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GENERAL INFORMATION

Storage – Electric Vehicle

2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual

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WARNING

• Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse

handle or switch in the NEUTRAL position during storage. This is to prevent unintentionally
starting the vehicle or a fire hazard. Place the Tow/Run switch in the TOW position.

• Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery.

Frozen batteries can explode.

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CAUT ION

• Batteries in a low state of charge will freeze at low temperatures.

• To avoid exposing electrical components to moisture and subsequent damage, do not use

any type of pressure washing or steam cleaning equipment to wash the vehicle.

PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE

1. Fully charge batteries.

See Battery Charger on page 24-12.

2. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of

baking soda and water (237 mL (1 cup) baking soda per 3.8 L (1 gallon) of water). Rinse solution off bat-
teries. Do not allow this solution to enter the batteries. Be sure terminals are tight. Let the terminals dry
and then coat them with Battery Terminal Protector Spray.

3. Store vehicle in a cool, dry place. This will minimize battery self-discharge.

4. Adjust tires to recommended tire pressure.

See Section 2 – Vehicle Specifications.

5. Perform semiannual periodic lubrication.

See Periodic Lubrication Schedules on page 10-4.

6. Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle.

7. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling.

8. Keep batteries fully charged during storage.

•

Leave battery chargers plugged in during storage. The onboard computer will automatically activate
the charger when necessary. If charger cannot remain plugged in, or AC power will not be available
during extended storage, disconnect the batteries for storage

(Figure 1-2, Page 1-3)

.

See following

CAUTION.

CAUT ION

• Be sure to check the batteries and charger monthly to maintain correct battery water level and

to ensure the charger is operating correctly during storage.

RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE

1. If necessary, connect batteries, and tighten terminals to 12.4 N·m (110 in-lb).

2. Fully charge batteries.

3. Adjust tires to recommended tire pressure.

See Section 2 – Vehicle Specifications.

4. Perform the Pre-Operation and Daily Safety Checklist.

See the vehicle owner’s manual.

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Summary of Contents for 2007 XRT 800

Page 1: ...MANUAL NUMBER 103209106 EDITION CODE 0907D0808C XRT 800 810 and 850 GASOLINE ELECTRIC 2007 2008 MAINTENANCE SERVICE MANUAL ...

Page 2: ......

Page 3: ...r advises that all repairs and or service be performed by an authorized Club Car distributor dealer representative or by a Club Car factory trained technician It is the policy of Club Car to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efficient service for vehicle owners Regional technical repre sentatives vehicl...

Page 4: ...ontin ually working to further improve its vehicles and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or procedures will be forwarded to all Club Car dealers and will when applicable appear in future editions of this manual Club Car reserves the right to change specifications and designs at any time without notice and...

Page 5: ...o Service 3 4 Storage Electric Vehicle 3 4 Preparing the Electric Vehicle for Extended Storage 3 5 Returning the Stored Electric Vehicle to Service 3 5 SECTION 4 BODY AND TRIM Cleaning the Vehicle 4 1 Seat Cleaning 4 1 Front and Rear Body Repair 4 2 Minor Scratches and Surface Blemishes 4 2 Small Scratches That Cannot Be Buffed Out 4 2 Gouges Punctures Tears Large Scratches and Abrasions 4 2 Front...

Page 6: ...4 12 Rear Body and Fenders 800 and 810 4 12 Rear Body Removal 4 12 Rear Fender Removal 4 14 Rear Fender Installation 4 14 Rear Body Installation 4 15 Rear Body 850 4 15 Rear Body Removal 4 15 Rear Body Installation 4 19 Floor Mat 4 19 Floor Mat Removal 4 19 Floor Mat Installation 4 19 SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake 5 1 Brake Pedal Removal 5 1 Brake Pedal Ins...

Page 7: ...n Disassembly 7 4 Steering Column Assembly 7 4 Steering Column Installation 7 5 Steering Adjustment 7 6 Rack and Pinion 7 7 Rack and Pinion Removal 7 7 Rack and Pinion Disassembly 7 7 Rack and Pinion Assembly 7 10 Rack and Pinion Installation 7 12 Tie Rod and Drag Link 7 12 Tie Rod and Drag Link Removal 7 12 Tie Rod and Drag Link Installation 7 12 Front Suspension 7 13 Lubrication 7 13 Wheel Align...

Page 8: ...rbers 9 1 Shock Absorber Removal and Inspection 9 1 Shock Absorber Installation 9 1 Leaf Springs 9 2 Leaf Spring Removal 800 and 810 9 2 Leaf Spring Removal 850 9 4 Leaf Spring Installation All Vehicles 9 4 Stabilizer Bar Removal 9 7 Stabilizer Bar Installation 9 7 SECTION 10 PERIODIC MAINTENANCE General Information 10 1 Periodic Service Schedules 10 1 Periodic Lubrication Schedules 10 4 Engine Oi...

Page 9: ...ECTRICAL COMPONENTS 800 AND 810 GASOLINE VEHICLES Starter Generator 13 1 Voltage Regulator 13 11 Diode 13 12 Key Switch 13 14 Solenoid 13 15 Fuse 13 16 Lockout Cam Limit Switch 13 17 Lockout Cam 13 18 Reverse Warning Buzzer 13 19 Reverse Buzzer Limit Switch 13 20 Oil Warning Light 13 20 Fuel Gauge Hour Meter 13 21 Fuel Level Sending Unit 13 22 RPM Limiter 13 23 Ignition Coil 13 24 Oil Level Sensor...

Page 10: ...ts 14 26 Voltage Limiter 14 28 Headlight Switch 14 29 Battery 14 30 Ground Cables 14 34 SECTION 15 ENGINE General Information 15 1 Before Servicing 15 1 Engine Rotation 15 1 Spark Plug 15 1 Cylinder Head 15 3 General Information 15 3 Breather Valve Reed Valve 15 3 Crankcase 15 3 Engine Removal 15 3 Crankcase Cover Removal 15 3 Oil Level Sensor 15 5 Crankcase Cover Installation 15 5 Ignition Coil a...

Page 11: ...llation 16 12 Air Box Removal 16 13 Air Box Installation 16 13 Intake Duct Removal 16 13 Intake Duct Installation 16 14 Air Filter 16 16 Fuel Filters 16 17 Fuel Filter Removal 16 17 Fuel Filter Installation 16 17 Fuel Pump 16 19 General Information 16 19 Fuel Pump Removal 16 19 Fuel Pump Disassembly 16 19 Fuel Pump Cleaning and Inspection 16 20 Fuel Pump Assembly 16 20 Fuel Pump Installation 16 21...

Page 12: ...Removal 18 19 Forward Reverse Shifter Cable Installation 18 19 Forward Reverse Shifter Cable Adjustment 18 20 SECTION 19 UNITIZED TRANSAXLE 850 GASOLINE VEHICLE General Information 19 1 Lubrication 19 2 Axle Shaft 19 2 Axle Shaft and Oil Seal Removal 19 2 Axle Bearing 19 3 Axle Shaft Installation 19 5 Unitized Transaxle Removal 19 6 Unitized Transaxle Installation 19 14 Forward Reverse Shifter Cab...

Page 13: ...CTRIC VEHICLE General Information 21 1 Wiring Diagram 21 2 Troubleshooting 21 4 Troubleshooting the Vehicle with the Diagnostic Handset 21 4 Troubleshooting Guide 1 21 5 Troubleshooting Guide 2 21 8 Test Procedures 21 10 Index of Test Procedures 21 10 Communication Display Module CDM 21 33 Using the CDM to Retrieve Data from the Onboard Computer 21 34 CDM Troubleshooting Guide 21 35 SECTION 22 IQ ...

Page 14: ... Motor Controller Output Regulator MCOR 23 8 Reverse Buzzer 23 9 Solenoid 23 10 Onboard Computer OBC 23 11 Solid State Speed Controller 23 13 Charger Receptacle 23 15 Receptacle Fuse Link 23 16 Battery Warning Light 23 17 SECTION 24 BATTERIES ELECTRIC VEHICLES General Information 24 1 Battery Troubleshooting Chart 24 2 Battery Testing 24 3 Battery Charger Test 24 3 On Charge Voltage Test 24 3 Hydr...

Page 15: ...propriate Battery Charger Maintenance and Service Manual SECTION 26 MOTOR MODEL 5BC59JBS6390 General Information 26 1 Motor Identification 26 1 External Motor Testing 26 1 Motor 26 2 Motor Component Testing and Inspection 26 5 Armature 26 5 Field Windings Inspection 26 6 Motor Components 26 6 Bearing Inspection 26 7 Bearing Removal 26 7 Bearing Installation 26 7 Speed Sensor Magnet Inspection 26 9...

Page 16: ...lation 27 13 SECTION 28 TRANSAXLE TYPE G ELECTRIC VEHICLE Transaxle Identification 28 1 Lubrication 28 1 Axle Bearing and Shaft 28 1 Axle Shaft 28 1 Axle Bearing 28 4 Transaxle 28 5 Transaxle Removal 28 5 Transaxle Disassembly Inspection and Assembly 28 7 Transaxle Disassembly and Inspection 28 7 Transaxle Assembly 28 9 Transaxle Installation 28 10 SECTION 29 IQ DISPLAY MODULE IQDM P PROGRAMMING P...

Page 17: ...hazardous situation that could result in property damage 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 Also other specific safety statements appear throughout this manual and on the vehicle ý DANGER Battery Explosive gases Do not smoke Keep s...

Page 18: ... discharge All vehicles 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 Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot engi...

Page 19: ...rning could result in severe 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 Figure 1 1 Gasoline Vehicle Figure 1 2 IQ System Electric Vehicle Viewed from passenger side of vehicle 1 Remove negative battery cable 2 Remove positive battery...

Page 20: ...1 ...

Page 21: ...reduced speed reverse 11 8 1 forward 17 1 1 reverse Torque converter Automatic variable speed dry type Electrical system 48 volts DC reduced speed reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity Batteries High capacity deep cycle Trojan PowerDrive 12 volt Charger Automatic 48 volt UL and CSA listed STEERING SUSPENSION...

Page 22: ... Forward speed 17 mph 27 km Standard seating capacity 2 Liquid Capacities Transaxle 22 oz 0 67 L Engine crankcase without filter 32 oz 0 95 L Engine crankcase with filter 38 oz 1 12 L Unitized transaxle 27 oz 0 8 L Fuel tank 7 gallons 26 5 L Tire Pressure Front and rear 18 20 psi 1 24 1 38 Bars 18 20 psi 1 24 1 38 Bars SPECIFICATIONS Electric XRT 800 E Electric XRT 810 E Gasoline XRT 800 Gasoline ...

Page 23: ...lt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity Batteries High capacity deep cycle Charger Automatic 48 volt UL and CSA listed STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front and rear tapered mono leaf springs with dual hydraulic shocks Brakes Dual rear wheel self adjusting brakes with cast iron drums and single ...

Page 24: ... 2 LIQUID CAPACITIES Transaxle 22 oz 0 67 L Engine crankcase without filter 32 oz 0 95 L Engine crankcase with filter 38 oz 1 12 L Unitized transaxle 27 oz 0 8 L Fuel tank 7 gallons 26 5 L TIRE PRESSURE Front and rear 14 16 psi 0 97 1 10 Bars SPECIFICATIONS Electric XRT 850 E Gasoline XRT 850 ...

Page 25: ... on the following topics Controls and Indicators Pre Operation and Daily Safety Checklist Driving Instructions Towing Transporting on a Trailer Subsequent Owner Registration Warranties SERIAL NUMBER IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted on the frame directly above the accelerator pedal Example XH0601 583947 Figure 3 1 Page 3 1 There is also a second...

Page 26: ... will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE 1 Store vehicle in a cool dry place This will minimize battery self discharge If the battery appears to be weak have it charged by a trained technician Use an automotive type 12 volt battery charger rated at 10 amps or less 2 Drain carburetor and seal the fuel tank 2 1 XRT 800 810 Place the Forward Reverse handle ...

Page 27: ...Let the terminals dry and then coat them with Battery Terminal Protector Spray 5 To protect the engine remove spark plug and pour 14 2 mL 1 2 oz of SAE 10 weight oil into the engine through the spark plug hole Rotate engine crankshaft by hand several times then install the spark plug and tighten to 27 N m 20 ft lb 6 Adjust tires to recommended tire pressure See Section 2 Vehicle Specifications 7 P...

Page 28: ...d Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts Turn the engine off and return the neutral lockout switch to the OPERATE position See following NOTE NOTE Due to the oil added to the engine in preparation for storage engine may smoke excessively for a sh...

Page 29: ... are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray 3 Store vehicle in a cool dry place This will minimize battery self discharge 4 Adjust tires to recommended tire pressure See Section 2 Vehicle Specifications 5 Perform semiannual periodic lubrication See Periodic Lubrication Schedules on page 10 4 6 Thoroughly clean front body rear body seats battery compart...

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Page 31: ...an result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains See following NOTE NOTE Dispose of waste water properly SEAT CLEANING To preserve seat appearance clean regularly with mild soap or detergent applied with a sponge or soft cloth Use a so...

Page 32: ...ly clean the affected area with alcohol and then dry thoroughly 2 Using 240 grit or finer sandpaper lightly sand the scratch to feather the edges Finish sand the scratch with 320 grit or finer paper to remove gloss from the surface Sand as little body surface as possible beyond the scratch See following CAUTION CAUTION Be careful not to sand completely through the finish to the body material 3 Usi...

Page 33: ...r or brush guard that is specifically designed and approved for use on this vehicle Instability in the vehicle could cause serious injury or death BUMPER BRUSH GUARD INSTALLATION 1 Position the bumper 1 or brush guard 2 against body and front frame and loosely install top bolts 3 and lock nuts 4 Figure 4 1 Page 4 3 or Figure 4 2 Page 4 3 See preceding WARNING 2 Install bottom screws 5 and tighten ...

Page 34: ...e 4 3 Page 4 5 3 Raise dash up and pass steering wheel through instrument panel opening to remove dash from vehicle MOLDED DASH INSTALLATION 1 Pass the steering wheel through the instrument panel opening in the dash Figure 4 3 Page 4 5 2 Attach the dash clips along the bottom edge of the dash onto the frame above the floor mat 3 Install the instrument panel 3 1 Attach electrical components to conn...

Page 35: ...brush guard firmly against the frame when removing the last bolt The brush guard weighs approximately 40 pounds Hold the brush guard securely during removal to avoid personal injury Do not operate the vehicle without an installed front bumper and brush guard that are specifically designed and approved for use on this vehicle Instability in the vehicle could cause serious injury or death Figure 4 3...

Page 36: ...RD STANDARD INSTALLATION 1 Position the standard brush guard 2 on vehicle and loosely install spacers 10 washers 9 bolts 8 and screws 7 Figure 4 4 Page 4 6 See preceding WARNING 2 Position the standard bumper 1 against body and front frame and loosely install top bolts 4 and lock nuts 5 3 Install bottom screws 6 and tighten to 14 ft lb 19 N m 4 Tighten lock nuts 5 to 17 5 ft lb 24 N m Figure 4 4 S...

Page 37: ...screws 6 and tighten to 14 ft lb 19 N m 3 Tighten lock nuts 5 to 17 5 ft lb 24 N m FRONT REMOVAL 1 Remove bumper brush guard See Bumper Brush Guard Standard Removal on page 4 5 or Bumper Brush Guard Heavy Duty Removal on page 4 7 2 Remove caps 1 from screws 2 Figure 4 5 Page 4 8 3 Remove screws 2 and plastic scalloped washers 3 securing the dash trim strip 4 and front body 5 4 Remove covers 6 and ...

Page 38: ...ed and remove the rue rings on the end of each clevis pin 2 Remove hinge clevis pins and remove bed from vehicle See following CAUTION and WARNING CAUTION Support bed as pins are removed Keep bed hinges as close to alignment as possible to avoid binding the pins during removal ý WARNING Keep hands and arms from between the bed and vehicle frame and do not allow the bed to drop Figure 4 5 Front Bod...

Page 39: ...oval ý WARNING Keep hands and arms from between the bed and vehicle frame and do not allow the bed to drop 3 Install rue rings and washers on the end of the hinge clevis pins 4 Lower the bed onto the bed latch plates Adjust the latch plates if necessary BED LATCH ASSEMBLY 1 Remove the two latch link support bolts and remove latch rod and catch plate assembly from bed Figure 4 6 Page 4 9 2 Remove a...

