Golf Cart Service Manuals – All Makes and Models

Golf Cart Service Manuals – All Makes and Models

If you own a golf cart or just inherited one you might just need something to steer you in the right direction to replace part or repair something. Pete has built a pretty extensive library of information for golf cart related stuff. Whether it is for a late model Club Car, Ezgo or Yamaha golf cart. Or a vintage cart like a Harley Davidson golf cart, or the Columbia Par Car Golf Cart he has you covered. Even the older odd ball stuff that has developed a following in recent years like the older Yamaha golf carts G1-G16 models…. Which are quite cool if you wanted to build a street racer. With the all steel tubular chassis and factory independent front suspension make for good bones to build a real screamer… Gas or Electric.

Anyhow, you will find herein all sorts of detailed information like golf cart parts diagrams, golf cart mechanical illustrations and explosion views to see what you need to see clearly and easily. Golf cart repair or service instructions. Step by Step… Detailed information pertaining to specific makes and models of golf carts new and old. All at your finger tips…

This section will only continue to grow and be updated with the latest makes and models once publicly available.

Aluma Car Service Manuals

 

Club Car Service Manuals

 

Columbia Par Car Service Manuals

 

Ezgo Service Manuals

 

Fairplay Service Manuals

 

GEM Car Service Manuals

 

Harley Davidson Service Manuals

 

Polaris-GEM Service Manuals

 

Star Ev Service Manuals

 

Taylor-Dunn Service Manuals

 

Tomberlin Service Manuals

 

Western Service Manuals

 

Yamaha Service Manuals

 

 

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Cool Harley Davidson Golf Cart Stuff

Harley Davidson Golf Cart Parts and Accessories

When building or repairing an older golf cart you need parts. Parts are sometimes hard to come by for certain things. Like where can you go to get vintage Harley Davidson Golf Cart Parts or Accessories. Surely not a the local golf cart shop or parts store. This is where I have loved the invention of the internet because it connected all of the automobilia collectors, gearheads, specialists and technicians to learn things and find things like golf cart service and repair manuals or shop maintenance manuals.

Harley Davidson Electric Golf Cart Parts

Harley Davidson Gas Golf Cart Parts

 

Custom Harley Davidson Golf Cart Seats

 

Harley Davidson Golf Cart Tire and Wheel Deals

 

 

 

 

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Vintage Golf Carts and Parts

Vintage Golf Cart Popularity

If you are looking into purchasing a golf cart or looking for your next project maybe a vintage golf cart is it? if you are anything like Pete or myself cool stuff just gets your heart pounding. I mean – cool to us is anything with an engine that goes fast ” The faster the better”, cars, boats, motorcycles and yes golf carts…. We never guessed we would ever drive a golf cart because we are not golfers but gearheads. Yet here we are building, driving, racing and wrenching on them more and more… crazy how life takes us down roads less traveled.

Anyhow, the vintage stuff is becoming more popular only because of the guys like us that want something different. Outside the norm – Club Car, Ezgo, Yamaha – yea… yea… yea… We sell tons of parts and accessories for all the new stuff, but we also offer quite a bit of parts for the old stuff as well. And if we do not there are other companies that offer them as well. So you can rebuild and restore a vintage golf cart with relative ease knowing alot of the parts you will need are readily available. Vintage Gas Golf Carts are a little harder to find parts sometimes, but only the rare ones… Columbia Par Car Golf Carts, Harley Davidson Golf Carts are still easy to find stuff for the old 2 cycle gas engines from the early 1960’s thru the 1990’s…  As for the electric stuff, man if you can find a solid chassis and cart with good bones and body panels… go for it! all the electric stuff can be upgraded… Think resto-mod! But for a golf cart not your classic or vintage Chevy or Ford!

