Club Car V-GLIDE Manual

Club Car
MANUAL NUMBER 102397604 
EDITION CODE 1203A00000
V-GLIDE 36-VOLT 
ELECTRIC VEHICLES
2004
MAINTENANCE
SERVICE
SUPPLEMENT

2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement 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 supplement provides detailed information for the maintenance and repair of V-Glide 36-Volt electric vehi-
cles and should be used in conjunction with the 2004 DS Golf Car Maintenance and Service Manual (CCI P/
N 102397601).
If you do not have a 2004 DS Golf Car Maintenance and Service Manual, you may order one from your local
Club Car representative.
This supplement, in addition to the 2004 DS Golf Car Maintenance and Service Manual, should be thoroughly
reviewed prior to servicing the vehicle.The procedures provided must be properly implemented, and the DAN-
GER, WARNING and CAUTION statements must be heeded.
This supplement was written for the trained technician who already has 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 tech-
nician.
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 supplement, used in conjunction with the 2004 DS Golf Car Maintenance and Service Manual, covers all
aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle.
If it appears that a service question is not answered in this supplement, you may write to us at: Club Car, Inc.,
P. O. Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car
Technical Service Representative at [phone], ext. 3580.
This supplement does not contain maintenance and service procedures for the battery charger. Contact your
local Club Car representative for information on how to obtain the appropriate battery charger maintenance
and service manual.
Copyright © 2003 Club Car, Inc.
Club Car and ArmorFlex are registered
trademarks of Club Car, Inc.
This manual effective July 28, 2003.

Page ii 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
∆
WARNING
•Read Section 1 – Safety in the DS Golf Car Maintenance and Service Manual 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 distributors and 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 supplement. See the limited warranty found in
the vehicle owner’s manual or write to: Club Car, Inc., P.O. Box 204658, Augusta, GA 30917-4658,
USA, Attention: Warranty Administration.

2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page iii
CONTENTS
SECTION 10 – PERIODIC MAINTENANCE
General Warning ............................................................................................................................... 10-1
General Information .......................................................................................................................... 10-2
Periodic Service Schedule ................................................................................................................ 10-2
Periodic Lubrication Schedule .......................................................................................................... 10-4
SECTION 11 – ELECTRICAL SYSTEM AND TESTING
General Information .......................................................................................................................... 11-1
Electrical Circuits .............................................................................................................................. 11-1
Control Circuit ............................................................................................................................... 11-1
Power Circuit ................................................................................................................................ 11-2
Charge Circuit ............................................................................................................................... 11-2
Wiring Diagram ................................................................................................................................. 11-4
Troubleshooting Guide ..................................................................................................................... 11-5
Test Procedures ............................................................................................................................... 11-7
Index of Test Procedures .............................................................................................................. 11-7
SECTION 12 – ELECTRICAL COMPONENTS
Key Switch ........................................................................................................................................ 12-1
Forward/Reverse Anti-Arcing Limit Switch ....................................................................................... 12-3
Accelerator Pedal Limit Switch ......................................................................................................... 12-3
Reverse Buzzer ................................................................................................................................ 12-4
Solenoid ............................................................................................................................................ 12-5
Resistors ........................................................................................................................................... 12-6
Wiper Switch ..................................................................................................................................... 12-8
Forward/Reverse Switch ................................................................................................................... 12-14
Charger Receptacle .......................................................................................................................... 12-15
Receptacle Fuse Link ................................................................................................................... 12-17
SECTION 13 – BATTERIES
General Information .......................................................................................................................... 13-1
Common Misconceptions About Batteries ........................................................................................ 13-3
Battery Replacement ........................................................................................................................ 13-3