Page 40: ...reely 3 Install bed catch rods Use new push nuts or use a flat washer and cotter pin to secure the ends of the rods Figure 4 9 Page 4 10 4 Install new springs from the catch plates to the catch rods Figure 4 8 Page 4 10 Bed Hinge and Support Bracket Removal 1 Remove steel bushings and urethane bushings from hinge brackets Figure 4 10 Page 4 11 2 Remove bolts from hinges and remove hinges from supp...

Page 41: ... latch link with screws Tighten hardware to 7 ft lb 9 5 N m Figure 4 6 Page 4 9 SEAT BACK SUPPORT BRACKETS 800 AND 810 See General Warning on page 1 1 NOTE The bed latch plates are a part of each of the seat back support bracket Removing latch plates will require adjustment for bed catch plates Figure 4 12 Page 4 11 SEAT BACK SUPPORT BRACKET REMOVAL 1 Remove bolts from seat back and support bracke...

Page 42: ... and bed support bolts to frame and tighten to 100 in lb 11 3 N m REAR BODY AND FENDERS 800 AND 810 See General Warning on page 1 1 NOTE The driver side rear fender can be removed without removing any other component but the pas senger side rear fender cannot be removed without either removing the fuel tank or removing the rear body It is easier to remove the rear body than to remove the fuel tank...

Page 43: ...Reverse switch is mounted on the rear body disconnect and remove Forward Reverse switch See Forward Reverse Switch Removal on page 23 4 Gasoline Vehicles NOTE To remove the rear body the choke button assembly does not have to be removed from the body However adjustment of the choke positioner may be necessary after the rear body is reinstalled 7 If the Forward Reverse shifter is mounted on the rea...

Page 44: ...e bolt Figure 4 17 Page 4 14 2 4 Remove the top body and fender bolt 2 5 Remove the two outside body and fender bolts and remove the fender from the vehicle 3 Passenger side rear fender 3 1 Remove the seat 3 2 Remove the cargo bed See Cargo Bed Removal on page 4 8 3 3 Remove the seat back support brackets See Seat Back Support Bracket Removal on page 4 11 3 4 Remove rear fender frame bolt 3 5 Remo...

Page 45: ...b 2 8 N m REAR BODY INSTALLATION NOTE This procedure is easier using two people 1 Position rear body with fenders attached onto the vehicle frame 2 Position front edge of the body behind floor mat back rail and down into the side trim 3 Install the front edge of the body to the rail with screws and tighten to 50 in lb 5 6 N m 4 Install the rear bolts on both fenders and tighten to 50 in lb 5 6 N m...

Page 46: ...ary after the rear body is reinstalled 7 Remove two nylon lock nuts from fuel pump and remove fuel pump from seat support Vehicles Equipped with Rear Facing Seat 8 Remove handrail and rear seat 8 1 Remove the hardware 1 that secures the rear handrails 2 and 3 to the rear footrest assembly Figure 4 20 Page 4 17 8 2 Remove the hardware 4 that connects the two rear handrails 2 and 3 together between ...

Page 47: ...BODY AND TRIM Rear Body 850 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual Page 4 17 4 Figure 4 20 Rear Seat Handrail 850 9 10 11 8 8 8 1 4 5 6 2 3 7 13 13 13 12 12 12 ...

Page 48: ...ion from the rear body 9 2 Remove the two bolts 2 nuts 3 flat washers 4 and spacers 5 that attach the cargo bed sup port 1 to the body Figure 4 21 Page 4 18 9 3 Remove the four screws 6 and flat washers 7 that attach the seat back supports 8 to the body 9 4 Remove cargo box and seat back assembly from the vehicle 10 Lift the rear body from the vehicle Figure 4 21 Cargo Bed 850 1 5 3 4 2 6 7 8 ...

Page 49: ...6 N m Figure 4 20 Page 4 17 1 6 Tighten the hardware 13 attaching the rear legs of the seat back support assembly to the chassis to 11 ft lb 14 9 N m 1 7 Tighten the hardware 10 7 and 1 to 124 in lb 14 N m 1 8 Tighten the hardware 8 securing the rear seat support 9 to the chassis to 108 in lb 12 2 N m 1 9 Tighten the hardware 4 to 65 in lb 7 35 N m Vehicles Equipped with Cargo Bed 1 10 Tighten the...

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Page 51: ...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 l...

Page 52: ...jam nut 12 at this time 2 Secure the equalizer rod 13 to the brake pedal assembly 8 with the clevis pin 14 and bow tie pin 15 as shown 3 Position and attach brake pedal assembly mounting blocks 23 and washers 2 to vehicle frame as shown Tighten the bolts and nuts to 113 in lb 12 8 N m Figure 5 1 Brake and Park Brake Pedal Assembly STOP 29 5 3 7 TYPICAL 2 PLACES 1 6 2 23 TYPICAL 2 PLACES 2 TYPICAL ...

Page 53: ... the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See following WARNING ý WARNING 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 liftin...

Page 54: ...spacer 22 and torsion spring 21 on the park brake pedal shaft on the brake pedal assembly 4 Install the two bushings 25 in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment Figure 5 3 Page 5 4 Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown Figure 5 4 Page 5 4 5 Install the push nut 2...

Page 55: ...the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Disconnect the accelerator rod assembly 17 18 and 19 Figure 5 5 Page 5 6 at the front and rear ball studs and remove it from the vehicle 4 Use a 9 16 inch socket and 9 16 inch wrench to remove the nut 23 two washers 25 and bolt 4 securing the accelerator pedal ...

Page 56: ...supports do not require replacement loosen but do not remove the four bolts 22 and lock nuts 15 to make installation of the pivot rod easier 13 Remove the accelerator pedal 1 from the vehicle 14 Inspect all parts for wear and damage Replace as necessary Figure 5 5 Accelerator Pedal Assembly Gasoline Vehicles TYPICAL 4 PLACES FLOORBOARD REMOVED FOR CLARITY 26 24 22 21 20 21 8 15 19 18 17 7 5 14 17 ...

Page 57: ...d with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of vehicle slide the ratchet onto the pivot rod do not slide the ratchet onto the pivot rod splines Release the brake pedal and allow the ratchet to rotate until its tip is pointed downward Figure 5 6 Page 5 7 The ratchet should now rotate freely on the rod 9 Rotate ratchet clockwise until it touches t...

Page 58: ... as instructed Figure 5 7 Page 5 9 See MCOR Removal Section 23 Page 23 8 4 Use a 9 16 inch socket and 9 16 inch wrench to remove the nut 7 two washers 5 and bolt 4 secur ing the accelerator pedal 1 to the pivot rod 6 Figure 5 7 Page 5 9 5 Remove the nut 10 and bolt 8 from the accelerator pivot rod assembly 6 6 Slide the spring retainer 11 off of the accelerator pivot rod 7 Inspect the pivot suppor...

Page 59: ...celerator Pedal Electric Vehicles 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual Page 5 9 5 Figure 5 7 Accelerator Pedal Electric Vehicle GO 3 2 11 10 7 5 4 5 1 8 9 6 TYPICAL 4 PLACES TYPICAL 4 PLACES 23 24 21 21 20 16 15 22 ...

Page 60: ...ess the brake pedal slightly and with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of the vehicle slide the ratchet onto the pivot rod do not slide the ratchet onto the pivot rod splines Release the brake pedal and allow the ratchet to rotate until its tip is pointed down ward Figure 5 8 Page 5 10 The ratchet should now rotate freely on the rod 9 Rotate...

Page 61: ...on the equalizer rods 1 Figure 5 9 Page 5 11 2 3 Loosen the brake stop jam nut 31 then relieve pedal pressure on the stop by pushing down slightly on the pedal Next adjust the brake stop bumper 22 up or down Figure 5 10 Page 5 11 Adjusting the bumper upward decreases distance between pedal and floorboard Adjusting the bumper downward increases distance between pedal and floorboard Proper brake ped...

Page 62: ...for excessive wear grooves cracks or chips If either the pawl or ratchet is damaged both must be replaced 4 2 Adjust retaining nut 7 on spring support rod until there is a 0 060 inch 1 5 mm gap between the pawl and the tips of the ratchet teeth Use a feeler gauge to verify the gap Figure 5 13 Page 5 13 The gap should be consistent through range of pawl movement If the gap is not con sistent loosen...

Page 63: ...engagement is too deep and must be adjusted 4 6 If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake rod and rotate the ball joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement Reconnect ball joint Figure 5 16 Page 5 14 4 7 If the accelerator push rod was disconnected from the accelerator pedal reconnect it 4 8 Check for...

Page 64: ... position against the floorboard and then tighten nut to 26 ft lb 35 3 N m 6 Adjust the accelerator rod See following DANGER ý DANGER Before servicing turn the key switch to OFF and place the Forward Reverse handle in the NEUTRAL position To prevent accidentally starting the vehicle disconnect the battery as instructed in WARNING To avoid unintentionally starting in General Warning on page 1 2 Thi...

Page 65: ...or rod hold the disconnected ball joint with locking pliers 6 3 Reconnect the accelerator rod at the accelerator pedal 6 4 Before tightening jam nuts on accelerator rod set park brake to first ratchet and pawl position Press accelerator pedal and make sure the following events occur in the exact order shown 6 5 If the events above occur as they should hold the ball joint at each end of the acceler...

Page 66: ...on the equalizer rods 1 Figure 5 20 Page 5 16 2 3 Loosen the brake stop jam nut 31 then relieve pedal pressure on the stop by pushing down slightly on the pedal Next adjust the brake stop bumper 22 up or down Figure 5 21 Page 5 16 Adjusting the bumper upward decreases distance between pedal and floorboard Adjusting the bumper downward increases distance between pedal and floorboard Proper brake pe...

Page 67: ...osition Figure 5 23 Page 5 17 4 Adjust park brake ratchet pawl gap and pawl engagement 4 1 Inspect the park brake pawl and ratchet for excessive wear grooves cracks or chips If either the pawl or ratchet is damaged both must be replaced 4 2 Adjust retaining nut 7 on spring support rod until there is a 0 060 inch 1 5 mm gap between the pawl and the tips of the ratchet teeth Use a feeler gauge to ve...

Page 68: ...If the measurement has changed ratchet tooth engagement is too deep and must be adjusted 4 6 If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake rod and rotate the ball joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement Reconnect ball joint Figure 5 27 Page 5 19 4 7 Check for proper brake operation prior to driving the...

Page 69: ...al height closest to the floorboard Figure 5 29 Page 5 19 Press the accelerator pedal until the end of the tool rests against the floorboard pedal height should be 5 5 8 inches 14 3 cm Use a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft lb 35 3 N m 6 Adjust the brakes See Brake Adjustment Section 6 Page 6 8 Figure 5 27 Brake Rod Adjustment Figure 5 28 ...

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Page 71: ...oid unintentionally starting in General Warning on page 1 2 2 Place chocks at the front wheels Loosen but do not remove lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle 3 Loosen the equalizer retaining nuts 2 and 3 on the equalizer rod 1 to loosen the brake cable Figure 6 1 Page 6 2 4 Remove the ...

Page 72: ...drum to be pulled free After completing step 6 skip step 7 See following NOTE NOTE Although step 6 allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes 6 Remove the axle 6 1 Using 90 snap ring pliers CCI P N 1012560 remove the axle retaining ring 1 Figure 6 2 Page 6 2 6 2 Pull the axle shaft 2 from the axle tube Figure 6 2 Page 6 2 Figure 6 1 Loo...

Page 73: ...ntenance and Service Manual Page 6 3 6 Figure 6 4 Self adjusting Wheel Brake Assembly 10 TYPICAL 4 PLACES 1 8 6 9 4 3 2 13 12 6 5 7 TYPICAL 2 PLACES 7 TYPICAL 2 PLACES 11 TYPICAL 4 PLACES 16 14 SEE SECTION 9 REAR SUSPENSION FOR MOUNTING 15 ELECTRIC VEHICLE GASOLINE VEHICLE 14 ...

Page 74: ... brake shoes are under pressure and can release suddenly when brake shoe retainers are removed 8 Grasp both brake shoes and pull them together with the springs out of the brake assembly as shown Figure 6 6 Page 6 4 9 Remove adjuster wheel 1 with two washers 2 and 3 from the backing plate Figure 6 7 Page 6 4 Figure 6 5 Remove Shoe Retainer Clip Figure 6 6 Remove Brake Shoes Figure 6 7 Remove Adjust...

Page 75: ...d cause diminished brake performance possibly resulting in property damage or severe personal injury 4 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent on each of the six raised bosses on the brake backing plate Figure 6 9 Page 6 5 See preceding WARNING 5 Use a small brush to carefully apply a light coat of white lithium NLGI 2 gre...

Page 76: ... 17T should be facing out and be visible On the driver side the 17L on the leading shoe should be facing out and be visible When installed on the backing plate the leading shoe stamped 17L is always oriented toward the rear of the vehicle 2 Install the shoe retainer clip using pliers to compress the clip 1 while turning the retainer pin 2 into position Figure 6 13 Page 6 6 3 Attach the springs ont...

Page 77: ...nder the adjusting arm and raise the arm off of the adjusting wheel While holding the arm up turn the wheel upward until it stops Figure 6 17 Page 6 7 Remove the screw driver 7 Install the axle shaft 2 into the axle tube and install the retaining ring 1 Figure 6 2 Page 6 2 See following WARNING and CAUTION ý WARNING Be sure retaining ring is properly seated in groove If ring is not properly instal...

Page 78: ...justment Gasoline Vehicle Section 5 Page 5 11 For electric vehicles See Pedal Group Adjustment Electric Vehicles Section 5 Page 5 16 BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warning on page 1 1 See also Warning on Page 6 1 Brake Cluster Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 2 Place chocks at the ...

Page 79: ...the transaxle 4 1 Insert the splined end of the axle shaft into the axle tube Be careful not to damage the seal on the inside of the axle tube hub Advance the shaft through to the bearing on the shaft and rotate it to align the shaft splines with the splined bore of the differential gear Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seal 4 2 U...

Page 80: ...e if engaged and loosen equalizer retaining nuts 1 on equalizer rod 2 to slightly loosen the brake cables 3 Figure 6 18 Page 6 10 4 Rotate the brake cable upward and pull cable end through hole in top of equalizer 4 5 Remove E clip from cable at vehicle frame 5 Figure 6 18 Page 6 10 Remove cable from frame 6 Remove bow tie pin 1 and the clevis pin 2 from the brake lever on each wheel and pull the ...

Page 81: ... hanger in the same manner as before 2 At the rear wheel brake connect the cable to the brake actuator arm using new clevis pin 2 and new bow tie pin 1 Figure 6 19 Page 6 10 3 Place the cable in the cable support bracket 5 and secure with new E clip 3 For Vehicles Originally Equipped With Clip 4 Insert a new 3 8 16 x 3 1 2 inch hex head bolt 5 through the leaf spring mount and leaf spring Figure 6...

Page 82: ...2008 XRT 800 810 and 850 Maintenance and Service Manual 6 Figure 6 20 Brake Cable Clip and P Clamp REMOVE BRAKE CABLE HANGER CLIPS BRAKE CABLE IS ROUTED FROM INBOARD TO OUTBOARD CROSSING UNDER LEAF SPRING TO BRAKE CLUSTER 1 2 5 6 TYPICAL 2 PLACES TYPICAL 2 PLACES A B 3 4 3 REF ...

Page 83: ... and steering shaft 19 so when the steering wheel is removed it can be placed back in exactly the same position on steering column shaft 4 Loosen the steering wheel nut 27 and back it off approximately 1 4 inch 6 mm Do not remove the nut 5 Use the steering wheel puller CCI P N 102061201 to remove steering wheel 5 1 Place the puller anvil 4 through the top opening of the steering wheel Figure 7 1 P...

Page 84: ... tighten to 13 ft lb 17 6 N m 3 Install the plate 28 Figure 7 3 Page 7 3 STEERING COLUMN See General Warning on page 1 1 STEERING COLUMN REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 2 Remove the steering wheel See Steering Wheel Removal on page 7 1 3 Remove the front body as instructed in Section 4 Body and Trim ...