Cool Looking Vintage Golf Carts

If you are shaking your head saying to yourself a cool looking golf cart? Really? These guys are nuts… Just checkout some of these pictures of cool looking classic and vintage golf carts. Ok.. so we agree not all of them are not so practical but that is what makes them cool…. Who ever said a 1966 Shelby Cobra was practical? But cool… Hell yea! Heck if you have one you want to share with us.. just comment on this post and attach a photo or two below… Even if you are looking to sell one stick it on there maybe someone will see it and buy. Nothing lasts forever …right! I am becoming more and more like Pete these days… I asked him once ” Pete… What is your favorite car? He said the next one! I am like ok… What is it? He says… ” I don’t know!” I love them all and way to many cars I would still like to play with and drive or enjoy… Once I am done working on one or restoring I drive it a few times and have some fun with it then sell it – just to buy another fixer… Ah some I have kept but very few compared to what I have owned over the years… These vintage golf carts are the same thing… I just like to bring things back to life or their former glory. I like to make things better…

Vintage Golf Cart Values

The value of something like a classic car or vintage golf cart is really very weird. It is all relative to what someone is willing to pay for it. Somethings like cars or motorcycles have a pretty solid base because of the popularity and following over the century but a golf cart or quirky things like that have value and we have seen them go for thousands more than when they where new…. Heck, someone just sold a Vintage Major League Baseball Support Vehicle ( The Bull-Pens Three Wheeler Harley Davidson Golf Cart) for like $14,000.00

Craziness huh? Not really… Here are a few other well noted sales over the last decade.

Vintage Golf Cart Parts

 

Vintage Golf Cart Custom Seats

 

Sneaky Pete Go Fast Goodies….

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How To Test Your Golf Cart Batteries

How To Check If Your Golf Cart Batteries Are Still Good

This will be an ongoing How To article because it is important to note the proper way to do something does not mean everyone has the tools required to do so. Surely not the average electric golf cart owner that is starting to experience performance issues with their golf cart. So they start to ponder possible options – which human instinct would suggest oh… great I will just replace the batteries. This is until you call to get someone to do the job for you as it is kinda overwhelming to a novice or someone who has never seen so many batteries in one place before much less wired together, oh and the size and weight…. Jeez those batteries look heavy. Average golf cart battery weight is 60 lbs ea… Then the shocker – the cost associated with replacing your golf cart batteries with a quality battery. Heck even the cheapest of cheapest made in Mexico/Korea black boxes will cost you 90-100 bucks each for a 6 volt, 100-120 each for an 8 volt, and even more for 12 volt batteries.

 

Golf Cart Battery Testing Methods

So back to square one… my golf cart is not running right or providing good range – Example – cannot complete a full 18 holes of golf. How do you determine what is wrong and if or how can you fix it?

Digital Volt Meter Test

 

Hydrometer Test

 

Battery Load Test

For example – On a full charge a good set of golf cart batteries will allow you to surely play a few rounds of golf. Using a 48 volt Club Car for example you can play a round of golf with a new set of fully charged batteries and after round is complete the cart will still be above the 48 volt threshold on the battery banks capacity. One because the start / stop load not very demanding vs all out start stops continuously without letting the golf cart or batteries catch their breath per se… Though this is also because a fully charged 48 volt cart with say 6x 8 volt batteries will be around 51 volts not 48 volts.

Proper Procedure For Load Testing A Golf Cart Battery

1.  Charge the batteries completely. If the batteries do not take a charge this is a good indication they need to be replaced. Unless your golf cart battery charger needs to be replaced or repaired because it is in fact the problem and why the cart is not performing as it should.
2. To get an accurate assessment you will need to make sure they are fully charged ( No Exceptions) and slightly rested ( Cool to your touch-Room Temperature)
3. Check voltage before each test with Digital Volt Meter or If you purchase the Load tester Pete recommends it has a volt meter on it to help facilitate a proper test.
4. Apply the load required based on Quick Guide below
5. Load the batteries to the advertised Amp Hour Ah rating at 20 hrs…. This information can be found on the top of all golf cart batteries – See learn how to interpret a Battery Information Sticker.
6. Test results you will want to see. See Golf Cart Battery Load Testing Results Explained below… the following to confirm they are still in good shape.

Quick Golf Cart Battery Capacity Guide –

• Average 6 volt golf cart batteries are 210-225Ah,
• Average 8 volt golf cart batteries are 165-170Ah, and
• Average 12 volt golf cart batteries are 150Ah….

Golf Cart Battery Load Testing Results Explained

• 6 volt battery will need to maintain 5 volts for 15 seconds at the advertised 20hr Ah rating,
• 8 volt battery will need to maintain 7 volts for 15 seconds at the advertised 20hr Ah rating, and then the
• 12 volt battery will need to maintain 11 volts for 15 seconds at the advertised 20hr Ah rating.