Page iv 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
Battery Care ..................................................................................................................................... 13-4
Preventive Maintenance ............................................................................................................... 13-4
Self-Discharge .............................................................................................................................. 13-5
Electrolyte Level ........................................................................................................................... 13-5
Vibration Damage ........................................................................................................................ 13-6
Battery Charging .............................................................................................................................. 13-6
Charger Does Not Shut Off Automatically .................................................................................... 13-7
Deep-Discharge ........................................................................................................................... 13-7
Early Excessive Discharging ........................................................................................................ 13-7
Incoming AC Service .................................................................................................................... 13-7
Fleet Rotation ............................................................................................................................... 13-7
Numbering Vehicles and Chargers .............................................................................................. 13-7
Battery Troubleshooting Chart ......................................................................................................... 13-8
Battery Testing ................................................................................................................................. 13-9
Battery Charger Test .................................................................................................................... 13-9
On-Charge Voltage Test .............................................................................................................. 13-9
Hydrometer Test .......................................................................................................................... 13-9
Discharge Test ............................................................................................................................. 13-11
Battery Troubleshooting Examples .............................................................................................. 13-13
Battery Storage ................................................................................................................................ 13-14
Charging a Battery Pack that has Low Voltage ................................................................................ 13-14
SECTION 14 – BATTERY CHARGER
Refer to the appropriate battery charger maintenance and service manual.
SECTION 15 – MOTOR
General Information ......................................................................................................................... 15-1
External Motor Testing ..................................................................................................................... 15-1
Motor ................................................................................................................................................ 15-3
Motor Component Testing and Inspection ....................................................................................... 15-5
Armature ...................................................................................................................................... 15-5
Field Windings Inspection ............................................................................................................ 15-6
Motor Components ....................................................................................................................... 15-7
Bearing Inspection ....................................................................................................................... 15-7
Bearing Removal .......................................................................................................................... 15-9
Bearing Installation ....................................................................................................................... 15-9
Reconditioning the Motor ................................................................................................................. 15-9
Motor Assembly ............................................................................................................................... 15-10
Motor Installation .............................................................................................................................. 15-11

2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page v
SECTION 16A – TRANSAXLE (TYPE G)
Transaxle Identification ..................................................................................................................... 16a-1
Lubrication ........................................................................................................................................ 16a-1
Axle Bearing and Shaft ..................................................................................................................... 16a-1
Axle Shaft ..................................................................................................................................... 16a-1
Axle Bearing ................................................................................................................................. 16a-4
Transaxle .......................................................................................................................................... 16a-4
Transaxle Removal ....................................................................................................................... 16a-5
Transaxle Disassembly, Inspection, and Assembly .......................................................................... 16a-7
Transaxle Disassembly and Inspection ........................................................................................ 16a-7
Transaxle Assembly ..................................................................................................................... 16a-9
Transaxle Installation ........................................................................................................................ 16a-10
SECTION 16B – TRANSAXLE (TYPE K)
Transaxle Identification ..................................................................................................................... 16b-1
Lubrication ........................................................................................................................................ 16b-1
Axle Bearing and Shaft ..................................................................................................................... 16b-1
Axle Shaft ..................................................................................................................................... 16b-1
Axle Bearing ................................................................................................................................. 16b-4
Transaxle .......................................................................................................................................... 16b-5
Transaxle Removal ....................................................................................................................... 16b-5
Transaxle Disassembly, Inspection, and Assembly .......................................................................... 16b-8
Transaxle Disassembly and Inspection ........................................................................................ 16b-8
Transaxle Assembly ..................................................................................................................... 16b-10
Shimming the Transaxle ............................................................................................................... 16b-12
Transaxle Installation ........................................................................................................................ 16b-13
SECTION i – INDEX

2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 10-1
10
SECTION 10 – PERIODIC MAINTENANCE
GENERAL WARNING
The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser-
viced. Service technicians should become familiar with these general safety statements, which can be found
throughout this manual. Also, other specific safety statements appear throughout this manual and on the vehi-
cle.
∆
DANGER
•Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full
face shield and rubber gloves when working on or near batteries.
•Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or
clothing. Antidotes:
- External: Flush with water. Call a physician immediately.
-Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
-Eyes: Flush with water for 15 minutes. Call a physician immediately.
∆ WARNING
•Follow the procedures exactly as stated in this manual, and heed all DANGER,WARNING, and
CAUTION statements in this manual as well as those on the vehicle and battery charger.
•Only trained technicians should repair or service the vehicle or battery charger. Anyone doing
even simple repairs or service should have knowledge and experience in electrical and
mechanical repair.
•Prior to servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF,
remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Chock the
wheels when servicing the vehicle.
•To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figure 10-1,
Page 10-2).
•Wear safety glasses or approved eye protection when servicing the vehicle or battery charger.
Wear a full face shield and rubber gloves when working on or near batteries.
•Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the
vehicle or battery charger.
•Moving parts! Do not attempt to service the vehicle while it is running.
•Hot! Do not attempt to service hot motor or resistors. Failure to heed this warning could result
in severe burns.
•Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
•Check the vehicle owner’s manual for proper location of all vehicle safety and operation
decals and make sure they are in place and are easy to read.
WARNING CONTINUED ON NEXT PAGE...