Page 85: ...g Column 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual Page 7 3 7 Figure 7 3 Steering Column 22 17 16 18 20 18 16 14 12 21 19 17 15 13 7 8 6 4 1 9 7 5 2 3 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES 28 25 27 10 11 29 ...

Page 86: ...of the tube to expose the retaining ring 22 Use pliers to twist the retaining ring 22 until it breaks off then remove the wedge 16 5 Remove the shaft 19 from the bottom of the tube 20 6 Use steering shaft 19 to push bearing seat 18 out from the opposite end of the steering tube 20 7 Insert a flat blade screwdriver between the bottom of the outer race of the bearing 17 and the bottom lip of the bea...

Page 87: ...6 to 20 ft lb 27 N m Figure 7 3 Page 7 3 2 For ease of assembly and to prevent corrosion apply a light coat of anti seize or lubricating compound to both splined ends of the steering shaft 3 Position the steering column assembly in the vehicle while inserting the steering column shaft into the upper universal joint 1 The flat portion of the steering shaft spline 19 must be aligned with the bolt ho...

Page 88: ... to the right so the passenger side spindle stop lightly touches the passenger side A Plate The internal stop on the rack must reach its limit of travel at the same time the spindle stops against the passenger side A plate with vehicle wheels turned to the right See following CAUTION CAUTION The drag link has both left and right hand threads The end of the drag link toward the spindle has left han...

Page 89: ... lock nuts 32 from the steering rack assembly mounting bracket Figure 7 8 Page 7 8 5 Remove the bolt 2 and flat washer 3 on the upper universal joint then remove the rack assembly and universal joint from the vehicle Figure 7 3 Page 7 3 RACK AND PINION DISASSEMBLY CAUTION The ball joint 23 Figure 7 8 Page 7 8 has left hand threads 1 Remove ball joint 23 and inspect it for excessive wear Figure 7 8...

Page 90: ...8 If necessary remove the dust seal 12 See following NOTE NOTE If the dust seal 12 is removed replace with a new one Figure 7 8 Page 7 8 9 Using snap ring pliers remove the internal snap ring 11 Figure 7 8 Page 7 8 10 Install the universal joint onto the pinion and place a large open end wrench under the universal joint Figure 7 9 Page 7 9 Use the wrench as a lever to pull the pinion from the hous...

Page 91: ...orn remove the ball joint and tab washer 4 from the rack Figure 7 11 Page 7 9 13 1 Secure the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage Figure 7 11 Page 7 9 13 2 Loosen and remove the inner ball joint with a wrench 14 Inspect the bushing inside the steering box assembly 6 for excessive wear If wear is excessive replace the steering b...

Page 92: ... bearing exerting all pressure on the inner race Figure 7 8 Page 7 8 5 Install the external snap ring 10 6 If the needle bearing 7 is damaged the steering box assembly CCI P N 101878302 must be replaced 7 Install pinion 8 and bearing 9 assembly into the housing 6 Figure 7 8 Page 7 8 Make sure the rack gear teeth will mesh with the gear teeth on the pinion The rack may need to be rotated slightly w...

Page 93: ...ck the screw off one quarter turn Tighten the lock nut to 28 ft lb 38 N m Figure 7 13 Page 7 11 See following NOTE NOTE When tightening the lock nut 15 make sure the screw 16 does not change adjustment Figure 7 13 Page 7 11 13 Install the dust seal bellows 20 and retaining ring 21 Figure 7 8 Page 7 8 14 Install the dust seal bellows 1 and hex nut 29 15 Install the universal joint on the pinion Tig...

Page 94: ...and 29 on the drag link Figure 7 8 Page 7 8 2 Remove the cotter pin 22 and ball joint retaining nut 25 Figure 7 8 Page 7 8 3 Remove the cotter pins 22 and ball joint retaining nuts 20 Figure 7 20 Page 7 18 4 Use a ball joint removal tool to remove ball joints 13 and 6 Figure 7 19 Page 7 17 and 23 Figure 7 8 Page 7 8 from the spindles 5 Remove the ball joints from the tie rod 11 Figure 7 19 Page 7 ...

Page 95: ...arning Section 1 Page 1 1 WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe in of the front wheels There is also a drag link adjustment to equalize the turning radius in both directions See Steering Adjustment on page 7 6 See following NOTE NOTE Prior to making any front suspension adjustments inspect components for wear or damage and r...

Page 96: ...half wheel revolutions until the marks appear on the forward facing surfaces of the tires at about the same height from the floor Figure 7 17 Page 7 14 4 Measure the distance between the marks on the forward facing surfaces of the tires Figure 7 17 Page 7 14 See following NOTE NOTE The front measurement must be less than the rear measurement 5 Subtract the measurement on the front of the tires fro...

Page 97: ...e of the hole in towing lug FRONT SUSPENSION COMPONENTS See General Warning on page 1 1 TAPERED LEAF SPRING REMOVAL 1 Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See General Warning Section 1 Page 1 1 2 Remove both front wheels 3 Remove t...

Page 98: ... be long enough to ream both bushings from one direction KINGPIN AND STEERING SPINDLE INSTALLATION 1 Inspect all parts and replace them as necessary 2 Install the kingpin 26 over the leaf spring eye Insert the bolt 25 and install the nut 14 Figure 7 20 Page 7 18 Tighten the bolt to 17 ft lb 23 N m 3 Install the wave washer 20 on the kingpin 4 Slide the spindle 38 with bushings 3 and 4 over the kin...

Page 99: ...XRT 800 810 and 850 Maintenance and Service Manual Page 7 17 7 Figure 7 19 Upper Front Suspension Assembly A Number of spacer plates used on vehicle Three on the 850 Five on the 800 810 9 8 18 12 13 11 9 14 5 20 2 4 25 2 1 3 2 4 2 3 2 10 5 14 6 7 10 27 26 17 23 24 22 A ...

Page 100: ...7 2008 XRT 800 810 and 850 Maintenance and Service Manual 7 Figure 7 20 Lower Front Suspension Assembly Number of spacer plates used on vehicle Three on the 850 Five on the 800 810 27 1 18 17 14 15 19 3 20 4 28 7 16 14 26 25 6 17 16 37 36 30 3 14 6 4 34 35 9 13 23 33 20 38 ...

Page 101: ...ntical part numbers 1 Install the shock absorber by reversing the removal procedure 2 Tighten the nuts to 20 ft lb 27 N m FRONT WHEEL BEARINGS AND HUBS See General Warning on page 1 1 NOTE The hubs used on this vehicle contain sealed bearings that cannot be serviced or replaced If the bearings are worn or damaged the entire hub must be replaced FRONT WHEEL FREE PLAY INSPECTION 1 Raise the front of...

Page 102: ... tighten to 50 ft lb 68 N m 4 Rotate the hub The hub should rotate smoothly without binding side play or any indication of rough spots during rotation 5 Repeat the procedure for the opposite wheel 6 Install wheels and finger tighten lug nuts 7 Lower the vehicle and finish tightening lug nuts using a crisscross pattern to the following amounts 7 1 For vehicles with steel wheels tighten the lug nuts...

Page 103: ...g nuts on the wheel to be removed 2 Raise the end of the vehicle from which the wheel is to be removed Make sure that the wheels are off the ground See General Warning on page 1 1 3 Remove the lug nuts and remove the wheel WHEEL INSTALLATION 1 Install wheel s and use a crisscross pattern to tighten the lug nuts until they are snug 2 Lower the vehicle and finish tightening lug nuts using a crisscro...

Page 104: ...upper part of the rim well Insert the tire tool under the lower bead as shown Figure 8 1 Page 8 2 Detail C and carefully pry the lower bead over the rim flange 3 4 Once the lower bead is started over the rim flange the tire can be removed from the rim by hand TIRE REPAIR 1 Determine the location and cause of the air leak 1 1 Remove the wheel See Wheel Removal on page 8 1 Inflate the tire to no mor...

Page 105: ... the tire on the rim from the valve stem side If there is no tire machine available use a rubber mallet and tire iron 5 Remove the valve core and position tire so that both beads are on the rim flange narrow bead seats 6 Place tire and wheel assembly against wall in upright position and push it against wall while inflating tire to 30 35 psi 2 07 2 42 Bars The three point contact wall floor and han...

Page 106: ... Maintenance and Service Manual 8 7 Quickly remove the air nozzle and install the valve core 8 Adjust air pressure in tire to recommended pressure See Section 2 Vehicle Specifications 9 Immerse the wheel and tire assembly in water to make sure there are no leaks ...

Page 107: ...ON 1 Check shock absorbers 7 for damage or fluid leakage at the point where the shaft enters the shock absorber body Replace damaged or leaking shock absorbers Figure 9 3 Page 9 3 and Figure 9 4 Page 9 5 2 To remove a shock absorber remove the nut 5 cup washers 9 and rubber bushings 10 from the stem at the top of the shock absorber 3 Remove the nut 5 cup washers 9 and rubber bushings 10 from lower...

Page 108: ...t 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 2 Place a floor jack under the transaxle differential casing to support but not lift the drivetrain Raise it just enough to relieve tension on the shock absorbers without compressing them 3 Remove the tire and wheel ass...

Page 109: ...end of the shackle brackets 1 8 Remove the nut 2 and bolt 15 attaching the front of the spring to the vehicle frame and remove the spring 9 Inspect the bushings 4 and spacers 3 in the spring eyes and replace them if they are worn or dam aged Figure 9 3 Rear Suspension Assembly and Mounting 800 and 810 1 11 9 10 9 5 7 16 3 4 12 2 4 3 4 2 1 15 4 3 4 15 17 18 14 13 20 15 2 ...

Page 110: ... the bow tie pin 1 and the clevis pin 2 at the brake lever and brake cable connection and pull the clevis 3 away from the lever Figure 9 2 Page 9 2 Detach the brake cable from the shock mount bracket 16 Figure 9 4 Page 9 5 5 Remove the nut 5 cup washers 9 and rubber bushings 10 from the lower mounting stem of the shock absorber 6 Remove the nuts 17 bolts 18 and bushing support 19 attaching the rea...

Page 111: ...SUSPENSION Leaf Springs 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual Page 9 5 9 Figure 9 4 Rear Suspension Assembly and Mounting 850 15 2 14 11 9 10 10 9 5 7 3 4 12 15 4 3 4 2 1 2 4 3 4 15 16 ...

Page 112: ...REAR SUSPENSION Leaf Springs Page 9 6 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual 9 Figure 9 5 Rear Stabilizer Bar Mounting 850 1 19 18 20 17 22 21 23 ...

Page 113: ...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 2 Remove the tire and wheel assemblies 3 Remove the nuts 17 bolts 18 and bushing support 19 attaching the rear stabilizer bar 21 to the shock mount bracket Figure 9 5 Page 9 6 4 R...

Page 114: ...9 ...

Page 115: ...local authorized distributor dealer to perform all repairs and semiannual and annual periodic ser vice PERIODIC SERVICE SCHEDULES See General Warning on page 1 1 ý WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to ma...

Page 116: ...pecifications General vehicle Wash battery compartment and underside of vehicle Semiannual service by trained technician only or every 50 hours of operation whichever comes first Brake system Check brake shoes replace if necessary See Section 6 Wheel Brake Assemblies Lubricate brake slides per Lubrication Schedule See Section 6 Wheel Brake Assemblies Check brake cables for damage replace if necess...

Page 117: ...service by trained technician only or every 50 hours of operation whichever comes first Battery Clean terminals and wash dirt from casing check electrolyte level See Battery on page 13 30 Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspension Electrical wiring and connections Check for tightness and damage Brake system Check brake shoes replace i...

Page 118: ...f operation whichever comes first Brake pedal shaft bearings Dry Moly Lube Brake linkage and pivots Dry Moly Lube Accelerator pivot rod supports Dry Moly Lube Charger receptacle WD 40 Brake slides Dry Moly Lube Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Annually by trained technician only or every 100 hours of operation whichever comes first Check fill transaxle to plug level 22 oz 0...

Page 119: ...push rod pivots mounts and shifter cable pivots Dry Moly Lube Front suspension 5 fittings Chassis Lube Brake slides Dry Moly Lube Annually by trained technician only or every 100 hours of operation whichever comes first Check fill unitized transaxle to plug level 27 oz 0 8 L 80 90 WT API Class GL 3 or 80 90 WT AGMA Class EP Gear Lube First change 100 hours additional change every 200 hours of oper...

Page 120: ...il level dipstick from the oil filler tube and wipe oil from dipstick Figure 10 4 Page 10 7 See following CAUTION ý CAUTION Do not remove dipstick while engine is running 2 Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it 3 If the oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full levels sa...

Page 121: ... entire body clear Failure to heed this warning could result in severe personal injury or death 3 Disconnect the battery cables negative cable first See WARNING To avoid unintentionally start ing in General Warning on page 1 2 4 Position a pan designed for oil changes under the front drain plug Figure 10 5 Page 10 8 5 Use a 14 mm socket or wrench to remove the drain plug turning it counterclockwis...

Page 122: ...ting bracket surface clean where the oil filter gasket seats 11 Install a new oil filter CCI P N 1016467 onto the engine oil filter port Apply a light coat of white lithium NLGI Number 2 grease Dow Corning BR2 Plus or equivalent or new engine oil to the rubber seal around the outside surface of the filter before attaching it to the oil filter port Figure 10 7 Page 10 9 This will help seal the filt...

Page 123: ...priate step for either or both items to correct the problem 17 Remove the dip stick and check the engine oil as a final step Replace the dip stick OIL VISCOSITY Choose the viscosity according to the temperature as indicated by the oil viscosity chart Figure 10 8 Page 10 9 See following NOTE NOTE Using multi grade oils 5W 20 10W 30 and 10W 40 will increase oil consumption Check oil level more frequ...

Page 124: ...PERIODIC MAINTENANCE Engine Oil Gasoline Vehicles Page 10 10 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual 10 ...

Page 125: ...ks The procedures used in making these checks can be found in the referenced sections of this maintenance and service manual TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine does not start easily Spark plug is partially fouled or in poor condition Section 15 Engine Spark plug wire is damaged or loose Section 15 Engine Loose wire connection at ignition coil or RPM limiter Section 11 Tr...

Page 126: ...el System Gasoline Vehicle Ignition coil or RPM limiter failed Section 11 Troubleshooting and Electrical System 800 and 810 Gas Test Procedures 14 15 and 16 Kill circuit grounded Section 11 Troubleshooting and Electrical System 800 and 810 Gas Test Procedures 17 and 18 Engine overheats Fan screen is partially blocked or plugged See the Engines and Transaxles manual CCI P N 102396501 Governor is im...

Page 127: ...lled with gasoline Section 16 Fuel System Gasoline Vehicle Carburetor vent is clogged Section 16 Fuel System Gasoline Vehicle Float needle valve not functioning properly Section 16 Fuel System Gasoline Vehicle Starter fails to operate Lockout cam is in the wrong position Section 11 Troubleshooting and Electrical System 800 and 810 Gas Lockout Cam on page 11 5 Fuse is blown Section 11 Troubleshooti...

Page 128: ... Gasoline Vehicle Insufficient low level of lubricant or wrong type of lubricant in transmission Lubrication on page 18 2 Internal gears are damaged or worn See the Engines and Transaxles manual CCI P N 102396501 Synchronizer rings are worn damaged or jammed See the Engines and Transaxles manual CCI P N 102396501 Excessive vehicle vibration Engine mounting nuts or bolts are loose Section 15 Engine...

Page 129: ... Reverse handle is in the NEUTRAL position See Section 15 Engine LOCKOUT CAM This key start vehicle is equipped with a lockout cam that allows the engine to be started and revved only when the Forward Reverse handle is in the NEUTRAL position The lockout cam yellow is located on the back of the Forward Reverse handle inside the engine compartment NOTE Be sure the cam is in the correct position The...

Page 130: ...IL LIGHT LIGHT SWITCH NEG POS REVERSE BUZZER FRONT S B M M KEY SWITCH A VOLTAGE LIMITER FUEL TANK SENDING UNIT CENTER DASH PANEL ASM OIL SENDING UNIT IGN KILL P N 1017721 POWER POINT ELECTRICAL COMPONENT BOX 6 7 1 4 2 18_ORG W25 14_YEL W10 18_BLU W11 18_WHT_BLK W12 16_BLU W15 14_BLU W26 16_BLK W16 16_BLK_WHT_STP W27 16_BLK W17 16_BLK W28 18_YEL W18 16_BLK W36 16_BLK W30 16_ORG W31 18_YEL W41 18_OR...

