskirt............................................................................................................................4-17
RearFenderandTailskirtRemoval...........................................................................................................4-17
RearFenderandTailskirtInstallation........................................................................................................4-17
ElectricBedLift...........................................................................................................................................4-19
ElectricBedLiftRemoval.........................................................................................................................4-20
ElectricBedLiftInstallation......................................................................................................................4-20
FloorMat....................................................................................................................................................4-21
FloorMatRemoval..................................................................................................................................4-21
FloorMatInstallation................................................................................................................................4-21
2018CaféExpressMaintenanceandServiceManualPageiii

SECTION5—AcceleratorandBrakePedalGroup.............................................................................................5-1
BrakePedalandParkBrake..........................................................................................................................5-1
BrakePedalRemoval(GasandElectricVehicles).......................................................................................5-1
BrakePedalInstallation(GasandElectricVehicles).....................................................................................5-1
ParkBrakeRemoval..................................................................................................................................5-4
ParkBrakeInstallation...............................................................................................................................5-4
AcceleratorPedal..........................................................................................................................................5-5
AcceleratorPedalRemoval–GasolineVehicles..........................................................................................5-5
AcceleratorPedalInstallation–GasolineVehicles.......................................................................................5-6
PedalGroupAdjustment................................................................................................................................5-7
SECTION6—WheelBrakeAssemblies.............................................................................................................6-1
GeneralInformation.......................................................................................................................................6-1
BrakeShoeRemoval.....................................................................................................................................6-1
BrakeAssemblyCleaning..............................................................................................................................6-3
BrakeShoeInstallation..................................................................................................................................6-5
BrakeAdjustment..........................................................................................................................................6-6
BrakeClusterAdjustment...........................................................................................................................6-6
BrakeCableEqualization...........................................................................................................................6-9
FinalBrakeClusterAdjustment.................................................................................................................6-10
TestDriveVehicle....................................................................................................................................6-10
BrakeClusterRemovalandInstallation..........................................................................................................6-11
FrontBrakeClusterRemoval.....................................................................................................................6-11
FrontBrakeClusterInstallation..................................................................................................................6-11
RearBrakeClusterRemoval....................................................................................................................6-13
RearBrakeClusterInstallation.................................................................................................................6-13
FrontBrakeCables......................................................................................................................................6-14
FrontBrakeCableRemoval.....................................................................................................................6-15
FrontBrakeCableInstallation...................................................................................................................6-15
RearBrakeCables......................................................................................................................................6-16
RearBrakeCableRemoval......................................................................................................................6-16
RearBrakeCableInstallation...................................................................................................................6-16
SECTION7—SteeringandFrontSuspension....................................................................................................7-1
GeneralInformation.......................................................................................................................................7-1
SteeringWheel..............................................................................................................................................7-1
SteeringWheelRemoval............................................................................................................................7-1
SteeringWheelInstallation.........................................................................................................................7-2
SteeringColumn............................................................................................................................................7-3
SteeringColumnRemoval..........................................................................................................................7-4
SteeringColumnDisassembly....................................................................................................................7-4
SteeringColumnAssembly........................................................................................................................7-4
SteeringColumnInstallation.......................................................................................................................7-5
SteeringAdjustment......................................................................................................................................7-6
RackandPinion............................................................................................................................................7-7
RackandPinionInspection........................................................................................................................7-7
RackandPinionRemoval–Maintenance-FreeBallJoints...........................................................................7-7
RackandPinionDisassembly....................................................................................................................7-8
RackandPinionAssembly.......................................................................................................................7-10
RackandPinionInstallation–Maintenance-FreeBallJoints.......................................................................7-13
TieRodandDragLink.................................................................................................................................7-14
TieRodandDragLinkRemoval–Maintenance-FreeBallJoints................................................................7-14
TieRodandDragLinkInstallation–Maintenance-FreeBallJoints..............................................................7-14
FrontSuspension........................................................................................................................................7-15
Lubrication..............................................................................................................................................7-15
WheelAlignment.....................................................................................................................................7-15
FrontSuspensionComponents.....................................................................................................................7-17
LeafSpringRemoval...............................................................................................................................7-17
LeafSpringInstallation.............................................................................................................................7-17
KingpinandSteeringSpindleRemoval–Maintenance-FreeBallJoints.......................................................7-17
KingpinandSteeringSpindleInstallation–Maintenance-FreeBallJoints....................................................7-20