PERIODIC MAINTENANCE General Information
Page 10-2 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
10
∆
WARNING
•Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
•Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic
floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold
vehicle in raised position. Use approved jack stands of proper weight capacity to support the
vehicle and chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
•If wires are removed or replaced, make sure wiring and wire harness are properly routed and
secured. Failure to properly route and secure wiring could result in vehicle malfunction,
property damage, personal injury, or death.
•Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance, severe personal injury, or death.
• Do not leave children unattended on vehicle.
GENERAL INFORMATION
See General Warning on page 10-1.
To ensure trouble-free vehicle performance, it is very important to follow an established preventive maintenance
program. Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that
can result from neglect. Any vehicle not functioning correctly should be removed from use until it is properly
repaired.This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions.
Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service.
PERIODIC SERVICE SCHEDULE
∆
WARNING
•Service, repairs, and adjustments must be made per instructions in the DS Golf Car
Figure 10-1 V-Glide Battery Configuration
1
2
3
4
6
5
FRONT
OF VEHICLE
DISCONNECT
BATTERY CABLES BEFORE
WORKING ON VEHICLE

PERIODIC MAINTENANCE Periodic Service Schedule
2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 10-3
10
Maintenance and Service Manual and this supplement.
NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, the preventive
maintenance procedures should be performed more often than recommended in the periodic ser-
vice and lubrication schedules.
Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to
keep the vehicle in optimum operating condition.
∆
WARNING
•If any problems are found during scheduled inspection or service, do not operate the vehicle
until repairs are made. Failure to make necessary repairs could result in fire, property
PERIODIC SERVICE SCHEDULE
REGULAR INTERVAL SERVICE
Daily service by owner Batteries Charge batteries after each use.
Weekly service by owner
Batteries Check electrolyte level. Add water if
necessary. See Section 13 – Batteries.
Monthly service by owner
or trained technician
Batteries Wash battery tops and clean terminals
with baking soda/water solution.
Tires
Check air pressure and adjust if
necessary. See Section 2 –
Specifications in the DS Maintenance
and Service Manual.
Wiper switch
Check for cracks or other damage; make
sure switch is securely fastened to frame.
Check movable contact for correct
operation.
General vehicle Wash battery compartment and underside
of vehicle.
Semiannual service by trained
technician only (every 50 hours of
operation or 100 rounds of golf)
Brake system
Check brake shoes; replace if necessary.
See Section 6 – Wheel Brake
Assemblies in the DS Maintenance and
Service Manual.
Lubricate brake slide. See Periodic
Lubrication Schedule on page 10-4.
See also Section 6 – Wheel Brake
Assemblies in the DS Maintenance and
Service Manual.
Check brake cables for damage; replace if
necessary.
Electrical wiring and connections Check for tightness and damage.
Forward/Reverse switch Check condition of contacts and wire connections; make sure connections are
tight.
Front wheel alignment and camber
Check and adjust as required. See
Section 7 – Steering and Front
Suspension in the DS Maintenance and
Service Manual.
Annual service by trained
technician only (every 100 hours
of operation or 200 rounds of golf)
Batteries If batteries are not performing as
expected, see Section 13 – Batteries.

PERIODIC MAINTENANCE Periodic Lubrication Schedule
Page 10-4 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
10
damage, severe personal injury, or death.
PERIODIC LUBRICATION SCHEDULE
PERIODIC LUBRICATION SCHEDULE
REGULAR INTERVAL SERVICE LUBRICATION
POINTS RECOMMENDED LUBRICANT
Semiannually by owner
or trained technician (every
50 hours of operation or
100 rounds of golf)
Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151)
Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151)
Accelerator push rod pivots and
mounts Dry Moly Lube (CCI P/N 1012151)
Forward/Reverse switch contacts
and charger receptacle WD 40
Brake slides Dry Moly Lube (CCI P/N 1012151)
Front suspension (5 fittings) Chassis Lube (EP NLGI Grade 2)
Annually by trained
technician only (every 100
hours of operation or 200
rounds of golf)
Check/fill transaxle to plug level 22 oz. (0.67 liter) SAE 30 WT. API, class
SE, SF, or SG oil (or higher)
Figure 10-2 V-Glide 36-Volt Vehicle Lubrication Points
1
2
3
4
5
6
7
5
7
5
3
4
4
FLOORBOARD
1
3
2
6
6
2
3
1
3
66
6

