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Unread 04-30-2012, 11:54 PM   #1
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Default Brakes lock up

My brakes basically lock up when i just barely tap them. Do you know where the one cable from the brake pedal connects with the two that go off to each brake pad? Is that the bolt that I need to adjust to soften them up a little? Also, is there supposed to be one nut on that bolt or two? My cart has two, and I think someone may have added an extra nut. I will try to take pics of what I am talking about tomorrow. Thanks
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Unread 05-01-2012, 07:34 AM   #2
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Default Re: Brakes lock up

Yes, you adjust the brake pedal free travel at that location . . should be 1/4 to 1/2 inch of travel before brakes begin to engage . . and yes, there should be two nuts on that threaded rod . . one is the adjustment and the second is a locking nut . . once you adjust the cables properly, hold the inner adjusting nut with one wrench, and then lock the two nuts together with a wrench on the second nut . . .
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Unread 05-01-2012, 07:45 AM   #3
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Default Re: Brakes lock up

And... If that doesn't work...

Myself, and others have found that the axle U bolts stretch a little after time,
causing the axle to become loose and "twist" when braking, in turn, causing brake lock up.

Check the tightness of your axle U bolts!

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Unread 05-01-2012, 08:44 AM   #4
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Default Re: Brakes lock up

Ok thanks to both of you guys. I'll check those things when I get home.
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Unread 05-01-2012, 05:10 PM   #5
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Default Re: Brakes lock up

Ok, I backed off those nuts, and now the brakes are a little "softer". I still have one more question though. On my old 1996 DS, there is a spring in place of the adjustable bolt. I like that system better because when you let off the pedal, it pops right back up, where as on my 2002, it just kind of stays there without popping back up. Why did they change the design? I think the old one is better because it keeps pressure off of the cables when your foot is not on the pedal. There are pics of both the old and new systems. Sorry some how the pics got upside down.
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File Type: jpg brake1.jpg (92.0 KB, 0 views)
File Type: jpg brake2.jpg (164.3 KB, 0 views)
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Unread 05-01-2012, 11:53 PM   #6
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Default Re: Brakes lock up

By the way I did check the u bolts and they were tight.
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Unread 05-02-2012, 07:06 AM   #7
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Default Re: Brakes lock up

Quote:
Originally Posted by jakesnake27 View Post
Ok, I backed off those nuts, and now the brakes are a little "softer". I still have one more question though. On my old 1996 DS, there is a spring in place of the adjustable bolt. I like that system better because when you let off the pedal, it pops right back up, where as on my 2002, it just kind of stays there without popping back up. Why did they change the design? I think the old one is better because it keeps pressure off of the cables when your foot is not on the pedal. There are pics of both the old and new systems. Sorry some how the pics got upside down.

If you look at the illustration on page 4-4 below, it shows a brake return spring at detail #3 . . .

2001-2002 Club Car DS Gas/Electric IPL
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Unread 05-02-2012, 09:11 AM   #8
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Default Re: Brakes lock up

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Originally Posted by Stevegrmich View Post
If you look at the illustration on page 4-4 below, it shows a brake return spring at detail #3 . . .

2001-2002 Club Car DS Gas/Electric IPL
Hmmm so I guess it may have fallen off at some point?
I didn't notice a hole in the threaded rod, but it may just be plugged with dirt. I will check later.
Thanks
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Unread 05-02-2012, 11:28 AM   #9
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Default Re: Brakes lock up

Ok I looked at it again and it is missing the spring. I just ordered a new one. Thanks!
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Unread 05-02-2012, 05:50 PM   #10
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Default Re: Brakes lock up

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Originally Posted by jakesnake27 View Post
Ok I looked at it again and it is missing the spring. I just ordered a new one. Thanks!
. . .
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