Pageiv2018CaféExpressMaintenanceandServiceManual

DeltaA-PlateRemoval.............................................................................................................................7-20
DeltaA-PlateInstallation..........................................................................................................................7-20
ShockAbsorberRemoval.........................................................................................................................7-20
ShockAbsorberInstallation......................................................................................................................7-20
FrontWheelBearingsandHubs...................................................................................................................7-21
FrontWheelFreePlayInspection.............................................................................................................7-21
FrontHubandWheelBearingsRemoval...................................................................................................7-21
FrontHubandWheelBearingsInstallation................................................................................................7-22
SECTION8—WheelsandTires........................................................................................................................8-1
GeneralInformation.......................................................................................................................................8-1
Wheels.........................................................................................................................................................8-1
WheelRemoval.........................................................................................................................................8-1
WheelInstallation......................................................................................................................................8-1
Tires.............................................................................................................................................................8-2
TireRemoval.............................................................................................................................................8-2
TireRepair................................................................................................................................................8-2
TireInstallation..........................................................................................................................................8-3
SECTION9—RearSuspension........................................................................................................................9-1
GeneralInformation.......................................................................................................................................9-1
ShockAbsorbers...........................................................................................................................................9-1
ShockAbsorberInspectionandRemoval...................................................................................................9-1
ShockAbsorberInstallation........................................................................................................................9-1
Multi-LeafSprings..........................................................................................................................................9-2
Multi-LeafSpringRemoval.........................................................................................................................9-2
Multi-LeafSpringInstallation......................................................................................................................9-3
SECTION10—PeriodicMaintenance..............................................................................................................10-1
GeneralInformation.....................................................................................................................................10-1
Pre-OperationandDailySafetyChecklist......................................................................................................10-1
PerformanceInspection...........................................................................................................................10-2
Maintenance...............................................................................................................................................10-2
PeriodicServiceSchedule............................................................................................................................10-3
PeriodicLubricationSchedule......................................................................................................................10-5
SECTION11—TroubleshootingandElectricalSystem:Pedal-StartGasVehicle.................................................11-1
GeneralInformation......................................................................................................................................11-1
Accessories..............................................................................................................................................11-1
LowOilWarningLight...............................................................................................................................11-1
GroundLocations.....................................................................................................................................11-1
FeaturesoftheElectronicFuelInjection(EFI)System................................................................................11-2
TroubleshootingGuide..................................................................................................................................11-2
ECUErrorCodes(DisplayedbytheLowOilWarningLight)........................................................................11-2
GasolinePowertrain.................................................................................................................................11-4
WiringDiagrams...........................................................................................................................................11-8
ElectricalSystem........................................................................................................................................11-13
TestProcedures.........................................................................................................................................11-14
TestingBasics........................................................................................................................................11-14
SECTION12—ElectricalComponents:Pedal-StartGasVehicle.......................................................................12-1
Starter/Generator.........................................................................................................................................12-1
Starter/GeneratorRemoval......................................................................................................................12-1
DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................12-1
BrushInspectionandReplacement...........................................................................................................12-2
BrushSpringInspectionandReplacement................................................................................................12-2
Starter/GeneratorAssembly.....................................................................................................................12-3
DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................12-4
BearingCleaningandInspection..............................................................................................................12-5
2018CaféExpressMaintenanceandServiceManualPagev

BearingRemoval.....................................................................................................................................12-6
FieldCoilAssembly.................................................................................................................................12-6
VisualInspectionofArmature...................................................................................................................12-6
CommutatorCleaningandInspection.......................................................................................................12-7
ArmatureGroundTest..............................................................................................................................12-8
VisualInspectionofFieldCoils.................................................................................................................12-9
Starter/GeneratorRework........................................................................................................................12-9
Starter/GeneratorAssembly.....................................................................................................................12-9
Starter/GeneratorInstallation...................................................................................................................12-12
BeltTensionAdjustmentforEFIEngines..................................................................................................12-13
VoltageRegulator.......................................................................................................................................12-15
VoltageRegulatorRemoval.....................................................................................................................12-15
VoltageRegulatorInstallation..................................................................................................................12-16
EngineControlUnit(ECU)..........................................................................................................................12-17