Lester Charge/Discharge Tester

 

 

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How To Avoid Motor Damage On Your Electric Golf Cart

Things To Know – How To Avoid Motor Damage On Your New Electric Golf Cart

There are sorts of things to learn and know about your new electric golf cart. How about this one… It is a doosie! How not to blow up or ruin the motor in your electric golf cart. Believe it or not as bullet proof as some of us know an electric golf cart motor to be people never surprise me how they can still destroy on in short order. So being here is another how to article or “Things To Know” about your golf cart.

Basic Do’s and Don’ts For The Electric Golf Cart Owner

This is a quick look guide at the major things you should avoid while operating your electric golf cart. Golf Cart Ownership is another responsibility just like owning a car boat or truck. There are things you need to know, things to maintain and things you just do not attempt to do. Unless ofcourse you have money trees growing in your back yard and just needed the golf cart to go back and forth to get all that money back to the house. If that’s the case  just set aside a handful or three to keep it running and driving properly. For most of us though buying an electric golf cart was a decision we made based on numerous factors – one of which is the super low cost of annual ownership.

Avoid Water

Do not try to drive your golf cart into or thru a puddle you do not know how deep it is. Really I suggest just avoid water at all costs… I mean rain on the road or cart path no worries, but what I am talking about is standing water in your direction of travel. Just avoid it! It will keep your cart cleaner as well.

 

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What Does The Run Tow Switch On My Electric Golf Cart Actually Do?

People ask me this question all the time. Or on other occasions I here someone say they flip the run tow switch off when they leave for the holidays or for vacation or until next season. I can only smile sometimes as I think this guy doesn’t even have a clue – but up until recently most people have had to learn about their golf cart by trial and error or by just experience with issues as a golf cart owner. No much out there in the way of actual useful information unless you are in the know. Accessorizing, Building or Repairing golf carts everyday of your life.

Anyhow, So lets get into why you need to turn your new style golf cart from run to tow mode when it is not able to move under its own power. Meaning you will need to push it, pull and or tow it home. Not because the motor blew up or you broke a drive shaft or the transmission or differential went out like in a car or truck. This actually happens more often then you might think being it is a battery operated thing. People go out and about sometimes not knowing if their golf cart battery charger charged the batteries last night. Or they are really using it one day getting around an event or car show and the batteries just finally die. Or the batteries are just so old they do not provide the motive power or range that they did when they where new. Whatever the scenario is – it happens… and quite frequently. My advise if you use your golf cart often and for regular transportation get a golf cart battery meter or battery state of charge indicator so you know how much juice you still have in your golf cart batteries. This will allow you to better determine range or run time. Not everyone uses a golf cart to play a round of golf anymore. Golf carts have become a very utilitarian type of device or vehicle in today’s society.

 

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How To Revive Your Golf Cart If Your Batteries Are Completely Dead

How to get your golf cart battery charger to charge dead batteries…

This is a scenario that happens a lot more than you might think. In the world of golf carts and our daily lives golf carts get left behind or neglected on a regular basis. When this happens the lead acid batteries in your vehicle drain down over months of neglect to the point the golf cart will not move or operate any longer because the voltage is so low in the system. So being we get calls all the time like ” How do I get my golf cart battery charger to charge my golf cart? The golf cart is completely dead…

The Issue – Old Style Golf Cart Battery Chargers Vs New Style Chargers

In the world of Golf Cart Battery Chargers only recently have the manufacturers come up with a solution to this issue. Old style chargers will only charge once then shut off. So if you leave for months unattended and do not unplug and then plug in again the charger will not charge the batteries again and over time these type of batteries drain down just naturally. ( At a rate of approx. 10% a month) Even faster if the golf cart batteries have a parasitic load on them from say a new golf cart light kit not installed correctly or a sound system like a golf cart Bluetooth sound bar. Though due to recent advances in charging technology you can now purchase a Smart charger for your golf cart that will basically baby sit your batteries while you are away on vacation for the summer or whenever. Just keep a new style golf cart battery charger like the new Lester Summit II Chargers plugged into your golf cart and it will do it’s thing. It will automatically kick on every 10 days to top off your golf cart batteries or if the voltage ever drops below a set number. ( Technically – I think that number is like 2.08 volts per cell. ) If you want to avoid this whole process I am about to explain in the future. Learn More About These Awesome Golf Cart Battery Chargers here –

Get Yours Today and Save BIG!!! Plus Receive Free Shipping! Comes With a 4 Year Manufacturers Warranty – Now That is Piece of Mind! 