Page 131: ...R GENERATOR SOLENOID VOLTAGE REGULATOR FUSE BLOCK FORWARD LIMIT SWITCH REVERSE LIMIT SWITCH ENGINE BARE P N 1014948 P N 102264001 ELECTRICAL COMPONENT BOX BATTERY WHITE RED 10_NON_INSUL W37 18_BLK W14 18_BLK W40 16_BLK W42 18_BLK W43 18_GRN W07 6_RED W38 6_BLK W35 6_WHT W08 18_YEL W09 10_RED W39 6_BLK W02 6_GREEN_HIGH_TEMP W34 18_RED W44 18_YEL W45 16_ORG W31 14_YEL W10 18_RED W04 18_ORG W25 18_OR...

Page 132: ... Starter Generator Starter Function 9 Wire Continuity 10 Diode Generator Circuit 11 Starter Generator Generator Function 12 Voltage Regulator 13 Grounded Kill Wire 14 Ignition Spark 15 RPM Limiter 16 Ignition Coil 17 Key Switch Engine Kill Circuit 18 Engine Kill Wire 19 Reverse Buzzer Limit Switch 20 Reverse Buzzer 21 Oil Level Sensor 22 Oil Warning Light 23 Lockout Cam 24 Battery Test Under Load ...

Page 133: ...ve the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Check for loose or corroded battery terminal connections Clean tighten and replace connections as necessary Hydrometer Test A hydrometer CCI P N 1011478 measures the specific gravity The higher the specific gravity the higher the state of charge of the battery A fully charged battery should read between 1 250 a...

Page 134: ...mperature For each 10 F 5 6 C above 80 F 27 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 27 C subtract 0 004 from the reading Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined by referring to the following table If the difference between the cells is 0 020 or more the low cell should be suspected It may require a catch up charge or it ma...

Page 135: ...the load tester to the ON position 3 Read the battery voltage after the load tester has been turned ON for 15 seconds Compare the battery s voltage reading with the table below Make sure you have the correct ambient temperature 4 If the battery is found to be good or if the electrical problem continues after the battery has been replaced with a good one test the electrical circuits TEST PROCEDURE ...

Page 136: ...located on the oil filler bracket on the engine Figure 11 7 Page 11 12 Place the black probe on the vehicle frame The reading should be continuity If the reading is incorrect clean and tighten wire connections If the connections are good and the reading is incorrect repair or replace the wire 5 Check voltage regulator ground connection at battery frame ground Make sure it is clean and tight 6 Chec...

Page 137: ...14 See Key Switch Removal Section 13 Page 13 14 6 With the key still in the ON position place the red probe of the multimeter on the B terminal and the black probe on the S terminal of the key switch The reading should show no continuity If the reading is incorrect replace the key switch See Key Switch Removal Section 13 Page 13 14 If the reading is correct leave the probes connected and proceed t...

Page 138: ... With the multimeter set to 200 ohms place the red probe of the multimeter on the B terminal and the black probe on the L terminal of the key switch Figure 11 9 Page 11 14 The reading should be continuity If the reading is incorrect replace the key switch See Key Switch Removal Section 13 Page 13 14 Figure 11 9 Key Switch Test Accessory Terminal Figure 11 10 Key Switch Test Starter Circuit Figure ...

Page 139: ... read ing on the multimeter should be no continuity Turn the key switch to the START position and listen for the solenoid click While holding the key in the START position there should be continuity After the key is released it should rotate to the ON position and should be no continuity If either reading is incorrect replace the solenoid 10 With the Forward Reverse handle still in the NEUTRAL pos...

Page 140: ...he limit switch should make an audible click as it is pressed If it does not check for wear on the cam lobe If the cam lobe will not activate the limit switch replace the cam Figure 11 12 Test Solenoid Continuity Figure 11 13 Test Solenoid Ground Figure 11 14 Test Lockout Cam Limit Switch SOLENOID ELECTRICAL COMPONENT BOX 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAV...

Page 141: ...ded F1 or F2 terminal or a grounded field coil If the DF reading is incorrect it indicates a possible grounded DF terminal or a grounded field coil 5 Disconnect the ground wire from the A2 terminal and the green wire from the A1 terminal on starter gen erator 6 Using a multimeter set to 200 ohms place the red probe on the A1 terminal and the black probe on the A2 terminal The reading should be con...

Page 142: ...ing on page 1 1 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Disconnect the red and white wires of the diode assembly from the solenoid posts located within the electrical component box 3 1 Remove the...

Page 143: ...a range of 400 500 mV is acceptable Figure 11 19 Page 11 20 6 Connect either the black or red lead of the multimeter to the diode body case Connect the other multimeter lead to both the red and white lead terminals of the diode The multimeter should indicate an overload no continuity If continuity reading does occur it indicates that one or both of the diode leads are grounded to the diode body ca...

Page 144: ...it at full governed speed The reading should show the voltage rising on the meter If the voltage rises see Test Procedure 12 Voltage Regulator on page 11 20 If the voltage does not rise and the diode was found to be functioning properly in Test Procedure 10 a tear down inspection of the starter generator will be necessary See Starter Generator Removal Section 13 Page 13 1 5 Reconnect the yellow wi...

Page 145: ...ed speed If the reading is between 14 7 and 15 3 volts the regulator is good If the reading is lower than 14 7 volts but rising steadily check battery condition See Hydrometer Test on page 11 9 If the reading is lower than 14 7 volts and not rising and the starter generator is good or if the reading is over 15 3 volts and continues to rise replace voltage regulator See Voltage Regulator Removal Se...

Page 146: ... and remove the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Remove the plug wire from the spark plug Using an ignition spark gap test tool Thexton 404 or equiv alent check for correct spark Figure 11 21 Page 11 22 2 1 Adjust the tester probes to approximately to 18 000 volts 18 Kv setting SE Small Engine Setting on the Thexton 404 tool Connect the tester to the...

Page 147: ... most bad RPM limiters Some of them may bench test okay but fail under a load due to heat while operating Another method of testing is to replace the RPM limiter and then run the engine If the engine runs properly keep the new RPM limiter in the circuit TEST PROCEDURE 16 IGNITION COIL See General Warning on page 1 1 The following test procedures will properly detect a coil that has failed in most ...

Page 148: ...Figure 11 24 Primary Coil Resistance In Vehicle Test Figure 11 25 Secondary Coil Test In Vehicle Test 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED ...

Page 149: ...Using a multimeter set to 20k ohms measure the resistance of the secondary coil and spark plug cap together 4 1 Place the red probe of the meter into the end of the spark plug cap that normally connects to the spark plug and place the black probe on a clean unpainted surface of the engine or frame Figure 11 25 Page 11 24 4 2 If the resistance is between 12 0k 14 0k ohms the secondary coil and spar...

Page 150: ...the coil fails to function properly proceed to the following bench test procedures Ignition Coil Bench Test 1 Remove the coil from the engine See Ignition Coil Removal Section 13 Page 13 24 2 Using a multimeter set to 200 ohms measure the primary coil resistance 2 1 Place the black probe of the meter on the terminal on the ignition coil 1 and place the red probe on the core 2 Figure 11 30 Page 11 ...

Page 151: ...e 11 31 Secondary Coil and Cap Resistance Bench Test 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 1 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM ...

Page 152: ...tely from the spark plug cap 5 1 Using a multimeter set to 20k ohms place the red probe of the meter into the end of the spark plug wire and place the black probe on the core 2 Figure 11 32 Page 11 28 If the resistance is between 6 0k 11 0k ohms the secondary coil is within acceptable limits If the resistance is not between 6 0k 11 0k ohms the ignition coil has failed and must be replaced 6 If the...

Page 153: ...ls 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Disconnect white black wire bullet connector located at the engine RPM limiter Figure 11 22 Page 11 22 4 Connect red probe of multimeter to the male bullet terminal on the white black wire and connect the black probe to the vehicle frame 5 With the Forward Reverse handle ...

Page 154: ...on Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Remove the instrument panel See Key Switch Removal Section 13 Page 13 14 4 Check for proper wiring and tight connections Using a multimeter individually check for continuity through each wire that connects to the reverse buzzer If the buzzer will not func...

Page 155: ...es on the cam are pressing the lockout cam limit switch when the Forward Reverse shifter is in the NEUTRAL position only The limit switch should make an audible click as it is pressed If it does not check for wear on the cam lobe If the cam lobe will not activate the limit switch replace the cam TEST PROCEDURE 24 BATTERY TEST UNDER LOAD See General Warning on page 1 1 NOTE Keep the battery connect...

Page 156: ...he chart below may be used as a guideline to determine if the fuel level sending unit is operating correctly Make sure the float is at the surface of the fuel in the tank 6 If the readings are within the specifications listed above the fuel level sending unit is working properly If the readings are incorrect the fuel level sending unit has failed and the fuel tank must be replaced See Fuel Tank Re...

Page 157: ... terminal 3 to ground it whereas the gauge used from mid 2007 has two ground terminals 1 and 6 with a black jumper wire connecting them See following NOTE NOTE Keep the battery connected during this test procedure Test Procedure 26A Fuel Gauge Through mid 2007 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels Figure 11 34 Test F...

Page 158: ...he orange wire should remain disconnected for this step With the black probe still on the 3 terminal of the fuel gauge hour meter place the red probe of the multimeter on the 1 terminal of the fuel gauge hour meter Figure 11 38 Page 11 34 The voltage reading should be approximately 1 81 volts If the reading is incorrect replace fuel gauge hour meter Test Procedure 26B Fuel Gauge From mid 2007 1 Tu...

Page 159: ...ter easily denotes the type Follow the appro priate procedure The display on the meter used through mid 2007 only appears when the key switch is ON whereas the display on the meter used from mid 2007 is always on The meter used through mid 2007 has the orange wire connected to terminal 1 whereas the meter used from mid 2007 has it connected to terminal 4 in the center of the meter In addition the ...

Page 160: ...d actual engine running time and will not start adding incre ments until the engine is running and the oil pressure switch has opened 5 If the hour meter still does not function after the low oil warning light oil pressure switch and all of the appropriate wires have been checked for continuity replace the fuel gauge hour meter TEST PROCEDURE 28 LIGHT SWITCH See General Warning on page 1 1 1 Turn ...

Page 161: ... reading should be 11 12 volts If the there is no voltage read ing check continuity of the 16 gauge black wire from the headlight to the headlight diode Check conti nuity of the 16 gauge black wire from headlight diode to the vehicle frame If the wires show continuity and the readings are still incorrect replace the headlight diode See Voltage Limiter Removal Section 13 Page 13 28 8 With the Forwa...

Page 162: ...imeter onto the negative battery terminal and place the red probe into the blue wire terminal of the wire harness If multimeter reading is approximately 12 volts the blue wire has continuity 7 Check continuity of the 16 gauge black wire from the headlight to the ground terminal Using a multimeter set to 20 volts DC place the black probe of multimeter into the black wire terminal of the wire harnes...

Page 163: ...used in making these checks can be found in the referenced sections of the maintenance and service manual TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Engine does not start easily Spark plug is partially fouled or in poor condition Section 15 Engine Spark plug wire is damaged or loose Section 15 Engine Loose wire connection at ignition coil or RPM limiter Section 12 Troubleshoot...

Page 164: ...nnection at ignition coil or RPM limiter Section 12 Troubleshooting and Electrical System 850 Gas Test Procedures 13 14 and 15 Ignition coil or RPM limiter failed Section 12 Troubleshooting and Electrical System 850 Gas Test Procedures 13 14 and 15 Engine flooded with fuel as result of excess choking See Section 3 General Information See Choke Kill circuit grounded Section 12 Troubleshooting and E...

Page 165: ...asoline Vehicle Torque converter is not backshifting properly Section 20 Torque Converter Gasoline Vehicle Spark plug fouls repeatedly Incorrect plug Section 15 Engine Spark plug wire is damaged Section 15 Engine Unsuitable fuel or incorrect rich fuel mixture Section 16 Fuel System Gasoline Vehicle Ignition coil failed Section 12 Troubleshooting and Electrical System 850 Gas Test Procedures 13 14 ...

Page 166: ... lockout limit switch failed Section 12 Troubleshooting and Electrical System 850 Gas Test Procedure 7 Loose or broken wire in starter generator circuit Section 14 Electrical Components 850 Gasoline Vehicle Starter Generator on page 14 1 Cylinder and or crankcase flooded with fuel Section 16 Fuel System Gasoline Vehicle Starter generator does not charge battery Loose or broken wire in the starter ...

Page 167: ...line Vehicle Damaged drive clutch Section 20 Torque Converter Gasoline Vehicle Damaged starter generator pulley Section 14 Electrical Components 850 Gasoline Vehicle Starter Generator on page 14 1 RPM setting is incorrect Section 16 Fuel System Gasoline Vehicle Engine RPM Adjustment on page 16 12 Torque converter does not shift smoothly Drive belt is worn cracked glazed or frayed Section 20 Torque...

Page 168: ...ce and Service Manual 12 WIRING DIAGRAM Figure 12 1 Wiring Diagram for Pedal Start Gasoline Vehicles FUEL HOUR METER GUAGE 6 7 1 4 2 HEAD LIGHT LEFT HEAD LIGHT RIGHT LIGHT SWITCH VOLTAGE LIMITER 14_YEL W10 16_BLU W15 14_BLU W26 16_BLK W16 16_BLK_WHT_STP W27 16_BLK W17 16_BLU W23 16_BLK W24 16_BLU W32 14_YEL W10 ...

Page 169: ...TROUBLESHOOTING AND ELECTRICAL SYSTEM 850 GAS Wiring Diagram 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual Page 12 7 12 Figure 12 2 Wiring Diagram for Pedal Start Gasoline Vehicles TAN ...

Page 170: ... Lighting Circuit Recognizing and understanding the function of each of these circuits will help to quickly isolate the source of an electrical problem Use the appropriate test procedure to correct the electrical problem See Test Proce dures on page 12 8 For a complete wiring diagram see page 12 6 TEST PROCEDURES INDEX OF TEST PROCEDURES 1 Battery 2 Fuse 3 Ground Cables 4 Key Switch Starter Circui...

Page 171: ...ng 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 NOTE The battery must be properly maintained and fully charged in order to perform the following test procedures Battery maintenance procedure...

Page 172: ...f the bottom adjust the electrolyte level so that the float rides free of the bottom but does not strike the bottom of the rubber bulb Remove the hydrometer from the cell and release the pressure from the bulb 6 Hold the hydrometer vertically ensuring that the float is not contacting the sides of the glass tube Hold the hydrometer at eye level and read the scale at the level of electrolyte Figure ...

Page 173: ...ter than 1 225 the problem is not with the battery If the battery does not reach 12 4 volts or if the specific gravity of a cell is still less than 1 225 after charging replace the battery See following NOTE NOTE A fully charged battery that is in good condition should have a specific gravity of at least 1 225 in all cells and the difference in the specific gravity of any two cells should be less ...

Page 174: ...uld be con tinuity If there is no continuity determine and repair the cause of the fuse failure Replace the fuse with a properly rated new one TEST PROCEDURE 3 GROUND CABLES See General Warning on page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 2 Check the starter generator ground cable 2 1 Set the multimeter to 20...

Page 175: ...incorrect ensure that terminal connections are clean and tight If the connections are good and the reading is incorrect repair or replace the cable TEST PROCEDURE 4 KEY SWITCH STARTER CIRCUIT See General Warning on page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 2 Remove the center dash assembly See Key Switch Remo...

Page 176: ...COM terminal green wire of the limit switch and place the black probe on the normally closed NC terminal orange wire of the limit switch 4 Make sure the battery is disconnected With the key switch in the OFF position the Forward Reverse handle in NEUTRAL and the accelerator pedal in the UP position the reading should be no continuity With the accelerator pedal pressed the reading should be continu...

Page 177: ... tighten hardware to 144 in lb 16 N m 8 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAIN TENANCE position Turn the key switch to the ON position With the accelerator in the UP position the reading on the multimeter should be no continuity Press the accelerator pedal and listen for the solenoid click There should be continuity If either reading is ...