EngineControlUnitRemoval...................................................................................................................12-17
EngineControlUnitInstallation................................................................................................................12-17
KeySwitch.................................................................................................................................................12-18
KeySwitchRemoval...............................................................................................................................12-18
KeySwitchInstallation............................................................................................................................12-18
Maintenance/OperateSwitch.......................................................................................................................12-19
Maintenance/OperateSwitchRemoval.....................................................................................................12-19
Maintenance/OperateSwitchInstallation..................................................................................................12-19
NeutralLockoutLimitSwitch.......................................................................................................................12-19
NeutralLockoutLimitSwitchRemoval.....................................................................................................12-19
NeutralLockoutLimitSwitchInstallation...................................................................................................12-19
Solenoid.....................................................................................................................................................12-20
SolenoidRemoval..................................................................................................................................12-20
SolenoidInstallation................................................................................................................................12-20
Fuse..........................................................................................................................................................12-20
FuseRemoval........................................................................................................................................12-21
FuseInstallation.....................................................................................................................................12-21
KillLimitSwitch..........................................................................................................................................12-22
KillLimitSwitchRemoval........................................................................................................................12-22
KillLimitSwitchInstallation.....................................................................................................................12-22
ReverseWarningBuzzer.............................................................................................................................12-23
ReverseWarningBuzzerRemoval..........................................................................................................12-23
ReverseWarningBuzzerInstallation........................................................................................................12-23
ReverseBuzzerLimitSwitch.......................................................................................................................12-25
ReverseBuzzerLimitSwitchRemoval.....................................................................................................12-25
ReverseBuzzerLimitSwitchInstallation..................................................................................................12-25
LowOilWarningLight.................................................................................................................................12-27
LowOilWarningLightRemoval...............................................................................................................12-27
LowOilWarningLightInstallation............................................................................................................12-27
FuelGauge/HourMeter..............................................................................................................................12-27
GeneralInformation................................................................................................................................12-27
FuelGauge/HourMeterRemoval............................................................................................................12-27
FuelGauge/HourMeterInstallation..........................................................................................................12-28
FuelLevelSendingUnit..............................................................................................................................12-28
OilLevelSensor.........................................................................................................................................12-28
OilLevelSensorRemoval.......................................................................................................................12-28
OilLevelSensorInstallation....................................................................................................................12-28
VoltageLimiter...........................................................................................................................................12-28
VoltageLimiterRemoval.........................................................................................................................12-29
VoltageLimiterInstallation.......................................................................................................................12-29
HeadlightSwitch.........................................................................................................................................12-30
HeadlightSwitchRemoval.......................................................................................................................12-30
HeadlightSwitchinstallation....................................................................................................................12-30
Headlights..................................................................................................................................................12-30
HeadlightBezelRemoval........................................................................................................................12-30
HeadlightBezelInstallation.....................................................................................................................12-30
HeadlightBulbRemoval(Halogen)..........................................................................................................12-31
HeadlightBulbInstallation(Halogen).......................................................................................................12-31
HeadlightBulbRemoval(LED)................................................................................................................12-31
HeadlightBulbInstallation(LED).............................................................................................................12-31
Pagevi2018CaféExpressMaintenanceandServiceManual

Battery.......................................................................................................................................................12-33
GeneralInformation................................................................................................................................12-33
TestingtheBattery..................................................................................................................................12-33
PreventiveMaintenance..........................................................................................................................12-33
Self-Discharge........................................................................................................................................12-34
VibrationDamage...................................................................................................................................12-34
BatteryRemoval.....................................................................................................................................12-35
ChargingtheBattery...............................................................................................................................12-35
BatteryInstallation..................................................................................................................................12-35
BatteryStorage......................................................................................................................................12-36
ChargingaDeadBattery.........................................................................................................................12-36
GroundCables...........................................................................................................................................12-36
SECTION13—Engine(SubaruEX40).............................................................................................................13-1
GeneralInformation.....................................................................................................................................13-1
BeforeServicing......................................................................................................................................13-1
EngineRotation.......................................................................................................................................13-1
