How to Adjust the Brakes on an old style Club Car Golf Car

Before you start:

    • Disconnect the battery or battery pack

Note: Use proper lifting equipment and proper jack stands to support the golf car.

Note: Some electric cars will have a run/tow switch. The run/tow switch must be moved to the tow position before disconnecting the battery packs.

    • Lift the rear of the golf car and place the jack stands in a secure spot that will support the golf car.

The following steps will allow for optimal adjustment:

    • Remove both wheel assemblies.
    • Release the brake pedal parking brake.
    • Back off the brake cable adjusting rod, so there is not any cable tension on the shoe lever arm.
    • Remove the brake drum.

Note: On some models it may be necessary to remove keeper clips on the wheel studs.

Note: On some units it may be necessary to back off the brake adjuster in order to remove the drum. Some units use an axle nut, that hold the drum in place. With this style, retain the cotter pin for use later.

    • After the shoes and backing plate are exposed, inspect the shoes for wear, sticking, debris, or poor fitting to drums.

Warning: Before you move on to step 6 it’s a good idea to wear some sort of respiratory device/mask to protect your lungs from foreign debris.

    • With light air pressure blow the brake dust and debris from the shoes and backing plate. Clean the drum in the same manner. You can also use a cleaning solution; such as, CRC brake cleaner. DO NOT directly breathe the solution.
    • Now that things are clean and no binding or sticking is noticed in the shoe movement we can move to the adjustment.

Note: For self-adjusting brakes, the drums should slide on and off and turn freely without any resistance. If it is too tight, take the drum back off and back off the star adjuster until the drum is free to turn 360 degrees without dragging to a stop. From this point on, the shoe will self adjust under normal operating conditions. Likewise, if the drum is too loose, you will need to tighten the shoes to a drag and then back off to free movement.

Note: For manually adjusted shoes put the drum back on the axle, turn the adjuster screw or star until the drum locks up. At this point, back the adjuster off 3-5 clicks and at this point the drum should turn freely.

    • Put the ties back on and torque the lugs to 50lbs.
    • Adjust the brake pedal height. (Do not confuse this with brake shoes adjusting.) As you push on the pedal you should feel 2-3 clicks or ¾ – 1 inch free play. If you do not see this amount of travel, adjust the cable-adjusting rod that you released in Step No. 3.
    • Connect the battery or batteries
    • Move the tow switch back to the run position if required.
    • Lower the golf car to the ground and test drive in a safe area.

If no problems exist, Congratulations! You are finished. If you notice a problem, please review the above procedures as you may have missed something.

Note: Make sure everything is tight and in place before normal usage.


A solenoid, often referred to as a switch, is normally activated manually or mechanically i.e. key switch.  Solenoids switches are activated by external electrical input.  A solenoid is used to break an electrical circuit, or make one.  Some folks call a solenoid “a contactor”. 

There are two basic circuits to a solenoid.  Primary and Secondary.  The primary, also referred to as activation circuit, has both activation wiring and an internal primary coil.  With electrical voltage, the internal primary coil activates and brings two contact points together to allow an electric current to come through the secondary circuit.  That coil requires a + and – potential for electric voltage to pass through and activate it.  Most golf carts activate the soelnoid with normal battery pack volts.  However, some older cars that use tapped voltage, and the solenoid must be connected to a specific voltage.  Taps are connecting points on a battery pack.  The power circuit aka secondary circuit is the circuit being activated by the solenoid coil.  This circuit has large power contacts inside the solenoid switch that allow heavy load of electric current to flow to the motor or a starter generator when activated.  Be sure to have the correct wiring diagram for the test. 

1.  Does the solenoid make a clicking noise?  If it doesn’t, we need to determine if activation voltage is present at the small terminals.  Connect a voltmeter across the small posts and activate the system.  Caution safety:  Raise rear wheels off the ground and use stands BEFORE you test as car may lunge forward so be cautious.  Put the car in run mode and key switch on, car in forward and accelerator pedal pushed.  If voltmeter displays system voltage and solenoid does not click, solenoid is defective and needs to be replaced.

2.  The solenoid does not click and you do not read system voltage, this tells us one of the voltage potentials is ‘mia’ at one of the two connections.  To find out which one is missing, leave the red lead of voltmeter connected to terminal 2, the positive connection (usually blue or red wire).  However wire colors may vary!  Use correct diagram for your make and model year for correct diagnoisis.  Place black lead of voltmeter to battery’s negative post on the No. 6 battery (last in the series from the first positive battery connection).  Activate system, if voltmeter reads system voltage, the positive input is correct.  Meaning key switches, micro switches & wiring are good & you are missing negative input.

3.  Positive connection at Terminal 1: Continue the diagnosis by connecting the black negative lead from voltmeter to teriminal No. 1, and the red lead of voltmeter to battery No. 1’s positive post (first positive connection to the car).  Activate system again.  If you are not reading system voltage on your voltmeter, you’ve confirmed the battery negative is missing.  Depending on the system the car is using, the missing negative will need to be traced to the source.  Some systems supply negative from a controller output (some Club Cars, the onboard computer)  Most gas cars use the frame as ground.  Electric cars do not use a frame ground.  Determined by using correct wiring diagram.

4.  Negative connection at Terminal 1.  If we are missing the positive at connection terminal No. 2, it means the key switch, micro switch and or accelerator switch is open or out of adjustment.  Please note:  Some cars use the key circuit as a negative circuit & adjust accordingly  per correct wiring diagram.  Trace voltage to each component in that circuit & determine where voltage is lost.  If your car uses the diode in the solenoid system, be sure you make proper connections as the diode is polarity sensitive.


It is important to keep your golf car clean, and maintained. You should do this yourself, or have a professional do it.  It will save you alot of head aches, and costly repairs in the future. There is a list you should follow when performing maintenance.

IT INCLUDES:  keeping batteries clean of acid (on electric, and gas golf cars), checking tire ware, visual check on brakes for ware, use an air compressor to clean out brake dust from brakes, and brake drums (brake dust will prevent your golf car from slowing, stopping, or parking), your brakes will not hold on an incline, keeping tire pressure at 22lbs, for standard golf car tires, lube the front if there are grease fittings, (some golf cars won’t have fittings), keep batteries filled to the proper level with distilled water (over filling, or lack of water will nullify any warranty that may exist), use distilled water only, check front bearings for ware ( pack with grease if required), have bearings replaced if necessary, call for advice if needed, YOU CAN PRESSURE WASH THE BATTERY COMPARTMENT WITHOUT HARMING BATTERIES, OR COMPONENTS. These tips will extend the life of your golf car.





One main fuse for power supply, Sub Harness for horn and floor button. hor and floor button sold separately, relay. wiring diagram included



KIT no. 970 $121.10

Kit includes: Push pull switch, Turn signal switch, 18 inch cover, Flasher, Horn, 12v power plug, Horn button, Sub harness, 6 wire blade fuse board, Fuses, cover, and 12v relay included.