Page 178: ...nd replace cam if necessary TEST PROCEDURE 8 STARTER GENERATOR STARTER FUNCTION See General Warning on page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 2 Ensure that wires are connected correctly and are tight If they are not rewire or tighten as necessary 3 Disconnect the wires from all the terminals on the starter...

Page 179: ...erator Removal on page 14 1 6 With the wires still disconnected using a multimeter set on 200 ohms place the red probe on the F1 terminal and the black probe on the F2 terminal The reading should be between approximately 0 1 and 0 3 ohms If the reading is incorrect a possible open field coil or bad connections at terminals may be the cause The starter generator will need to be removed from the veh...

Page 180: ...ce the red probe on the positive post of the battery and place the black probe on the negative post Start the engine and run it at full governed speed The reading should show the voltage rising on the meter If the voltage rises above 15 3 volts DC test the volt age regulator See Test Procedure 11 Voltage Regulator on page 12 18 If the voltage does not rise a tear down inspection of the starter gen...

Page 181: ...Disconnect the engine kill white black wire at the bullet connector located next to the RPM limiter Figure 12 17 Page 12 20 3 Start the engine in a well ventilated area Turn the key switch to the ON position Press the accelerator pedal to start the engine 4 If the engine begins to run test the engine kill circuit for a shorted wire or other failed components in the engine kill circuit See Test Pro...

Page 182: ...the spark is a faint yellow or red color test components of the ignition circuit See Test Procedure 15 Ignition Coil on page 12 21 3 If the spark gap tester tool indicates a strong blue spark it is possible the spark plug has failed internally Check the spark plug gap The gap should be set at 0 027 to 0 031 of an inch 0 69 to 0 79 mm If the gap is correct replace the spark plug with a new part and...

Page 183: ...te the engine for several minutes to ensure that the coil functions at normal operating temperature If the new coil functions properly keep the new coil in the circuit Test Procedure 15A Ignition Coil In Vehicle Test 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 2 Using a multimeter set to 200 ohms measure the primary coi...

Page 184: ...l Resistance In Vehicle Test 1 200 Ohm Setting Figure 12 20 Secondary Coil Test In Vehicle Test 1 20k Ohm Setting 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 ...

Page 185: ...ondary coil must be tested independently from each other 4 Test the spark plug cap separately from the secondary coil 4 1 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the spark plug wire 3 Figure 12 21 Page 12 23 4 2 Remove the cap from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire Figure 12 22 Page 12 23...

Page 186: ...g Cap Test 1 20k Ohm Setting 2 Spark Plug Cap Figure 12 24 Secondary Coil Test Without Cap 1 20k Ohm Setting 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 1 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 ...

Page 187: ... the engine See Ignition Coil Removal on page 14 23 2 Using a multimeter set to 200 ohms measure the primary coil resistance 2 1 Place the black probe of the meter on the terminal on the ignition coil 1 and place the red probe on the core 2 Figure 12 25 Page 12 25 2 2 If the resistance is not between 0 6 1 7 ohms replace the ignition coil 3 Using a multimeter set to 20k ohms measure the resistance...

Page 188: ...mally connects to the spark plug and place the black probe into the end of the cap with the internal screw Figure 12 23 Page 12 24 If the resistance is not between 4 5k 6 0k ohms the cap has failed and must be replaced Proceed to the next step with the spark plug cap still removed 5 Test the secondary coil separately from the spark plug cap 5 1 Using a multimeter set to 20k ohms place the red prob...

Page 189: ...continuity If either reading is incorrect replace the limit switch Figure 12 28 Page 12 27 4 Connect wires to limit switch and check for tight connections TEST PROCEDURE 17 KEY SWITCH ENGINE KILL CIRCUIT See General Warning on page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 2 Remove the center dash assembly See Key...

Page 190: ...ming this test procedure The reverse buzzer limit switch is located on the Forward Reverse shifter red white and orange wires are connected to it 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAIN TENANCE position Chock the wheels 2 Move the Forward Reverse handle to REVERSE and listen for an audible click from the limit switch If there is no clic...

Page 191: ...ing an alligator clip jumper wire connect the low oil warning light terminal to the vehicle frame Connect the red battery cable to the positive battery post then attach the black cable to the negative battery post 5 Turn the key switch ON The low oil warning light should illuminate If it does not check continuity of the yellow wire that connects the key switch to the low oil warning light If there...

Page 192: ... wires involved TEST PROCEDURE 24 BATTERY TEST UNDER LOAD See General Warning on page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAIN TENANCE position Chock the wheels 2 Set a multimeter to 20 volts DC and place the red probe on the F2 white wire terminal on the starter ge...

Page 193: ... To avoid the possibility of fire or explosion make sure the fuel tank cap is securely in place while performing this test procedure 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 2 Disconnect the orange wire from the center post of the fuel level sending unit 3 With a multimeter set to 2k ohms place the red probe of the m...

Page 194: ... Also check the continuity of the blue wire from the fuel gauge hour meter to the key switch and the black ground wires at the fuel level sending unit and at the fuel gauge hour meter See Fuel Gauge Hour Meter Removal on page 14 21 7 If the readings are correct according to the position of the float but give an incorrect reading on the fuel gauge hour meter test the fuel gauge hour meter See Test ...

Page 195: ...ng recorded earlier If not check the continuity of the blue and black wires Figure 12 33 Page 12 33 8 The orange wire should remain disconnected for this step Place the black probe of the multimeter on the 1 terminal of the fuel gauge hour meter and place the red probe on the 4 terminal of the fuel gauge hour meter Figure 12 34 Page 12 33 The voltage reading should be approximately 4 94 volts If t...

Page 196: ...ard Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Remove the instrument panel See Key Switch Removal Section 13 Page 13 14 4 Using a multimeter set on 20 volts DC place alligator clips on the multimeter probes Connect the red probe to the light switch terminal wit...

Page 197: ... should be 11 12 volts If the there is no voltage read ing check continuity of the 16 gauge black wire from the headlight to the voltage limiter Check continuity of the 16 gauge black wire from voltage limiter to the vehicle frame If the wires show continuity and the readings are still incorrect replace the voltage limiter See Voltage Limiter Removal Section 13 Page 13 28 8 With the Forward Revers...

Page 198: ...er onto the negative battery terminal and place the red probe into the blue wire terminal of the wire harness If multimeter reading is approximately 12 volts the blue wire has continuity 7 Check continuity of the 16 gauge black wire from the headlight to the ground terminal Using a multimeter set to 20 volts DC place the black probe of multimeter into the black wire terminal of the wire harness an...

Page 199: ...Reverse handle is in the NEUTRAL position Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Disconnect the wires from the starter generator 1 Mark wires before disconnecting Loosen the pivot nuts 7 and bolts 5 Figure 13 1 Page 13 2 4 Remove the mounting adjustment nut 12 washer 9 and bolt 11 Lower the start...

Page 200: ...ack from the center of the commutator end cover The springs will help prevent them from sliding back towards the center Figure 13 6 Page 13 4 2 Remove brush covers 29 and 30 screws 25 lockwashers 26 brush springs 28 and brushes 27 Figure 13 3 Page 13 2 See following NOTE NOTE To clean and inspect the armature commutator and the bearings see Disassembly of the Starter Generator to Service the Armat...

Page 201: ...h in color 2 Install the four brushes 27 into their holders and insert the four brush springs 28 Figure 13 3 Page 13 2 Using a spring scale test brush spring tension If any spring has a tension less than 24 ounces 6 67 N replace all four springs Figure 13 5 Page 13 3 See following CAUTION CAUTION When checking brush spring tension do not push springs beyond the point they would normally be if ther...

Page 202: ...nd cover 23 Figure 13 3 Page 13 2 Disassembly of the Starter Generator to Service the Armature Commutator 1 Remove the two bolts 20 and pull commutator end cover 23 free of the starter generator housing 24 Figure 13 2 Page 13 2 See following NOTE NOTE Brushes must be removed to avoid damaged from commutator removal Lift the brush springs out of the notches in the brushes and pull the brushes back ...

Page 203: ... Page 13 6 2 Discard the bearings 3 Slide the bearing retainer 32 off of the output end of the shaft Figure 13 7 Page 13 5 Field Coil Removal 1 Remove the retaining nut from each field coil terminal and slide the insulator out of the slots in the hous ing Remove the four pole piece screws from the housing Remove the four pole pieces from inside the housing Remove the field coils from the inside of...

Page 204: ...nsulation Improperly cured varnish Thrown solder Flared armature windings Worn burned or glazed commutator Loose or raised commutator bars Bruised or damaged armature core laminations Worn armature bearing or shaft Dirty or oily commutator Figure 13 9 Bearing Removal Figure 13 10 Field Coil Removal USE A 1 2 INCH SOCKET OR PIPE PRESS RAM USE A 1 2 INCH SOCKET OR PIPE SUPPORT INNER RACE OF BEARING ...

Page 205: ...commutator diameter is less than 1 535 inches 39 mm at any of the four loca tions replace the armature assembly and bearings Figure 13 11 Page 13 7 Armature Ground Test CAUTION Do not submerge armature in solvent NOTE Before testing wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars 1 Use a multimeter set on 200 ohms and place the positive ...

Page 206: ...en through the insulators Install a flat washer lockwasher and nut onto each threaded terminal on the outside of the housing Tighten nuts to 47 5 in lb 5 4 N m Figure 13 10 Page 13 6 See following CAUTION Figure 13 12 Armature Ground Test ITEM SERVICE LIMIT Commutator diameter minimum 1 535 in 39 mm Concentric with armature shaft within 0 002 in 0 051 mm Limit depth of cut when machining commutato...

Page 207: ...over 23 onto the armature shaft Align the locating pin and hole in the cover Install the two M6 x 180 mm bolts 20 and tighten to 100 in lb 11 3 N m Figure 13 2 Page 13 2 10 Push the brushes down into the holders Place springs into the notches in the brushes Install the brush cover 30 that has the drain hole in it next to the A2 terminal Install the remaining three brush covers 29 onto the openings...

Page 208: ...acket carriage bolt 11 and hex nut 12 are finger tight Figure 13 13 Page 13 10 4 Push the starter generator down to its lowest point of adjustment travel With the starter generator belt in place around the drive clutch pulley install the starter generator belt 3 5 Place a pry bar 13 between the top of the starter generator mounting bracket 2 and the underside of the starter generator by passing th...

Page 209: ...the voltage regulator mounting screw 8 and remove the voltage regulator 9 Voltage Regulator Installation 1 Position the voltage regulator 9 in the electrical component box and install the mounting screw 8 and tighten screw to 23 in lb 2 6 N m Figure 13 15 Page 13 12 2 Connect the voltage regulator red wire 1 at the large post on the solenoid with the other red wires the yellow wire 4 at the bullet...

Page 210: ...noid posts and disconnect the diode wires from the solenoid 5 1 Observe color orientation of the wires with the terminal locations on the solenoid The 12 gauge red wire from the diode should be attached to the same terminal as the red wire from the fuse block and the red wire from the battery The 12 gauge white wire should be attached to the other large solenoid post along with the red wire from t...

Page 211: ... 16 Page 13 13 See following NOTE NOTE Diodes are mounted in one of two different locations depending on the vehicle model Figure 13 16 Page 13 13 4 Route and connect the red and white diode wires to the solenoid posts in the electrical component box See following WARNING ý WARNING Incorrect wiring could result in severe injury or death Diode and solenoid connections must have correct polarity Kee...

Page 212: ... with Battery Terminal Protector Spray CCI P N 1014305 KEY SWITCH See General Warning on page 1 1 Testing the Key Switch See Test Procedure 4 Section 11 Page 11 13 Also see Test Procedure 17 Key Switch Engine Kill Circuit on page 11 28 Key Switch Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect the battery ...

Page 213: ...144 in lb 16 3 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 SOLENOID See General Warning on page 1 1 Testing the Solenoid See Test Procedure 6 Section 11 Page 11 15 Solenoid Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid uni...

Page 214: ...key switch to the small post on the solenoid 2 4 Connect the 18 gauge green wire from the Forward Reverse limit switch to the other small post on the solenoid 3 Tighten the hex nuts on the large solenoid posts to 55 in lb 6 2 N m Tighten the nuts on the small sole noid posts to 22 in lb 2 5 N m 4 Install the snap on electrical box cover by firmly pressing down on all corners and install the screw ...

Page 215: ...age 1 2 3 Disconnect the wires from the lockout cam limit switch 5 located on the back of the Forward Reverse shifter assembly Figure 13 19 Page 13 18 4 Remove two nuts 2 and washers 6 from the lockout cam limit switch 5 and slide the lockout cam limit switch off of the screws Lockout Cam Limit Switch Installation 1 Install the limit switch 5 with washers 6 and nuts 2 and tighten to 5 in lb 0 6 N ...

Page 216: ...page 1 2 3 Remove the external snap ring 14 Figure 13 20 Page 13 18 4 Remove the plastic washer 12 and the spring 13 5 Remove the cam 11 Lockout Cam Installation 1 Install the cam 11 Figure 13 20 Page 13 18 2 Install the spring 13 and the plastic washer 12 3 Install the external snap ring 14 into the groove on the shaft The lockout limit switch should be activated only when the Forward Reverse han...

Page 217: ...gure 13 21 Page 13 19 5 Remove the screw 3 nut 4 lockwasher 5 and flat washer 6 securing the buzzer to the vertical frame support Reverse Warning Buzzer Installation 1 Install the screw 3 through the buzzer 2 bracket tab and frame secure with hardware and tighten to 14 in lb 1 6 N m Figure 13 21 Page 13 19 See following NOTE NOTE The reverse warning buzzer is secured at one hole only 2 Connect the...

Page 218: ...witch 4 and then install two spacers 9 against the limit switch 2 Install the lockout cam limit switch 5 with two washers 6 and two nuts 2 and tighten to 5 in lb 0 6 N m See following CAUTION ý CAUTION Do not overtighten the retaining nuts If the nuts are overtightened limit switches could be damaged 3 Place the Forward Reverse handle in REVERSE to make sure that only the reverse buzzer limit swit...

Page 219: ...eneral Warning on page 1 1 Testing the Fuel Gauge Hour Meter See Test Procedure 26 Section 11 Page 11 33 Also see Test Procedure 27 Hour Meter on page 11 35 2006 to mid 2007 vehicles With the key switch in the OFF position the fuel gauge hour meter fields are blank When the key switch is turned to ON both fields activate Mid 2007 and newer vehicles With the key switch in the OFF position the fuel ...

Page 220: ... 1 Install a new gauge meter into hole in dash until flange seats against dash Figure 13 22 Page 13 21 2 Secure the fuel gauge hour meter 2 1 2006 to mid 2007 vehicles Slide the mounting bracket onto the two threaded studs on the fuel gauge hour meter Secure the fuel gauge hour meter with two lockwashers and two hex nuts Tighten to 2 5 in lb 28 N m Place one drop of Loctite on each hex nut Do not ...

Page 221: ...ation 1 Place the RPM limiter on the damper squarely so that RPM limiter fits tightly against the damper 2 Place the RPM limiter with damper on the front of the RPM limiter mounting bracket Figure 13 23 Page 13 23 3 Place the band over the RPM limiter and align the holes Place the brown wire ring connector onto the flange head bolt and secure the left side of the band Use another flange head bolt ...

Page 222: ...ator See Starter Generator Removal on page 13 1 See following NOTE NOTE The crankshaft has left hand threads at the clutch mounting hole 2 Remove the muffler See Muffler Removal Section 17 Page 17 1 3 Remove the engine mounting hardware items 1 2 and 5 Figure 15 4 Page 15 4 4 Remove the two nuts 6 and washers 3 from the stud bolts on the engine body 5 Slide the engine away from the transaxle housi...

Page 223: ... the old spark plug wire Clean the grommet and place it on the new spark plug wire 5 5 Install the protector tube 3 onto the new wire Figure 13 26 Page 13 26 6 Slide the gasket 1 onto the end of the new spark plug wire 7 Install the cap 2 on the new coil spark plug wire by rotating it clockwise three or four revolutions while applying light pressure on the cap 8 Install the gasket 1 on the cap 2 9...

Page 224: ...plate and transaxle housing Loosely attach the two nuts 6 finger tight Figure 15 4 Page 15 4 17 Attach the engine to the bottom of the engine mounting plate using the bolts 1 washers 2 and nuts 5 Tighten hardware to 21 ft lb 28 4 N m Figure 15 4 Page 15 4 18 Tighten the two engine body bolt nuts 6 to 17 ft lb 23 1 N m 19 Install the engine and transaxle assembly See Unitized Transaxle Installation...