TorqueSpecications...............................................................................................................................13-2
AdjustmentsandSettings.........................................................................................................................13-2
EngineOil–GasolineVehicle...................................................................................................................13-2
SparkPlug..............................................................................................................................................13-5
Breather..................................................................................................................................................13-6
ValveClearanceCheckandAdjustment....................................................................................................13-7
EngineRemoval..........................................................................................................................................13-8
EngineInstallation......................................................................................................................................13-10
Flywheel....................................................................................................................................................13-10
FlywheelRemoval..................................................................................................................................13-11
FlywheelInstallation...............................................................................................................................13-12
OilLevelSensor.........................................................................................................................................13-12
TestingtheOilLevelSensor....................................................................................................................13-12
OilLevelSensorRemoval.......................................................................................................................13-12
OilLevelSensorInstallation....................................................................................................................13-13
IgnitionCoil................................................................................................................................................13-14
TestingtheIgnitionCoil...........................................................................................................................13-14
IgnitionCoilRemoval..............................................................................................................................13-14
IgnitionCoilInstallation...........................................................................................................................13-14
Snubber.....................................................................................................................................................13-15
SnubberRemoval...................................................................................................................................13-15
SnubberInstallation................................................................................................................................13-15
SECTION14—FuelSystem:GasolineVehicles...............................................................................................14-1
GeneralInformation.....................................................................................................................................14-1
EFISystemFeatures/Specications..........................................................................................................14-1
RelievingFuelPressure...............................................................................................................................14-2
ToRelieveFuelPressure.........................................................................................................................14-2
ThrottleBody...............................................................................................................................................14-3
ThrottleBodyRemoval.............................................................................................................................14-3
ThrottleBodyInstallation..........................................................................................................................14-4
EngineControlLinkages..............................................................................................................................14-6
GeneralInformation.................................................................................................................................14-6
GroundSpeed.........................................................................................................................................14-7
AcceleratorRod.......................................................................................................................................14-7
GovernorCable.......................................................................................................................................14-9
AcceleratorCable...................................................................................................................................14-11
ClosedThrottleorIdleAdjustment–Pedal-StartVehicles.........................................................................14-12
HowtoMeasureGroundSpeed...............................................................................................................14-13
EngineRPMAdjustment.........................................................................................................................14-13
AirIntakeSystem.......................................................................................................................................14-14
AirFilter.................................................................................................................................................14-15
AirCleanerRemoval...............................................................................................................................14-15
AirCleanerInstallation............................................................................................................................14-15
FuelLine....................................................................................................................................................14-16
2018CaféExpressMaintenanceandServiceManualPagevii

FuelLineRemoval..................................................................................................................................14-16
FuelLineInstallation...............................................................................................................................14-17
FuelPumpModule......................................................................................................................................14-18
GeneralInformation................................................................................................................................14-18
FuelPumpModuleRemoval...................................................................................................................14-18
FuelPumpModuleInstallation.................................................................................................................14-18
FuelTank...................................................................................................................................................14-21
GeneralInformation................................................................................................................................14-21
FuelTankRemoval.................................................................................................................................14-21
FuelTankDisposal.................................................................................................................................14-22
FuelTankStorage..................................................................................................................................14-22
FuelTankInstallation..............................................................................................................................14-22
FuelFilter...................................................................................................................................................14-23
GeneralInformation................................................................................................................................14-23
FuelFilterRemoval.................................................................................................................................14-23
FuelFilterInstallation..............................................................................................................................14-24
FuelingInstructions–GasolineVehicle........................................................................................................14-24
SECTION15—ExhaustSystem:GasolineVehicles.........................................................................................15-1
Mufer........................................................................................................................................................15-1
MuferRemoval......................................................................................................................................15-1
MuferInstallation....................................................................................................................................15-1
SECTION16—Clutches:GasolineVehicles.....................................................................................................16-1