2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 11-1
11
SECTION 11 – ELECTRICAL SYSTEM AND
TESTING
∆
DANGER
• See General Warning, Section 10, Page 10-1.
∆
WARNING
• See General Warning, Section 10, Page 10-1.
GENERAL INFORMATION
To properly service and maintain the V-Glide 36-volt vehicle, it is necessary to understand the electrical cir-
cuitry and the functions of all the electrical components (Figure 11-2, Page 11-4) . On the V-Glide 36-volt vehi-
cle, there are three separate circuits: 1) the control circuit, 2) the power circuit, and 3) the charge circuit. A
reverse buzzer is also included on every vehicle.
ELECTRICAL CIRCUITS
There are three separate circuits which make up the electrical system of the V-Glide 36-volt vehicle:
• Control circuit
• Power circuit
• Charge circuit
A reverse buzzer is also included on every vehicle.
CONTROL CIRCUIT
The control circuit consists of the following:
• Key switch
• Forward/Reverse anti-arcing limit switch
• Accelerator pedal limit switch
• Solenoid
• Connecting wires
The key switch has two positions, ON and OFF, and is used to disable (open) the control circuit when the vehi-
cle is not in use. With the key in the OFF position, the vehicle will not operate.
The Forward/Reverse anti-arcing limit switch prevents arcing on the contacts of the Forward/Reverse switch.
When the vehicle is in NEUTRAL, the limit switch is open.The Forward/Reverse anti-arcing limit switch closes
only after full contact has been made on the Forward/Reverse switch. As the Forward/Reverse switch is dis-
engaged, the Forward/Reverse anti-arcing limit switch opens the power circuit by opening the control circuit
before the contacts are separated. By using the Forward/Reverse anti-arcing limit switch to control power to
the Forward/Reverse switch, arcing is prevented on the contacts of the Forward/Reverse switch.

ELECTRICAL SYSTEM AND TESTING Electrical Circuits
Page 11-2 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
11
Control Circuit, Continued:
As the accelerator pedal is pressed, the lever of the accelerator pedal limit switch is released by the V-Glide
wiper arm, closing that portion of the control circuit. When the accelerator pedal is fully upright, the V-Glide
wiper arm presses the accelerator pedal limit switch lever and keeps that portion of the control circuit open.
When the accelerator pedal is pressed (which closes the accelerator pedal limit switch) and the Forward/
Reverse handle is in FORWARD or REVERSE (which closes Forward/Reverse anti-arcing limit switch), and
key switch is in the ON position, the control circuit is complete.The solenoid coil (enclosed in the solenoid) will
then be activated and the solenoid power contacts will close, allowing power to reach the V-Glide wiper switch.
The reverse buzzer is a warning device that is activated when the Forward/Reverse handle is placed in
REVERSE.The reverse buzzer will sound continuously until the vehicle is shifted to NEUTRAL or FORWARD.
POWER CIRCUIT
The power circuit consists of the following:
• V-Glide wiper switch contacts
• Resistors
• Forward/Reverse switch
• Solenoid power contacts
• Motor
• Batteries
• All connecting wires
The motor and batteries are discussed in separate sections in this manual. See Section 15 – Motor. See
also Section 13 – Batteries.
When the control circuit is closed, the vehicle will start in first speed. As the accelerator pedal is pressed, the
brush on the wiper switch arm moves across the contacts until the last contact is reached and full speed is
attained. The V-Glide wiper switch brush and contacts conduct the motor current through or around each
resistor, thereby controlling the speed (Figure 11-1, Page 11-3) .
The Forward/Reverse switch changes the direction of vehicle movement by changing the direction of electrical
current through the motor, and consequently, the direction the motor turns. By limiting maximum voltage avail-
able in REVERSE to one-half that available in FORWARD, maximum vehicle speed in REVERSE is limited to
one-half the maximum vehicle speed in FORWARD.
CHARGE CIRCUIT
The charge circuit consists of the following:
• Battery charger
• Charger plug
• Charger receptacle
• Onboard fuse link
• Batteries
The batteries are discussed in a separate section in this manual. See Section 13 – Batteries. The battery
charger is discussed in the battery charger maintenance and service manual. See the appropriate battery
charger maintenance and service manual.