Page 225: ...ght Socket See Test Procedure 30 Section 11 Page 11 37 Headlight Bulb Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 From the front of vehicle reach under body and turn the wire harness halogen ...

Page 226: ...ighten the terminals to 144 in lb 16 3 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 VOLTAGE LIMITER See General Warning on page 1 1 Testing the Voltage Limiter See Test Procedure 29 Section 11 Page 11 37 Voltage Limiter Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect the battery...

Page 227: ... as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Loosen the set screw locking the light switch knob 1 to the shaft Figure 13 30 Page 13 28 4 Remove the instrument panel See Key Switch Removal on page 13 14 5 Disconnect the wires from the light switch 6 Remove the outer nut 2 from the light switch 3 and remove Light Switch installation 1 Connect the wire...

Page 228: ... dead battery using another battery and jumper cables General Information See preceding DANGER and WARNING statements Gasoline vehicles are equipped with 12 volt low maintenance batteries that requires infrequent watering When changing a 12 volt battery in any gasoline powered vehicle the same size battery with adequate amperage ratings should be used as a replacement A group 70 side post battery ...

Page 229: ...attery on page 13 33 5 Keep battery hold down clamp tight See Vibration Damage on page 13 32 Self Discharge Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery To prevent self discharge the battery should always be kept clean Hot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a battery will disch...

Page 230: ...eral content analysis Battery Removal See General Warning on page 1 1 and DANGER on page 13 30 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Remove the battery hold down clamp from the battery 4 Lift t...

Page 231: ...mp rate Battery Installation See General Warning on page 1 1 and DANGER on page 13 30 1 Place the battery into the vehicle with the battery posts facing the engine 2 Secure the battery to the vehicle with the clamp and install bolt washer and locknut and tighten to 144 in lb 16 3 N m A loose battery clamp may allow the battery to become damaged from vibration or jar ring 3 Connect the battery cabl...

Page 232: ... is recommended that the area be heated to at least 60 F 16 C prior to charging The battery will not charge effectively in cold temperatures for the same reasons that it does not discharge as rapidly in cold temperatures Charging a Dead Battery See General Warning on page 1 1 and DANGER on page 13 30 The vehicle is equipped with a starter generator The generator is not designed to charge a dead ba...

Page 233: ... Disconnect battery cables as instructed See WARNING To avoid unintentionally starting in Gen eral Warning on page 1 2 2 Place the neutral lockout switch in the MAINTENANCE position Access the engine compartment by removing the seat See Section 4 Body and Trim 3 Disconnect the wires from the starter generator 1 Mark wires before disconnecting Loosen the pivot nuts 7 and bolts 5 Figure 14 1 Page 14...

Page 234: ...e brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 14 6 Page 14 4 2 Remove brush covers 29 and 30 screws 25 and lock washers 26 brush springs 28 and brushes 27 Figure 14 3 Page 14 2 See following NOTE NOTE To clean and inspect the armature commutator and the bearings ...

Page 235: ... four lock washers 26 and four screws 25 making sure the crossover leads are connected also Tighten the screws to 31 in lb 3 5 N m Figure 14 3 Page 14 2 2 To prevent contact between the brushes and commutator as the commutator is installed and possible damage to the brushes lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cove...

Page 236: ... center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 14 6 Page 14 4 2 Remove the two bolts 20 and pull commutator end cover 23 free of the starter generator housing 24 Figure 14 2 Page 14 2 3 To separate armature 33 from output end cover 36 remove nut 41 lock washer 40 pulley 39 shaft key 34 ...

Page 237: ...bearings unless they are to be replaced Bearing Removal 1 Place the wedge attachment tool CCI P N 1012812 between the bearing and the armature Make sure the wedge attachment tool is supporting the inner race of the bearing If a press is not available secure a bearing puller CCI P N 1012811 to the wedge attachment tool and pull the bearing off of the end of the armature shaft Support the armature s...

Page 238: ...est Procedure 8 Starter Generator Starter Function on page 12 16 Visual Inspection of Armature Obvious defects can be seen by examining the armature If an armature has frayed or charred insulation bro ken wires or thrown solder it is obvious without testing that it should be replaced Faults seen during the visual inspection can aid in diagnosing the original cause of the failure Items to look for ...

Page 239: ...cants on the commutator or brushes 2 Using a micrometer measure the outside diameter at two points along the commutator If the commu tator outside diameter is less than 1 535 inches 39 mm replace the armature and bearings Figure 14 11 Page 14 7 Armature Ground Test ý CAUTION Do not submerge armature in solvent NOTE Before testing wipe the armature with a clean cloth and remove carbon dust and meta...

Page 240: ...r Generator service specifications are listed in the following table Figure 14 12 Armature Ground Test ITEM SERVICE LIMIT Commutator diameter minimum 1 535 in 39 mm Concentric with armature shaft within 0 002 in 0 051 mm Limit depth of cut when machining commutator 0 007 in 0 2 mm If undercut of segment insulator is less than 0 016 inch 0 406 mm then it should be undercut to 0 031 in 0 8 mm Dielec...

Page 241: ...onto the output end of the shaft Press against the inner race of the new bearing until it is fully seated 6 Install the output end cover 36 onto the armature Secure the bearing retainer 32 to the cover and tighten the screws 43 to 39 in lb 4 4 N m Figure 14 7 Page 14 4 7 Slide the housing with field coils over the armature Use the locating pin to align housing to the cover NOTE The terminal insula...

Page 242: ...gh the starter generator Install a lock washer 9 and 5 16 inch nut 12 onto the end of the adjustment bolt 11 Tighten to finger tight Figure 14 13 Page 14 10 4 Install the belt 3 then tighten the mounting bolts See Belt Tension Adjustment on page 14 11 5 Connect the yellow wire from the voltage regulator to the DF terminal on the starter generator Install a flat washer lock washer and nut onto the ...

Page 243: ...elt tension using a Krikit gauge 1 available at NAPA Auto Parts stores or equivalent Proper tension for a new starter generator belt should be 75 ft lb 101 7 N m or 45 ft lb 61 N m for an existing belt Figure 14 14 Page 14 10 7 While maintaining the tension tighten the adjustment nut 12 to 144 in lb 16 3 N m Tighten the two pivot bolts 5 and hex nuts 7 to 23 ft lb 31 2 N m Figure 14 13 Page 14 10 ...

Page 244: ...th Battery Terminal Protector Spray CCI P N 1014305 to minimize corro sion 5 Place Forward Reverse handle in NEUTRAL and place the neutral lockout switch in the MAINTENANCE position Start the engine and check regulator for proper functioning as described in the voltage regulator test procedure See Test Procedure 11 Voltage Regulator on page 12 18 KEY SWITCH See General Warning on page 1 1 Testing ...

Page 245: ...the wires from the key switch 4 Remove the key switch 4 1 Remove the key switch cap with a small flat blade screwdriver 4 2 Remove key switch from the dash by holding the key switch and turning the nut on the outside of the dash with a 1 inch socket wrench Remove the keyed washer with key switch Key Switch Installation 1 Reverse removal procedures to install key switch in the dash Connect wires to...

Page 246: ...o the large post on the solenoid 2 2 Connect the 6 gauge red wire from the battery terminal and the 10 gauge red wire from the fuse block to the other large post on the solenoid 2 3 Connect the 18 gauge orange wire from accelerator pedal limit switch to small post on the solenoid 2 4 Connect the 18 gauge blue wire from the key switch to the other small post on the solenoid 3 Tighten the hex nuts o...

Page 247: ...3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corro sion KILL LIMIT SWITCH See General Warning on page 1 1 Testing the Kill Limit Switch See Test Procedure 16 Kill Limit Switch on page 12 27 Kill Limit Switch Removal 1 Disconnect battery cables as instructed See WARNING To avoid unintentionally starting in Gen eral Warning on page 1 2 2 Remove electrical compon...

Page 248: ...e to 144 in lb 16 N m Figure 1 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corro sion NEUTRAL LOCKOUT LIMIT SWITCH See General Warning on page 1 1 Testing the Neutral Lockout Limit Switch See Test Procedure 7 Neutral Lockout Limit Switch on page 12 16 Neutral Lockout Limit Switch Removal 1 Disconnect the battery cables as instructed See WARNING To av...

Page 249: ...he gray wire to the normally closed NC terminal of the neutral lockout limit switch See Wiring Diagram on page 12 6 3 Connect battery cables positive cable first and tighten hardware to 144 in lb 16 N m Figure 1 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corro sion 4 Check limit switch operation Place the Forward Reverse handle in the NEUTRAL positi...

Page 250: ...buzzer to the center dash Reverse Warning Buzzer Installation 1 Install the screws 3 through the buzzer bracket tabs and tighten to 3 5 in lb 0 40 N m Figure 14 20 Page 14 18 2 Connect the black wire from the key switch to the negative terminal on the buzzer 3 Connect the red white wire from the wire harness to the positive terminal on the buzzer 4 Reverse removal procedures to install the center ...

Page 251: ...witch 4 and slide the reverse buzzer limit switch off the screws Reverse Buzzer Limit Switch Installation 1 Install the reverse buzzer limit switch 4 and then install two spacers 9 against the limit switch 2 Install the neutral lockout limit switch 5 with two washers 6 and two nuts 2 Tighten to 5 in lb 0 6 N m See following CAUTION ý CAUTION Do not overtighten the retaining nuts If the nuts are ov...

Page 252: ...ow wires to touch 4 Press the retaining tabs and remove the low oil warning light from the center dash Low Oil Warning Light Installation 1 Push a new unit into hole in dash until plastic tabs engage dash Figure 14 21 Page 14 20 2 Connect yellow wire from the key switch and yellow wire from the oil level sensor to the low oil warning light 3 Install the center dash in reverse order of removal Be s...

Page 253: ...n page 1 2 2 Remove the center dash panel See Key Switch Removal on page 14 12 3 Disconnect the wires from the fuel gauge hour meter 1 Figure 14 22 Page 14 20 Do not allow wires to touch 4 Remove the mounting clip 2 that secures the gauge meter Alternate pulling the lower and upper tabs away from the gauge housing to remove clip 5 Pull gauge meter from the instrument panel Fuel Gauge Hour Meter In...

Page 254: ...re 14 RPM Limiter on page 12 20 RPM Limiter Removal 1 Disconnect battery cables as instructed See WARNING To avoid unintentionally starting in Gen eral Warning on page 1 2 2 Remove seat to access engine compartment See Section 4 Body and Trim 3 Disconnect the white black wire from the black wire at the bullet connector located near the RPM limiter Figure 14 23 Page 14 22 4 Disconnect the other bla...

Page 255: ...the Ignition Coil See Test Procedure 13 Ignition Spark on page 12 20 and Test Procedure 15 Ignition Coil on page 12 21 Ignition Coil Removal 1 Disconnect battery cables as instructed See WARNING To avoid unintentionally starting in Gen eral Warning on page 1 2 2 Remove seat to access engine compartment See Section 4 Body and Trim 3 Disconnect spark plug wire from the spark plug See WARNING To avoi...

Page 256: ... 1 through 8 for proce dures to remove and install these existing parts If the existing ignition coil will be remounted proceed to step 9 1 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the spark plug wire Figure 14 27 Page 14 25 2 Remove the cap 2 from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire Figure ...

Page 257: ... 012 inch 0 304 mm bronze feeler gauge to set the air gap between the ignition coil and the flywheel magnet Tighten the two mounting bolts 6 to 30 in lb 3 4 N m Figure 14 28 Page 14 25 11 Connect the 18 gauge black wire to the spade terminal on the coil 12 Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch on the housing 13 When installing fan hou...

Page 258: ...ion OIL LEVEL SENSOR See General Warning on page 1 1 Testing the Oil Level Sensor See Test Procedure 22 Oil Level Sensor on page 12 29 Oil Level Sensor Removal See Oil Level Sensor Removal on page 15 5 Oil Level Sensor Installation See Oil Level Sensor Installation on page 15 5 HEADLIGHTS See General Warning on page 1 1 Testing the Headlight Socket See Test Procedure 30 Voltage at Headlight Socket...

Page 259: ...taining tab should lock onto the halo gen bulb assembly Figure 14 29 Page 14 27 2 From the front of vehicle reach under cowl and insert wire harness halogen bulb assembly 4 and 6 into the headlight lens 7 3 Turn the wire harness halogen bulb assembly 4 and 6 counterclockwise one quarter turn 4 Connect battery cables positive cable first and tighten hardware to 144 in lb 16 N m Figure 1 1 Page 1 3 ...

Page 260: ...h Figure 14 30 Page 14 28 NOTE Identify terminal for solid black wire and terminal for black white wire 5 Remove the mounting hardware 2 from the voltage limiter and remove it from the vehicle Voltage Limiter Installation 1 Mount the voltage limiter to the frame using the mounting hardware and tighten to 25 in lb 2 8 N m Figure 14 30 Page 14 28 2 Connect the black white wire from harness to the ne...

Page 261: ...n 1 Connect the wires to the light switch See Wiring Diagram on page 12 6 2 Thread the check nut 4 onto the switch until an equal number of threads show on both sides Insert the switch through the center dash and install the nut on the outside of the dash Tighten the nut to 14 in lb 1 6 N m Figure 14 31 Page 14 28 3 Push the light switch shaft in Screw the knob onto the end of the shaft until the ...

Page 262: ... battery using another battery and jumper cables General Information See preceding DANGER and WARNING statements Gasoline vehicles are equipped with 12 volt low maintenance batteries that requires infrequent watering When changing a 12 volt battery in any gasoline powered vehicle the same size battery with adequate amperage ratings should be used as a replacement A group 70 side post battery CCI P...

Page 263: ...y on page 14 33 5 Keep battery hold down clamp tight See Vibration Damage on page 14 32 Self Discharge Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery To prevent self discharge the battery should always be kept clean Hot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a battery will discharge ...

Page 264: ... content analysis Battery Removal See General Warning on page 1 1 and DANGER on page 14 30 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Remove the battery hold down clamp from the battery 4 Lift the b...

Page 265: ...te Battery Installation See General Warning on page 1 1 and DANGER on page 14 30 1 Place the battery into the vehicle with the battery posts facing the engine 2 Secure the battery to the vehicle with the clamp and install bolt washer and locknut and tighten to 144 in lb 16 3 N m A loose battery clamp may allow the battery to become damaged from vibration or jar ring 3 Connect the battery cables po...

Page 266: ...ommended that the area be heated to at least 60 F 16 C prior to charging The battery will not charge effectively in cold temperatures for the same reasons that it does not discharge as rapidly in cold temperatures Charging a Dead Battery See General Warning on page 1 1 and DANGER on page 14 30 The vehicle is equipped with a starter generator The generator is not designed to charge a dead battery I...

Page 267: ...ee your authorized dealer BEFORE SERVICING Carefully read the applicable information and instructions before beginning engine service Diagrams DAN GER WARNING CAUTION and NOTE statements and detailed descriptions have been included wherever necessary Anyone attempting engine service should have knowledge and experience in small engine service and repair ENGINE ROTATION When turning the crankshaft ...

Page 268: ... of the engine when servicing vehicle To avoid ignition of fuel and serious personal injury or death never try to start the engine with plug removed from engine Testing the Spark Plug Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible Spark should be blue and strong and able to jump a 5 16 inch 8 mm gap Setting the Spark Gap 1 Pass a contact point...

Page 269: ...amber most oil separates from the air and drains back to the crankcase The air passes through a tube and vents to the intake manifold See Engines and Transaxles Manual for inspection and repair CRANKCASE See General Warning on page 1 1 ENGINE REMOVAL To perform repairs on crankcase components remove engine from the vehicle See following CAUTION ý CAUTION Before removal and disassembly clean the en...

Page 270: ...tic mallet on alternate sides near the dowel pins 5 Figure 15 3 Page 15 4 4 Remove the crankcase cover gasket completely It may stick to the flanged surface of the crankcase Figure 15 2 Oil Level Sensor Wire Figure 15 3 Crankcase Cover Figure 15 4 Engine Mounting Plate STARTER GENERATOR 12 11 3 4 1 2 5 5 SPACERS PROVIDED 2 PLACES FOR FE290 TYPICAL 4 PLACES 3 1 4 5 2 TYPICAL 2 PLACES 6 3 WASHERS PR...