GeneralInformation.....................................................................................................................................16-1
Troubleshooting...........................................................................................................................................16-1
DriveBelt....................................................................................................................................................16-3
DriveBeltRemoval..................................................................................................................................16-3
DriveBeltInstallation...............................................................................................................................16-3
DriveClutch................................................................................................................................................16-4
DriveClutchRemoval..............................................................................................................................16-5
DriveClutchCleaningandInspection........................................................................................................16-6
DriveClutchDisassembly.........................................................................................................................16-7
InspectionofDriveClutchParts................................................................................................................16-9
DriveClutchAssembly............................................................................................................................16-10
DriveClutchInstallation..........................................................................................................................16-11
DrivenClutch.............................................................................................................................................16-12
DrivenClutchRemoval...........................................................................................................................16-13
DrivenClutchDisassembly......................................................................................................................16-13
DrivenClutchInspection.........................................................................................................................16-14
DrivenClutchAssembly..........................................................................................................................16-14
DrivenClutchInstallation.........................................................................................................................16-16
SECTION17—Transaxle(ED65):GasolineVehicles........................................................................................17-1
GeneralInformation.....................................................................................................................................17-1
ShifterLever............................................................................................................................................17-1
NeutralLockout.......................................................................................................................................17-1
GovernorSystem.....................................................................................................................................17-2
TransaxleService....................................................................................................................................17-2
Lubrication..............................................................................................................................................17-2
ToolsRequiredForThisSection...............................................................................................................17-3
RearHubs...................................................................................................................................................17-4
RearHubRemoval..................................................................................................................................17-4
RearHubInstallation...............................................................................................................................17-4
AxleTubes,AxleShaftsandWheelBearings................................................................................................17-6
AxleTubeandAxleShaftRemoval...........................................................................................................17-6
AxleTubeandAxleShaftInstallation........................................................................................................17-7
RearWheelBearingRemoval..................................................................................................................17-7
RearWheelBearingInstallation................................................................................................................17-7
AxleShaftOilSealRemoval.....................................................................................................................17-7
AxleShaftOilSealInstallation..................................................................................................................17-8
Pageviii2018CaféExpressMaintenanceandServiceManual

TransaxleRemoval......................................................................................................................................17-9
TransaxleInstallation..................................................................................................................................17-13
ShifterCable..............................................................................................................................................17-13
ShifterCableRemoval............................................................................................................................17-13
ShifterCableInstallation.........................................................................................................................17-14
ShifterCableAdjustment.........................................................................................................................17-14
SECTION18—RefreshmentUnit....................................................................................................................18-1
GeneralInformation.....................................................................................................................................18-1
RefreshmentCenterCompartments..........................................................................................................18-1
Cleaning.....................................................................................................................................................18-1
InteriorAluminumSurfaces......................................................................................................................18-1
ExteriorAluminumSurfaces.....................................................................................................................18-1
Drains.....................................................................................................................................................18-2
RefreshmentCenterDoors.......................................................................................................................18-2
CanopyCover.........................................................................................................................................18-2
Windshield..............................................................................................................................................18-2
Canopy.......................................................................................................................................................18-2
CanopyRemoval.....................................................................................................................................18-3
CanopyInstallation..................................................................................................................................18-4
CanopyFrameRemoval..........................................................................................................................18-4
CanopyFrameInstallation........................................................................................................................18-4
UnitMaintenanceandRepairs......................................................................................................................18-5
TrashDrawer..........................................................................................................................................18-5
SlideDoors.............................................................................................................................................18-6
CoffeeDoors...........................................................................................................................................18-7
Containers..............................................................................................................................................18-8
CupHolder..............................................................................................................................................18-8
Index..........................................................................................................................................................Index-1
2018CaféExpressMaintenanceandServiceManualPageix

SECTION1—SAFETY1
Safety
SAFETYDETAILS
ToensurethesafetyofthoseservicingClubCarvehicles,andtoprotectthevehiclesfrompossibledamageresulting
fromimproperserviceormaintenance,theproceduresinthismanualmustbefollowed.