ELECTRICAL SYSTEM AND TESTING Electrical Circuits
2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 11-3
11
The charger plug and receptacle connection is a critical link between the charger and the vehicle battery cir-
cuit. The contacts in the receptacle must grip the plug blades well enough to create enough pressure or drag
for an adequate electrical connection. If little or no drag is felt, the receptacle or plug must be replaced. If
either the plug or receptacle is damaged or feels hot when charging, one or both must be replaced. See
Charger Receptacle Inspection, Section 12, Page 12-16.
The onboard receptacle fuse link provides additional protection for the vehicle charging circuit. The fuse is
rated for use with a Club Car Accu-Power Charger only. If it is blown, the cause should be determined before
the fuse is replaced. Batteries in a vehicle with a blown fuse will not accept a charge. See Receptacle Fuse
Link, Section 12, Page 12-17.
Figure 11-1 Speed Controller
NO. 6 WHITE FROM V-GLIDE WIPER SWITCH
NO. 6 GRAY TO A2 TERMINAL OF MOTOR
SOLID BLACK LINE IS CURRENT PATH
OFF
1st SPEED
2nd SPEED
LAST SPEED
WIPER SWITCH ARM POSITION RESISTOR COILS

ELECTRICAL SYSTEM AND TESTING Wiring Diagram
Page 11-4 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
11
WIRING DIAGRAM
Figure 11-2 Wiring Diagram
-
+
+
-
-
-
+
+
+
+
-
-
A1
S2
A2
S1
1
2
3
4
6
5
1
+
-
WHITE
GREEN
1
2
BULLET
CONNECTOR
RED
RED
BLACK BLACK
WHITE
SPEED
SWITCH
WHITE
FORWARD /
REVERSE
SWITCH
REVERSE
BUZZER
FUSE AND
RECEPTACLE
ORANGE
BLUE
RED
WHITE
WHITE
SOLENOID
GREEN
GREEN
BLUE
BLACK
WHITE
RED
GREEN
WHITE
ORANGE
YELLOW
GREEN
BLUE
BLACK
BROWN
PURPLE
GREEN
RED
LIMIT
SWITCH
YELLOW
KEY
SWITCH
ORANGE
RED
WHITE
BLUE
BATTERY
BANK
BLACK
GREEN
WHITE
GRAY
BLACK
RESISTOR
BOARD
MOTOR
BROWN
PURPLE
GRAY
RED
SOLENOID
SNUBBER
WHITE
BLACK
RED
YELLOW
GREEN
WHITE
WHITE
DIODE