How To Make Electric Golf Cart Ownership Easy

Learn even more here with this great article on How to make life easier for the average electric golf cart owner. These are just a few basic tips and tricks I thought would be helpful for the new golf cart owner to consider and keep in mind.

Why Is Your Golf Cart Battery Charger Not Working

Ok… So the first guess or main reason why your golf cart battery charger is not working right now is because the batteries in your golf cart are completely dead. ( Not always but usually 90% of the time) This is because the federal government years ago made it mandatory that all manufacturers of these types of charging systems but a few safe guards into the device to avoid injury to you or another, electrocution or fire hazard.

Example – Your grandson ( AKA Dennis ) Finds grandpa’s battery charger in the garage and your grand daughter is bothering him somehow so he decides to start chasing her around the garage and shocking her by touching the connector on the end of the cord ( designed to be plugged into the golf cart ) to her skin causing harm.

Charger Manufacturers Mandate – All charging devices with an external connection will only be activated when connection is confirmed and a load or voltage is present to avoid possible electrocution or injury. ALL GOLF CART BATTERY CHARGERS MUST SENSE VOLTAGE BEFORE THEY WILL APPLY AMPERAGE!

So basically if the batteries in your golf cart are dead then the charger does not know it is plugged into a golf cart because it does not sense any voltage.

How To Get Some Electricity Back Into Dead Golf Cart Batteries

There are a few options in this process. The basic objective is to just get some energy back into the batteries so the golf cart battery charger can sense the voltage present at the charger receptacle and turn itself on again to charge the golf cart and the batteries completely. I recommend getting the batteries charged back up to their advertised voltage prior to plugging in the golf cart battery charger again. Depending on the size of the battery bank and the batteries. 6 volt, 8 volt or 12 volt batteries will determine how best to get that required energy back into them. Please note this process is a bit of a pain in the you know what but a valuable lesson to take better care of your electric golf cart. As letting the batteries go completely dead is very bad for the batteries and will definitely cut the life expectancy short.

In the golf cart business we use a golf cart battery recovery unit like BatteryPete’s Super Charger to jump start the golf cart in seconds or minutes to get the customers golf cart battery charger to kick on… It is kinda like a AED you would find in the airport or hospital to shock someone back to life after having a heart attack. At the push of a button you can apply a massive amount of voltage to a golf carts battery bank. Hence tricking the charger to turning on. Otherwise you can use a regular 12 volt or 24 volt battery charger for a car, boat or Rv to get some energy back into those dead batteries. More realistic as well because you or neighbor probably have one handy. The Heavy Duty Recovery Unit like the Super Charger run several hundred dollars but for the Golf Cart Guy it is a bargain because time is money and on average a service call will cost you $65-75 bucks… This device will allow him to put that money in his pocket in minutes and move on to the next service call or issue.

Most older style golf cart battery chargers require approx 75% of the chargers operating voltage present to activate. Others require a little less. So for example a 36 volt battery charger would require approx. 25-30 volts to activate, whereas a 48 volt charger would require 30-35 or even 40 volts present to activate. I recommend getting a digital volt meter out to start testing and checking voltage across the battery bank and the system in general. If you do not have one they can be purchased at any parts store, Home Depot or Harbor Freight for a few bucks… A volt meter is a valuable tool for anyone who owns a electric vehicle to check and test basic systems or doing basic diagnostics like this.

Charging Select Golf Cart Battery Configurations

Depending on the Year, Make and Model or the golf cart you own will determine the best or fastest way to revive your golf cart batteries when completely dead. See some basic examples below that will cover most major makes and models..

36 Volt Golf Carts –

Systems comprised of 6x 6 volt batteries… Usually found in older golf carts across the board Club Car, Ezgo and Yamaha Brands but also Columbia, Harley Davidson ( Yep – Harley used to make a golf cart as they also made boats under AMF) other carts include Fairplay, Par Car or Western. For this system you will need either a 6 volt battery charger to charge individually by placing the charger connections on the positive and negative terminals of each individual battery. Or you can use a 12 volt battery charger and place the charger connections on the positive terminal of the first battery and then the negative connection on that of the second battery. See Illustrations and images below.

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