Page 271: ...hold the sensor to the bracket 5 Oil Level Sensor Installation 1 If the oil level sensor was removed from the bracket install sensor 6 into bracket 5 and secure with three screws 7 Figure 15 5 Page 15 5 Tighten to 17 in lb 1 9 N m 2 Position the sensor and bracket on inside of crankcase and install two mounting screws 3 Connect sensor wire 2 to cord connector 1 Figure 15 5 Page 15 5 4 Install scre...

Page 272: ...ts in two steps First in the sequence shown tighten all eight bolts to approximately 130 in lb 14 N m Then repeating the sequence tighten them to 250 in lb 28 2 N m Figure 15 6 Page 15 6 5 Connect the yellow jumper wire 11 to the cord connector 12 Figure 15 2 Page 15 4 IGNITION COIL AND FLYWHEEL See General Warning on page 1 1 Ignition Coil and Flywheel Removal 1 Loosen three screws and remove the...

Page 273: ... CAUTION ý CAUTION The flywheel nut has right hand threads Turn it clockwise to tighten or counterclockwise to loosen Do not damage the fan blades with the strap wrench Do not place screwdriver or pry bar in the fan blades 4 Remove the flywheel with a puller CCI P N 1016627 5 Remove the flywheel key from its groove Figure 15 7 Flywheel Housing Figure 15 8 Ignition Coil Figure 15 9 Flywheel Nut Fig...

Page 274: ...FLYWHEEL INSTALLATION 1 Insert the flywheel key into the keyway in the crankshaft Then align the keyway in the flywheel to the key and push the flywheel and fan assembly onto the crankshaft until it seats Install flat washer and nut finger tight 2 Use a strap wrench 3 to keep the flywheel and fan assembly 1 from turning while tightening the fly wheel nut to 63 ft lb 85 4 N m Figure 15 11 Page 15 8...

Page 275: ...lter on the crankcase Fill the crankcase to the proper level with the cor rect type of oil This engine should be regarded as a new engine for next scheduled oil change See Section 10 Periodic Maintenance 8 Check all hardware for proper torque tightness 9 Check engine oil level Figure 15 12 Page 15 9 9 1 With vehicle on level surface remove dip stick and clean with cloth Figure 15 12 Page 15 9 9 2 ...

Page 276: ... m Starter Generator bracket to block bolts M8 200 in lb 23 N m Oil drain plug M14 20 ft lb 27 1 N m Fan housing screws M6 90 in lb 10 N m Fan shroud screws M6 25 in lb 2 8 N m Bolts marked with 4 when used with nuts M8 M6 M5 130 in lb 15 N m 50 in lb 5 9 N m 30 in lb 3 4 N m ITEM LIMITS Spark plug gap standard 0 027 to 0 031 in 0 69 to 0 79 mm Ignition coil air gap standard 0 012 in 0 304 mm Comp...

Page 277: ...15 1 Air filter element See Air Filter on page 16 16 Fuel filters See Fuel Filters on page 16 17 Choke and air intake system for restriction of air flow See Choke and Air Intake System on page 16 12 Fuel pump Fuel lines from fuel tank to filter to pump to filter to carburetor See Fuel Lines on page 16 25 Exhaust system for restrictions See Section 17 Exhaust System Gasoline Vehicles If the carbure...

Page 278: ...FUEL SYSTEM GASOLINE VEHICLE Carburetor Page 16 2 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual 16 Figure 16 1 Carburetor Mounting 1 2 3 4 13 15 12 30 21 26 10 21 11 19 18 22 23 14 16 17 ...

Page 279: ...or intake pipe 17 and the carburetor body 12 so that it can be replaced in the same orientation Figure 16 1 Page 16 2 When removing the carburetor body the throttle return spring 11 must be disconnected Note its proper orientation so that it can be replaced in the same orientation The carburetor must be kept upright during removal 2 Position the carburetor with the drain screw 11 over a catch basi...

Page 280: ...ing normal operation the fuel bowl retains the float pivot pin 6 Make sure that the float pivot pin does not fall out of the carburetor body after the fuel bowl is removed 6 Remove the main jet 8 from the carburetor body and discard it Figure 16 4 Page 16 4 See follow ing NOTE NOTE Make sure the fuel nozzle 7 does not fall out of the carburetor body after removal of the main jet This is best accom...

Page 281: ...tioned properly by aligning the marks applied in step 4 See following CAUTION ý CAUTION Make sure the fuel bowl is properly seated against the carburetor fuel bowl gasket and the gasket is not pinched 10 Install the fuel bowl retaining screw and tighten it to 61 in lb 6 9 N m 11 Write the size of the main jet on the fuel bowl with an indelible ink marker This should be written in a loca tion that ...

Page 282: ...5 or Figure 16 19 Page 16 25 19 Connect battery cables positive cable first and tighten hardware to 144 in lb 16 N m Figure 1 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corro sion 20 Test drive the vehicle ENGINE CONTROL LINKAGE See General Warning on page 1 1 ý DANGER To ensure the vehicle does not run over you while you disconnect or adjust the ac...

Page 283: ...nstallation and Adjustment 1 Before installing the accelerator rod adjust accelerator pedal position See Pedal Group Adjustment Gasoline Vehicle on page 5 11 2 Install the ball joint on the ball stud at the accelerator pedal Figure 16 6 Page 16 7 3 Access the engine compartment 4 Remove the electrical box screw and cover Figure 16 7 Page 16 8 5 Adjust length of accelerator rod With the ball joint ...

Page 284: ... pliers tighten the jam nuts against the ball joints accelerator ball joint first at each end of the accelerator rod 10 Check rod adjustment for proper switch activation 11 After the pedal group and accelerator rod are properly adjusted adjust the engine RPM setting See Engine RPM Adjustment on page 16 12 12 Install the electrical box cover and tighten retaining screw to 18 in lb 2 0 N m 13 Connec...

Page 285: ...overnor cable support bracket 10 Figure 16 9 Page 16 10 Remove the cable 2 from the vehicle Governor Cable Installation and Adjustment 1 Install the cable onto the governor cable support bracket 10 and the engine bracket 11 Figure 16 9 Page 16 10 2 Push the cable dust shields onto the ends of the cable conduit 3 Connect the governor cable to the carburetor throttle at the carburetor 4 Connect the ...

Page 286: ...trical box screw and cover and loosen the cable housing retaining nuts Figure 16 7 Page 16 8 3 Disconnect cable 1 from cam 17 in the electrical box Figure 16 9 Page 16 10 4 Disconnect the spring 16 from the engine governor arm 5 Remove the accelerator cable from the accelerator cable bracket 5 Remove the cable assembly from the vehicle Figure 16 9 Governor and Accelerator Cables 6 14 12 10 15 17 1...

Page 287: ...of the cable conduit 6 Before tightening the cable housing retaining nuts make sure the engine RPM adjustment is correct See Engine RPM Adjustment on page 16 12 7 Install the electrical box cover and tighten the retaining screw to 18 in lb 2 0 N m 8 Connect battery cables positive cable first and tighten hardware to 144 in lb 16 N m Figure 1 1 Page 1 3 Coat terminals with Battery Terminal Protecto...

Page 288: ...oor the tachometer should read 3300 30 RPM 800 810 or 2600 30 RPM 850 7 To reduce RPM loosen the accelerator cable retaining nut on the outside of the electrical box wall and tighten the retaining nut on the inside of the wall until the specified RPM is reached Figure 16 7 Page 16 8 To increase RPM loosen the cable retaining nut inside the electrical box and tighten the nut outside the box until t...

Page 289: ...e vehicle Figure 16 12 Page 16 15 AIR BOX INSTALLATION NOTE The intake duct must be in place before the air box can be installed 1 Check to be sure the intake seal 11 is seated correctly Figure 16 12 Page 16 15 The seal fits tightly onto the bottom side of the air box If seal is not in place moisture will enter the air intake system 2 Place the air box assembly into vehicle and install three flat ...

Page 290: ...the front of the duct to the underside of the floorboard with two pop rivets 27 and flat washers 28 Figure 16 12 Page 16 15 3 Install air box See Air Box Installation on page 16 13 4 Install steering joint assembly See following NOTE NOTE Make sure steering wheel and front wheels are properly aligned before installing steering joint 4 1 Position steering joint assembly 1 on vehicle as shown Instal...

Page 291: ...XRT 800 810 and 850 Maintenance and Service Manual Page 16 15 16 Figure 16 12 Air Intake and Choke Assemblies TYPICAL 3 PLACES 29 1 TYPICAL 3 PLACES 22 4 5 2 3 18 15 7 9 14 17 16 11 TYPICAL 2 PLACES REFERENCE CARBURETOR 8 10 12 26 26 21 19 30 23 20 27 28 28 24 27 28 28 ...

Page 292: ...lip of the box or the box will not seal properly 5 Install new air filter by inserting back edge first and pushing down using the palm of your hand to seat filter evenly onto inside lip of air box Ensure filter fits correctly and that the wire latches are not caught between lid and air box Close the lid 6 Fasten wire latches 12 Make sure latches securely engage the bottom half of the box See follo...

Page 293: ...FUEL FILTER INSTALLATION ý CAUTION Fuel filters are marked with flow direction arrows Make sure that filters are installed with arrows pointing in the direction of fuel flow from tank to carburetor 1 Install the primary fuel filter 17 in the fuel line Use new clamps 16 Figure 16 13 Page 16 18 2 Install the secondary fuel filter 22 in the fuel line Use new clamps 16 3 Turn the fuel shut off valve t...

Page 294: ...SOLID COLOR CLEAR 1 Fuel tank to primary fuel filter 7 0 in 17 8 cm 2 Primary fuel filter to fuel pump 6 5 in 16 5 cm 3 Fuel pump to carburetor 17 0 in 43 2 cm 4 Vent tube Carburetor 11 0 in 27 9 cm 5 Vent tube Gas Tank 18 0 in 45 7 cm 6 Impulse line 16 0 in 43 2 cm Total 46 5 in 118 1 cm 29 0 in 99 1 cm 16 15 14 19 18 5 4 3 6 16 23 14 16 16 17 16 1 25 26 2 24 16 16 11 12 10 14 ...

Page 295: ...FF position Figure 16 18 Page 16 25 or Figure 16 19 Page 16 25 4 Remove hardware attaching the fuel pump 24 and lift the fuel pump out of the engine compartment Figure 16 13 Page 16 18 5 Remove the clamp and impulse line 7 from fuel pump 6 Disconnect the fuel lines 2 and 3 from the pump and plug them to prevent fuel leakage See following WARNING ý WARNING Carefully drain any fuel remaining in the ...

Page 296: ...4 Page 16 20 3 If a valve assembly is damaged the rubber retaining plug 33 and valve assembly must be replaced FUEL PUMP ASSEMBLY 1 Install the fuel gasket 35 and diaphragm 34 on the back cover 36 Figure 16 14 Page 16 20 2 Install the valve assembly in the pumping chamber 30 See following CAUTION ý CAUTION If the valve assembly is not installed exactly as shown Figure 16 14 Page 16 20 the impulse ...

Page 297: ... Use a new clamp 16 4 Install the fuel pump Tighten nylon lock nuts to 38 in lb 4 3 N m 5 Connect battery cables positive cable first and tighten hardware to 144 in lb 16 N m See Figure 1 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 6 Turn the fuel shut off valve on top of the fuel tank to the open position Figure 16 18 Page 16 25 or Figure ...

Page 298: ...ve the carburetor drain screw 11 and drain fuel remaining in the carburetor bowl into an approved container Figure 16 4 Page 16 4 Retighten carburetor drain screw 7 Using a siphon with a suction device siphon all fuel out of the tank and into an approved container See following DANGER and WARNING ý DANGER Gasoline Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and se...

Page 299: ...a flush the fuel tank with water to remove any remaining fuel 3 In a well ventilated area set the tank upside down so that the water can drain out of it To make sure that the tank dries completely allow the tank to sit for 24 hours 4 Store the tank upside down with the cap installed in a well ventilated area FUEL TANK INSTALLATION 1 With the retaining straps correctly positioned install the fuel t...

Page 300: ... XRT 800 810 Place the Forward Reverse handle in the NEUTRAL position and chock the wheels See following DANGER 13 XRT 850 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and the neu tral lockout switch in the MAINTENANCE position See following DANGER 14 Turn the key switch to the START position and start the engine See following DANGER ý DANGER Do not operate gasoline ve...

Page 301: ...he primary fuel filter Fuel line no 4 runs from the outlet of the secondary fuel filter to the carburetor Figure 16 13 Page 16 18 Small spring steel band clamps are used on all hose connections except at the carburetor A screw band clamp 16 should be used at the carburetor Figure 16 13 Page 16 18 FUEL SHUT OFF VALVE See General Warning on page 1 1 The fuel shut off valve is located on top of the f...

Page 302: ...properly vented as shown Figure 16 17 Page 16 24 To avoid the possibility of fire clean up any spilled fuel before operating the vehicle ý CAUTION To allow for expansion do not fill higher than 2 54 cm one inch from the top of the fuel tank Avoid spilling fuel NOTE Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Vehicles to be stored for extended periods shou...

Page 303: ...s 10 and lock washers 11 from the manifold 6 Remove the muffler 1 from the vehicle MUFFLER INSTALLATION NOTE Any time the muffler is removed from the vehicle install a new muffler clamp 6 CCI P N 1017689 and muffler gasket 12 FE290 CCI P N 1015330 Figure 17 1 Page 17 2 1 Loosely secure muffler 1 to muffler bracket 2 with clamp 6 2 Place a new gasket 12 on the cylinder block exhaust stud bolts 3 At...

Page 304: ...Reverse handle in the NEUTRAL position and chock the wheels 11 XRT 850 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and the neu tral lockout switch in the MAINTENANCE position 12 Start the engine and check for exhaust leaks and proper engine operation See following DANGER ý DANGER Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine...

Page 305: ...ates vehicle ground speed It is mounted inside the unitized transaxle and is driven by transaxle gears If any of the governor linkages are removed in order to service other components read justment of the governor linkage is required See Governor Cable Installation and Adjustment on page 16 9 Unitized Transaxle Service The unitized transaxle is extremely durable and should require very little serv...

Page 306: ...n on page 18 6 AXLE SHAFT AND OIL SEAL REMOVAL 1 Turn the key switch to the OFF position and remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Loosen the lug nuts on the wheel to be removed 4 Place chocks at the front wheels and lif...

Page 307: ...embly to be sure the bearing 71 and collar 73 have not slipped and are still seated against the shoulder on the axle shaft Figure 18 6 Page 18 4 10 Inspect the bearing If the bearing is damaged or worn replace it AXLE BEARING Axle Bearing Removal 1 Use external retaining ring pliers 0 047 inch tip to remove the retaining ring 74 Place a bearing puller wedge attachment CCI P N 1012812 on the axle s...

Page 308: ...lar 73 off together Figure 18 6 Page 18 4 See also Figure 18 7 Page 18 6 See following NOTE NOTE It may be necessary to heat the collar to remove it Do not remove the large axle retaining ring 70 from the axle Figure 18 6 Page 18 4 Since the inner diameter of the retaining ring 70 is smaller than the outer diameter of the bearing 71 the ring must be in place on the axle before a new bearing and co...

Page 309: ...UTION If the bearing was removed from the shaft replace it with a new one Do not tighten the bearing puller wedge attachment against the axle shaft This could damage the axle shaft when the bearing and collar are pressed on 7 Use external snap ring pliers 0 047 in tip to install collar retaining ring 74 Figure 18 6 Page 18 4 AXLE SHAFT INSTALLATION 1 Clean bearing and seal seats in axle tube 75 or...

Page 310: ...eath UNITIZED TRANSAXLE REMOVAL See General Warning on page 1 1 1 Turn the key switch to the OFF position and remove the key and place the Forward Reverse handle in the NEUTRAL position 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Close the fuel shut off valve on fuel tank Figure 16 18 Page 16 25 or Figure 16 19 Page 1...

Page 311: ... line can be plugged with a 1 4 inch bolt Figure 18 12 Page 18 7 4 5 Remove the cover from the electrical component box Then loosen the hardware securing the accelerator cable to the box Disconnect the cable from the actuator cam and remove it from the box Figure 18 13 Page 18 8 4 6 Remove retaining nut and disconnect the engine ground wire from the oil filler tube mounting bracket Figure 18 14 Pa...