ELECTRICAL SYSTEM AND TESTING Troubleshooting Guide
2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 11-5
11
TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
Vehicle will not operate – no solenoid
click Battery connections Test Procedure 1 – Batteries/Voltage Check on page 11-8
Batteries discharged Test Procedure 1 – Batteries/Voltage
Check on page 11-8
Loose wiring at key switch Test Procedure 2 – Key Switch on
page 11-8
Failed key switch Test Procedure 2 – Key Switch on
page 11-8
Loose wiring at Forward/Reverse anti-
arcing limit switch Test Procedure 3 – Forward/Reverse Anti- Arcing Limit Switch on page 11-9
Failed Forward/Reverse anti-arcing limit
switch Test Procedure 3 – Forward/Reverse Anti- Arcing Limit Switch on page 11-9
Cam is not activating Forward/Reverse
anti-arcing limit switch Test Procedure 3 – Forward/Reverse Anti- Arcing Limit Switch on page 11-9
Accelerator rod disconnected See Section 5 – Accelerator and Brake Pedal Group in the DS Golf Car
Maintenance and Service Manual
Loose wiring at accelerator pedal limit
switch Test Procedure 4 – Accelerator Pedal Limit Switch on page 11-9
Disconnected or improperly connected
wires at accelerator pedal limit switch Test Procedure 4 – Accelerator Pedal Limit Switch on page 11-9
Failed accelerator pedal limit switch Test Procedure 4 – Accelerator Pedal
Limit Switch on page 11-9
Loose solenoid switch
Test Procedure 10 – Solenoid Contacts
(Power Off) on page 11-15 and Test
Procedure 11 – Solenoid Contacts (Power
On) on page 11-15
Failed solenoid coil Test Procedure 5 – Solenoid Activating
Coil on page 11-10
Vehicle will not operate – solenoid
clicks Loose wiring at Forward/Reverse switch Test Procedure 8 – Forward/Reverse Switch on page 11-12
Failed Forward/Reverse switch contacts Test Procedure 10 – Solenoid Contacts
(Power Off) on page 11-15
Failed solenoid contacts Test Procedure 10 – Solenoid Contacts
(Power Off) on page 11-15
Loose wiring or broken wire connections
at V-Glide wiper switch Test Procedure 12 – V-Glide Wiper Switch on page 11-16
V-Glide wiper switch brush or contacts are
dirty, burned, corroded, shorted, or worn
Test Procedure 12 – V-Glide Wiper Switch
on page 11-16
See Section 12 – Electrical Components
Incorrect wiring at V-Glide wiper switch See Wiring Diagram on page 11-4
Loose wiring at motor Test Procedure 9 – Motor on page 11-14
Motor circuits open Test Procedure 9 – Motor on page 11-14,
see also Section 15 – Motor
Motor brushes worn Test Procedure 9 – Motor on page 11-14
Troubleshooting Guide continued on next page...

ELECTRICAL SYSTEM AND TESTING Troubleshooting Guide
Page 11-6 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
11
Vehicle skips one or more speeds Loose or broken wire connections at
V-Glide wiper switch Test Procedure 12 – V-Glide Wiper Switch on page 11-16
V-Glide wiper switch brush contacts are
dirty, burned, corroded, shorted, or worn
Test Procedure 7 – Resistors on
page 11-11
See Section 12 – Electrical Components
Incorrect wiring at V-Glide wiper switch See Wiring Diagram on page 11-4
Loose or broken resistor Test Procedure 7 – Resistors on
page 11-11
Vehicle runs slowly Poor wire connections at V-Glide wiper
switch See Wiring Diagram on page 11-4
V-Glide wiper switch contact points dirty or
worn Test Procedure 12 – V-Glide Wiper Switch on page 11-16
Loose or corroded battery terminals Test Procedure 1 – Batteries/Voltage Check on page 11-8
See Section 13 – Batteries
Incorrect wiring at batteries See Wiring Diagram on page 11-4
Failed batteries See Section 13 – Batteries
Batteries not fully charged Refer to the appropriate battery charger
maintenance and service manual
Accelerator rod is improperly adjusted See Section 5 – Accelerator and Brake Pedal Group in the DS Golf Car
Maintenance and Service Manual
Loose wiring at motor Test Procedure 9 – Motor on page 11-14
Worn or misaligned motor brushes Section 15 – Motor
Dirty or rough motor commutator Section 15 – Motor
Dragging brakes See Section 5 – Accelerator and Brake Pedal Group in the DS Golf Car
Maintenance and Service Manual
Under-inflated or flat tires See Section 8 – Wheels and Tires in the DS Golf Car Maintenance and Service
Manual
Vehicle operates in first speed when
the Forward/Reverse switch is placed
in FORWARD or REVERSE with the key
switch OFF
Solenoid contacts are welded closed Test Procedure 10 – Solenoid Contacts
(Power Off) on page 11-15
Vehicle operates in first speed when
the Forward/Reverse switch is placed
in FORWARD or REVERSE with key
switch ON
Incorrect wiring at V-Glide wiper switch See Wiring Diagram on page 11-4
Accelerator pedal limit switch failed in the
closed position Test Procedure 4 – Accelerator Pedal Limit Switch on page 11-9
Accelerator rod is bent or improperly
adjusted
See Section 5 – Accelerator and Brake
Pedal Group in the DS Golf Car
Maintenance and Service Manual
V-Glide wiper switch brush or accelerator
pedal is stuck
See Section 5 – Accelerator and Brake
Pedal Group in the DS Golf Car
Maintenance and Service Manual
V-Glide wiper switch is improperly
adjusted See Wiper Switch, Section 12 – Electrical Components
Troubleshooting Guide continued on next page...
TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION

ELECTRICAL SYSTEM AND TESTING Test Procedures
2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 11-7
11
TEST PROCEDURES
The entire electrical system can be tested using the following procedures without major disassembly of the
vehicle. See following WARNING.
∆ WARNING
•If wires are removed or replaced, make sure wiring and wire harness is properly routed and
secured. Failure to properly route and secure wiring could result in vehicle malfunction,
property damage, personal injury, or death.
INDEX OF TEST PROCEDURES
1. Batteries/Voltage Check
2. Key Switch
3. Forward/Reverse Anti-Arcing Limit Switch
4. Accelerator Pedal Limit Switch
5. Solenoid Activating Coil
6. Reverse Buzzer
7. Resistors
8. Forward/Reverse Switch
9. Motor
10. Solenoid Contacts (Power Off)
11. Solenoid Contacts (Power On)
12. V-Glide Wiper Switch
Vehicle will operate in Forward but not
in Reverse, or will operate in Reverse
but not in Forward
Improper actuation or faulty Forward/
Reverse anti-arcing limit switch Test Procedure 3 – Forward/Reverse Anti- Arcing Limit Switch on page 11-9
Dirty or corroded Forward/Reverse switch
contacts See Section 12 – Electrical Components
Incorrect wiring at batteries See Wiring Diagram on page 11-4
Vehicle not being fully charged Loose wires at charger receptacle,
batteries or Forward/Reverse switch Refer to the appropriate battery charger maintenance and service manual
Improper engagement of charger plug and
receptacle Refer to the appropriate battery charger maintenance and service manual
Blown onboard receptacle fuse Refer to the appropriate battery charger
maintenance and service manual
Incorrect incoming AC charger voltage Refer to the appropriate battery charger
maintenance and service manual
Charger output is low Refer to the appropriate battery charger
maintenance and service manual
Charger cord and plugs Refer to the appropriate battery charger
maintenance and service manual
TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION

ELECTRICAL SYSTEM AND TESTING Test Procedures
Page 11-8 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
11
TEST PROCEDURE 1 – BATTERIES/VOLTAGE CHECK
See General Warning, Section 10, Page 10-1.
1. With batteries connected and using a multimeter set to 200 volts DC, place red (+) probe on the positive
(+) post of battery no. 1 and the black (–) probe on the negative (–) post of battery no. 6 (Figure 11-3,
Page 11-8). The multimeter should indicate at least 36 volts with the batteries fully charged. If not, check
for loose battery connections or a battery installed in reverse polarity.The batteries are explained in detail
in another section. See Section 13 – Batteries.
TEST PROCEDURE 2 – KEY SWITCH
See General Warning, Section 10, Page 10-1.
1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in
General Warning, Section 10, Page 10-1.
2. Place the red (+) probe of a multimeter (set at Ω) on the forward terminal of the Forward/Reverse switch
and place the black (–) probe on the upper (COM) terminal of the Forward/Reverse anti-arcing limit
switch (Figure 11-4, Page 11-8). With the key in the OFF position, the reading should be no continuity.
3. Insert the key and turn the key switch to the ON position. The reading should be continuity.
4. If the reading is incorrect at either of steps 2 or 3, check the wires and terminals. If no problems are found
with the wires or terminals, replace the key switch. See Section 12 – Electrical Components.
5. Connect the battery cables, positive (+) cable first, and tighten to 110 in-lb (12.4 N·m). Coat with Battery
Te r minal Protector Spray (CCI P/N 1014305) to minimize corrosion.
Figure 11-3 Battery Test Figure 11-4 Key Switch Test
-+
2m
20
m
200
m
2k 200
200
200
200
20
2
200
m
500
20k
200k
2000
k
Ω
Ω
1000 OFF
WAVETEK 5XL
V
V
V
A
!!
COM 200nA
MAX
1000 ---
750V FUSED
1
2
3
4
6
5
-+
2m
20
m
200
m
2k 200
200
200
200
20
2
200
m
500
20k
200k
2000
k
Ω
Ω
1000 OFF
WAVETEK 5XL
V
V
V
A
!!
COM 200nA
MAX
1000 ---
750V FUSED
RED WIRE
BLUE WIRE