ItisimportanttonotethatthroughoutthismanualtherearestatementslabeledDANGER,WARNING,orCAUTION.
Thesespecialstatementsrelatetospecicsafetyissues,andmustberead,understood,andheededbefore
proceedingwithprocedures.TherearestatementslabeledNOTE,whichprovideotheressentialserviceor
maintenanceinformation.
PERSONALSAFETY
DANGER
•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.The
colorassociatedwithDangerisRED.
WARNING
•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.
ThecolorassociatedwithWarningisORANGE.
CAUTION
•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin
minorpersonalinjury.ThecolorassociatedwithCautionisYELLOW.
MACHINESAFETY
CAUTION
•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould
resultinpropertydamage.
ACAUTION,withoutthesafetyalertsymbol,isintendedformachineandpropertysafety.Itisusedthroughoutthis
manualfollowedbyspecicinstructionstopreventmachineorpropertydamage.FailuretofollowtheseCAUTION
messagescouldresultinmachineorpropertydamage.
INFORMATION
NOTE:Instructionsthatclarifysteps,procedures,orotherinformationinthismanual.
GENERALWARNINGS
Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Other
specicsafetystatementsappearthroughoutthismanualandonthevehicle.
2018CaféExpressMaintenanceandServiceManualPage1-1

1GeneralWarningsSAFETY
DANGER
•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice
area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand
rubbergloveswhenworkingonornearbatteries.
•Gasoline–Flammable!Explosive!Donotsmoke.Keepsparksandamesawayfromthevehicleand
servicearea.Serviceonlyinawell-ventilatedarea.
•Donotoperateengineinanenclosedareawithoutproperventilation.Theengineproducescarbon
monoxide,whichisanodorless,deadlypoison.
•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.If
caughtinastormwhiledrivingaClubCarvehicle,exitthevehicleandseekshelterinaccordancewith
applicablesafetyguidelinesforyourlocation.
WARNING
•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and
CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.
•Donotleavechildrenunattendedinvehicleatanytime.
•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,placethe
Forward/ReversehandleorswitchintheNEUTRALposition,turnthekeyswitchtotheOFFposition,
andremovethekey.Chockthewheelswhenservicingthevehicle.
•Improperuseofthevehicleorfailuretoproperlymaintainitcanresultindecreasedvehicle
performance,seriouspersonalinjury,ordeath.
•Anymodicationorchangetothevehiclethataffectstheelectricalsystem,stabilityorhandlingof
thevehicle,orincreasesmaximumvehiclespeedbeyondfactoryspecications,canresultinserious
personalinjuryordeath.
•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare
inplaceandareeasytoread.
•Forvehicleswithcargobeds,removeallcargo(includingaccessories)beforeraisingthebedor
servicingthevehicle.Ifthevehicleisequippedwithaproprod,ensurethatitissecurelyengaged
whilebedisraised.Donotclosebeduntilallpersonsareclearofcargobedarea.Keephandsclearof
allcrushareas.Donotdropcargobed;lowergentlyandkeepentirebodyclear.Failuretoheedthis
warningcanresultinseriouspersonalinjuryordeath.
•Onlytrainedtechniciansshouldserviceorrepairthevehicle.Anyonedoingevensimplerepairsor
serviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.Theappropriate
instructionsmustbeusedwhenperformingmaintenance,service,oraccessoryinstallation.
•Toavoidunintentionallystartingthevehicle,disconnectthebatteryandsparkplugwire.See
DisconnectingtheBattery-GasolineVehiclesonpage1-3.
•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery
cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or
anyothermetalcomponent.
•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicle.Wearafullfaceshieldand
rubbergloveswhenworkingonornearbatteries.
•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthevehicle.
WARNINGCONTINUEDONNEXTPAGE
Page1-22018CaféExpressMaintenanceandServiceManual

SAFETYGeneralWarnings1
WARNING
•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto
avoidshortingofcomponentsorwiring.
DISABLINGTHEVEHICLE
1.Engageparkbraketolockwheels.
2.TurnthekeyswitchOFFandremovethekey.
3.PlacetheForward/ReversecontrolintheNEUTRALposition.
4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.
DISCONNECTINGTHEBATTERY-GASOLINEVEHICLES
1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.
2.Removepositiveterminalcover.
3.Disconnectthebatterycables,negative(–)cablerst,asshown(Figure1-1).
4.Disconnectthesparkplugwire(s)fromthesparkplug(s).
(Viewedfromdriversideofvehicle)
1.Removepositiveterminalcover.
2.Removenegativebatterycable.
3.Removepositivebatterycable.
Connectbatterycablesinreverseorder.
3167
Figure1-1Top-PostBattery-BatteryCable
Removal-GasolineVehicles
CONNECTINGTHEBATTERY-GASOLINEVEHICLES
1.Connectthebatterycables,positive(+)cablerst.
2.Tightenbatteryterminalsto41in·lb(4.3N·m).
3.CoatterminalswithBatteryT erminalProtectorSpray(CCP/N1014305)tominimizecorrosion.
4.Attachpositiveterminalcover.
5.Connectthesparkplugwire(s)tothesparkplug(s).
2018CaféExpressMaintenanceandServiceManualPage1-3

1GeneralWarningsSAFETY
RECYCLINGLEAD-ACIDBATTERIES
WARNING
•Lead-acidbatteriescontainlead(Pb),othermetals,acidsandothercompounds.Ifimproperlyhandled,
theycancontaminatebothwaterandsoil,causingenvironmentaldamageandpersonalinjury.
Lead-acidbatteriesareidentiedbythesymbolshownbelowandshouldbeproperlyrecycled(Figure1-2).They
cannotbedisposedasmunicipalwasteandmustbecollectedseparately.Responsibilityforenvironmentalprotection
mustbeshared,notonlybythemanufacturersofthebatteries,butbypeoplewhousethebatteriesaswell.Please
contactyournearestClubCardealerordistributorforinformationonhowtoproperlyrecycleyourbatteries.
1403
Figure1-2DisposeofLead-acidBatteriesProperly
Page1-42018CaféExpressMaintenanceandServiceManual

SAFETYGeneralWarnings1
INTERNATIONALSAFETYSYMBOLSONBATTERIES
Anyoneusing,repairing,orservicingthevehiclemustunderstandandheedthesafetysymbolsonthevehiclebattery
orbatteries.
_
1.Shieldeyes.3.Nosmoking,noopenames,nosparks.5.Batteryacidhazard.
2.Readandfollowoperatinginstructions.4.Keepawayfromchildren.6.Explosivegashazard.
RefertoGeneralWarningsformoreinformation.
1642
Figure1-3InternationalSafetySymbolsonBatteries
2018CaféExpressMaintenanceandServiceManualPage1-5

PaginationPage
1GeneralWarningsSAFETY
Page1-62018CaféExpressMaintenanceandServiceManual

SECTION2—VEHICLESPECIFICATIONS2
VehicleSpecications
VEHICLESPECIFICATIONS
NOTE:Enginehorsepowerandtorquespecicationsareprovidedbytheenginemanufacturer.Actualhorsepower
andtorqueinusemaydifferandaredependentonenvironmentalconditionsaswellasmaintenance
conditionoftheengine.
SPECIFICATIONSCAFEEXPRESS
POWERSOURCEGASOLINE
Engine:4cycle,OHC,404cc,14.0Horsepower(10.4kW)ratedengine@3600RPM(perSAEJ1940),
singlecylinder,aircooled,withsplashlubricationsystem●
Fuelsystem:Electronicfuelinjection(EFI),high-pressurerotaryfuelpumpwith10micronfuellter●
Battery:12-volt,Top-PostBattery●
Governor:Automaticgroundspeedsensing,internallygearedintransaxle●
Ignition:DigitalCDIwithelectronicRPMlimiter●
Transaxle:Precisionhelicalgears,forward/reversewithneutralposition(11.47:1forward;15.63:1reverse),
withoptionallimitedslipdifferential●
Electricalsystem:12volt,525CCA,85minutereservecapacity●
GasolineVehicleElectricalChargingSystem:
23ampsatmax.RPM.●
Torqueconverter:Automatic,variablespeed,drytype●
STEERING/SUSPENSION/BRAKES
Steering:Self-adjustingrackandpinion●
Suspension:Independentleafspringwithdualhydraulicshocks●
Brakes:Mechanicalbrakecablesystemtomanually-adjusteddrumbrakesonallfourwheels.Parkbrake
isautomaticallyreleased.Multi-latchratchetandpawl.●
BODY/CHASSIS
Frame/chassis:TwinI-Beamweldedaluminum●
Sideandrearbody:Aluminum●
Frontbody:ArmorFlex®●
Frontbodynish:Automotive-gradepaintwithclear-coatnish●
Tires:20x10-10tubeless,6-plyratedloadrangefrontandrear●
DIMENSIONS/WEIGHT
Overalllength:Standardconguration
AddforHeavy-DutyBumper:1.8in(4.5cm)125.5in(318.7cm)
Overallwidth
withmirrors:
51.4in(130.5cm)
62.6in(159.0cm)
Overallheight:atsteeringwheel47.1in(119.6cm)
Overallheight:withcanopy70.7in(179.5cm)
Wheelbase78.1in(198.3cm)
Groundclearance5.2in(13.2cm)
Frontwheeltread36.6in(92.9cm)
2018CaféExpressMaintenanceandServiceManualPage2-1

2VehicleSpecicationsVEHICLESPECIFICATIONS
SPECIFICATIONSCAFEEXPRESS
POWERSOURCEGASOLINE
Rearwheeltread39.5in(100.3cm)
Weight:StandardgasolinevehiclewithCafeExpressunit(dryfueltank)
Curbweight:
1147lb(520.2kg)
1175lb(532.9kg)
Maximumforwardspeed12to14mph(19to23km/h)
Outsideclearancecircle(diameter)248.5in(631.19cm)
Turningradius(perSAEJ695)119in(302.2cm)
Intersectingaisleclearance52.5in(133.3cm)
Floorboardheight7.2in(18.2cm)
Loadbedsize:CafeExpressunitdimensions56.7x50.5x41.5in
(144x128.2x105.4cm)
Vehicleratedcapacity:Levelsurfaceonly850lb(385.6kg)
Standardseatingcapacity:(persons)2
LIQUIDCAPACITIES
Enginecrankcase40.5-oz(1.2L)
Transaxle67.6-oz(2L)
Fueltank4.6gallons(17.4L)
TIREPRESSURE
Frontandrear28to32psig
(193to221kPa)
NOISEANDVIBRATION
Drive-bynoiseleveltooperator
Testmethod:EN12053:2001
71.3dBa
Uncertainty:2dBa
Vibrationatdriver'sseat
Testmethod:EN13059:2002
0.6(m/s2.)2
Uncertainty:0.18(m/s2.)2
Page2-22018CaféExpressMaintenanceandServiceManual