Page 312: ...ine oil level sensor wire 18 gauge yellow at the connector just to the rear of the starter generator Figure 18 17 Page 18 9 4 10 Disconnect the engine kill switch wire 18 gauge white black from the bullet connector at the lower right front of the engine Figure 18 18 Page 18 9 4 11 Cut away the wire ties securing the engine kill wire at the lower right front of the engine below the exhaust header t...

Page 313: ...w tie pins 1 brake cable clevis pins 2 and E clips 3 Figure 18 19 Page 18 9 5 2 Remove the cable from the cable support bracket Figure 18 19 Page 18 9 Figure 18 17 Oil Level Sensor Jumper Wire Figure 18 18 Ignition Kill Wire Figure 18 19 Brake Cable STARTER GENERATOR YELLOW OIL SENDING UNIT JUMPER WIRE WHITE BLACK WIRE BLACK WIRE 1 4 3 2 REAR OF VEHICLE AS SEEN FROM DRIVER SIDE OF VEHICLE ...

Page 314: ...then remove the bolts securing the leaf springs to the shackles Figure 18 22 Page 18 10 9 Remove the bolts securing the leaf springs to their front mounts Figure 18 23 Page 18 10 10 Continue raising vehicle until frame or trailer hitch is higher than the top of the unitized transmission enough to allow transaxle and engine to be rolled under and out of vehicle Figure 18 24 Page 18 11 Figure 18 20 ...

Page 315: ...cket in the vehicle frame and lower it to the floor Figure 18 26 Page 18 11 The powertrain should be completely disconnected from the vehicle and resting on the floor 14 Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle Figure 18 27 Page 18 11 15 Place blocks under the engine pan so they will completely support the engine and keep it l...

Page 316: ...kwise while pulling it off driven clutch Figure 18 29 Page 18 12 17 Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle Figure 18 30 Page 18 12 18 Loosen but do not remove the governor arm retaining bolt 1 Figure 18 31 Page 18 12 Remove the governor arm from the shaft Do not disconnect cables 19 Remove screws 1 securing the governor cable bracket to tra...

Page 317: ...x bolts mounting the unitized transaxle to the engine 22 1 Remove four transaxle mounting bolts one at each corner of the transaxle mounting plate Figure 18 34 Page 18 13 22 2 Remove two middle transaxle mounting nuts from the engine block studs 23 Remove leaf springs wheels and brake assemblies from the transaxle UNITIZED TRANSAXLE INSTALLATION See General Warning on page 1 1 Figure 18 32 Governo...

Page 318: ...ll the governor cable bracket on transaxle case Tighten the mounting screws to 134 in lb 15 1 N m Figure 18 32 Page 18 13 8 Install governor lever arm on governor shaft Figure 18 37 Page 18 14 8 1 With the governor lever arm loose on the governor shaft turn the governor arm shaft counterclock wise until it stops Then pull the governor lever arm rearward until the carburetor throttle is in the wide...

Page 319: ...jack high enough to support the vehi cle Figure 18 40 Page 18 15 Make sure the vehicle is stable on the jack then remove the jack stands 14 After the jack stands are removed lower the vehicle to approximately its normal height Position the leaf springs in the front spring mounts and install the bolts and lock nuts Tighten to 15 ft lb 20 3 N m 15 Adjust the vehicle height with the floor jack to pos...

Page 320: ... Install three wire ties to secure the engine kill wire to the accelerator cable where they both route together on the passenger side of the engine 20 Connect the oil level sensor wire 18 gauge yellow to the jumper wire Figure 18 44 Page 18 16 21 Connect the 6 gauge white wire to the F2 post the 6 gauge black ground wire to the A2 post and tighten both wires to 48 in lb 5 4 N m Connect the 16 gaug...

Page 321: ...saxle and tighten the mounting nuts to 22 ft lb 29 8 N m Connect shifter cable rod end to the shifter arm Figure 18 46 Page 18 17 24 Attach the ground wire to the mounting screw on the oil filler tube mounting bracket and tighten to 50 in lb 5 7 N m Figure 18 47 Page 18 17 25 Connect accelerator cable to actuator cam in the electrical box Position the accelerator cable in the mounting slot in the ...

Page 322: ...clamp Figure 18 51 Page 18 18 29 Connect carburetor vent tube to carburetor and secure with hose clamp Figure 18 52 Page 18 18 30 Install transaxle drain plug and tighten to 21 ft lb 28 5 N m 31 Fill transaxle with 27 oz 0 8 liter 80 90 Wt API class GL 3 or 80 90 WT AGMA class EP gear lube Install and tighten the level indicator hole plug to 21 ft lb 28 5 N m 32 Ensure that all wiring is secured p...

Page 323: ... key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Remove the ball joint socket 2 from the Forward Reverse shifter assembly ball stud 3 Figure 18 54 Page 18 21 4 Remove the ball joint socket 10 from the shifter arm ball stud 11 on the transaxl...

Page 324: ...routed and secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or death FORWARD REVERSE SHIFTER CABLE ADJUSTMENT With the shifter lever of the unitized transaxle in the NEUTRAL position Figure 18 54 Page 18 21 the For ward Reverse handle 9 should be straight up For minor adjustments the nut 1 may be loosened and the ball joint soc...

Page 325: ...usted with the Forward Reverse handle 9 Figure 18 54 Page 18 21 in the NEUTRAL position the shift lever of the transaxle will also be in the NEUTRAL position Figure 18 55 Page 18 21 Retighten nuts at the transaxle to 22 ft lb 29 8 N m retighten nuts at the Forward Reverse assembly to 43 in lb 4 9 N m Figure 18 54 Forward Reverse Shifter Cable Figure 18 55 Forward Reverse Positions C O M N C N O 11...

Page 326: ......

Page 327: ...or system regulates vehicle ground speed It is mounted inside the unitized transaxle and is driven by transaxle gears If any of the governor linkages are removed in order to service other components read justment of the governor linkage is required See Governor Cable Installation and Adjustment on page 16 9 Unitized Transaxle Service The unitized transaxle is extremely durable and should require v...

Page 328: ...n page 19 6 AXLE SHAFT AND OIL SEAL REMOVAL 1 Turn the key switch to the OFF position and remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Loosen the lug nuts on the wheel to be removed 4 Place chocks at the front wheels and lift t...

Page 329: ...pect the axle shaft assembly to be sure the bearing 71 and collar 73 have not slipped and are still seated against the shoulder on the axle shaft Figure 19 6 Page 19 4 10 Inspect the bearing If the bearing is damaged or worn replace it AXLE BEARING Axle Bearing Removal 1 Use external retaining ring pliers 0 047 inch tip to remove the retaining ring 74 Place a bearing puller wedge attachment CCI P ...

Page 330: ...73 off together Figure 19 6 Page 19 4 See also Figure 19 7 Page 19 6 See following NOTE NOTE It may be necessary to heat the collar to remove it Do not remove the large axle retaining ring 70 from the axle Figure 19 6 Page 19 4 Since the inner diameter of the retaining ring 70 is smaller than the outer diameter of the bearing 71 the ring must be in place on the axle before a new bearing and collar...

Page 331: ...ON If the bearing was removed from the shaft replace it with a new one Do not tighten the bearing puller wedge attachment against the axle shaft This could damage the axle shaft when the bearing and collar are pressed on 7 Use external snap ring pliers 0 047 in tip to install collar retaining ring 74 Figure 19 6 Page 19 4 AXLE SHAFT INSTALLATION 1 Clean bearing and seal seats in axle tube 75 or 76...

Page 332: ...onal injury or death UNITIZED TRANSAXLE REMOVAL See General Warning on page 1 1 1 Turn the key switch to the OFF position and remove the key and place the Forward Reverse handle in the NEUTRAL position 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Close the fuel shut off valve on fuel tank Figure 16 18 Page 16 25 or Fig...

Page 333: ...ted end of the line can be plugged with a 1 4 inch bolt Figure 19 12 Page 19 7 4 5 Remove the cover from the electrical component box Then loosen the hardware securing the accelerator cable to the box Disconnect the cable from the actuator cam and remove it from the box Figure 19 13 Page 19 8 4 6 Remove retaining nut and disconnect the engine ground wire from the oil filler tube mounting bracket F...

Page 334: ... sensor wire 18 gauge yellow at the connector just to the rear of the starter generator Figure 19 17 Page 19 9 4 10 Disconnect the engine kill switch wire 18 gauge white black from the bullet connector at the lower right front of the engine Figure 19 18 Page 19 9 4 11 Cut away the wire ties securing the engine kill wire at the lower right front of the engine below the exhaust header the wire harne...

Page 335: ...al Page 19 9 19 5 Disconnect the brake cables 5 1 Remove bow tie pins 1 brake cable clevis pins 2 and E clips 3 Figure 19 19 Page 19 9 5 2 Remove the cable from the cable support bracket Figure 19 19 Page 19 9 Figure 19 17 Oil Level Sensor Jumper Wire Figure 19 18 Ignition Kill Wire Figure 19 19 Brake Cable Rear View 1 4 3 2 ...

Page 336: ...o relieve tension from leaf springs then remove the bolts securing the leaf springs to the shackles Figure 19 22 Page 19 10 9 Remove the bolts securing the leaf springs to their front mounts Figure 19 23 Page 19 10 10 Continue raising vehicle until frame or trailer hitch is higher than the top of the unitized transmission enough to allow transaxle and engine to be rolled under and out of vehicle F...

Page 337: ...igure 19 25 Page 19 11 12 Pull the floor jack from beneath the vehicle and move it away 13 Carefully lift the snubber out of the snubber bracket in the vehicle frame and lower it to the floor Figure 19 26 Page 19 11 The powertrain should be completely disconnected from the vehicle and resting on the floor 14 Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out ...

Page 338: ... belt 16 1 Grasp belt midway between drive and driven clutch and pull up on belt to force the driven clutch sheaves apart Roll the belt counterclockwise while pulling it off driven clutch Figure 19 29 Page 19 12 17 Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle Figure 19 30 Page 19 12 18 Loosen but do not remove the governor arm retaining bolt 1 Fi...

Page 339: ...racket to transaxle Figure 19 33 Page 19 13 21 Remove the six bolts mounting the unitized transaxle to the engine 21 1 Remove four transaxle mounting bolts one at each corner of the transaxle mounting plate Figure 19 34 Page 19 13 21 2 Remove two middle transaxle mounting nuts from the engine block studs 22 Remove leaf springs wheels and brake assemblies from the transaxle Figure 19 32 Governor Ca...

Page 340: ...Tighten the mounting screws to 134 in lb 15 1 N m Figure 19 33 Page 19 13 7 Install the governor cable bracket on transaxle case Tighten the mounting screws to 134 in lb 15 1 N m Figure 19 32 Page 19 13 8 Install governor lever arm on governor shaft Figure 19 36 Page 19 14 8 1 With the governor lever arm loose on the governor shaft turn the governor arm shaft counterclock wise until it stops Then ...

Page 341: ...k high enough to support the vehi cle Figure 19 39 Page 19 15 Make sure the vehicle is stable on the jack then remove the jack stands 14 After the jack stands are removed lower the vehicle to approximately its normal height Position the leaf springs in the front spring mounts and install the bolts and lock nuts Tighten to 15 ft lb 20 3 N m 15 Adjust the vehicle height with the floor jack to positi...

Page 342: ...igure 19 42 Page 19 16 19 Install three wire ties to secure the engine kill wire to the accelerator cable where they both route together on the passenger side of the engine 20 Connect the oil level sensor wire 18 gauge yellow to the jumper wire Figure 19 43 Page 19 16 21 Connect the 6 gauge white wire to the F2 post the 6 gauge black ground wire to the A2 post and tighten both wires to 48 in lb 5 ...

Page 343: ... in the mounting slot in the wall of the electrical box and tighten mounting nuts to 18 in lb 2 0 N m Figure 19 47 Page 19 17 Install electrical box cover and tighten mounting screw 25 Remove the 1 4 inch bolt from the fuel line and connect the fuel line to the carburetor and secure with a hose clamp Figure 19 48 Page 19 17 26 Connect the impulse line to the fuel pump and secure it with the hose c...

Page 344: ...oz 0 8 liter 80 90 Wt API class GL 3 or 80 90 WT AGMA class EP gear lube Install and tighten the level indicator hole plug to 21 ft lb 28 5 N m 31 Ensure that all wiring is secured properly See following WARNING ý WARNING If wires are removed or replaced make sure wiring and wiring harness is properly routed and secured to vehicle frame Failure to properly route and secure wiring could result in v...

Page 345: ... shifter assembly stud 2 Figure 19 52 Page 19 20 4 Depress and push down on tangs 3 anchoring front of cable jacket to chassis bracket 5 Remove the ball joint socket 4 from the shifter arm ball stud 5 on the transaxle 6 Loosen the retaining nuts 6 anchoring rear of cable jacket to bracket 7 at starter generator 7 If equipped remove wire tie s securing cable jacket to frame rail 8 Remove cable 8 fr...

Page 346: ...TIZED TRANSAXLE 850 GASOLINE VEHICLE Forward Reverse Shifter Cable Page 19 20 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual 19 Figure 19 52 Forward Reverse Shifter Cable 8 2 3 9 1 6 4 7 5 10 ...

Page 347: ... get the proper adjustment Figure 19 52 Page 19 20 See following CAUTION ý CAUTION Be sure threads of cable are engaged in ball joint socket at least 1 4 inch 6 35 mm If ball joint socket comes loose from the cable the Forward Reverse shifter will not operate properly For major adjustments the cable jacket retaining nuts 6 must be loosened and adjusted When the cable is properly adjusted with the ...

Page 348: ......

Page 349: ...ases At governed top speed the ratio of drive clutch to driven clutch is 0 92 to 1 On steep grades or when the vehicle is heavily loaded higher torques are achieved through the use of a torque sensing ramp device on the driven clutch This device overcomes the force of the centrifugal weights to close the driven clutch and open the drive clutch thus increasing axle torque with little or no change i...

Page 350: ...ed semiannually for wear and or glazing If it is excessively worn frayed or glazed replace the belt As the drive belt wears the engine RPM will increase to compensate for the change in torque converter ratio This will keep the vehicle s maximum ground speed correct See Section 2 Vehicle Specifications DRIVE BELT REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintention...

Page 351: ...TION Make sure fingers are not underneath the belt when rolling the belt off the driven clutch 4 Remove the belt from the drive clutch DRIVE BELT INSTALLATION 1 Position the new belt on the drive clutch then start the belt over the top of the driven clutch 2 With the belt started onto the driven clutch rotate the driven clutch counterclockwise and roll the belt over the driven clutch sheaves and o...

Page 352: ...e starter generator mounting and adjusting hardware and then remove the starter belt See WARNING Moving parts Do not in General Warning Section 1 Page 1 1 Figure 20 3 Loosen Retaining Bolt Figure 20 4 Drive Clutch Removal WAR NING Use Husqvarna clutch holder while tightening or loosening drive clutch retaining bolt CLUTCH HOLDER Hook clutch holder on boss of pully located behind drive clutch push ...

Page 353: ...utch mounting bolt has left hand threads The crankshaft has left hand threads at the clutch mounting hole 5 Lubricate the threaded portion of the clutch puller tool with a light oil and thread the clutch puller tool into the clutch retaining bolt hole 6 Use a 1 2 inch drive air wrench to tighten the clutch puller tool The drive clutch will come free of the crankshaft Figure 20 4 Page 20 4 7 Suppor...

Page 354: ...ERTER GASOLINE VEHICLE Drive Clutch Page 20 6 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual 20 Figure 20 5 Drive Clutch Assembly 2 1 3 13 4 5 6 7 11 12 12 16 15 14 22 20 21 17 19 TYPICAL 3 PLACES 10 ...

Page 355: ...ad the center bolt of the Drive Clutch Hub Puller CCI P N 1014497 into clutch until the stop nut touches the clutch then back the bolt out one half turn Figure 20 7 Page 20 7 2 3 Thread the three small bolts of the puller into corresponding holes in the clutch Tighten bolts evenly making sure the face of the puller plate is parallel to the face of the clutch Figure 20 7 Page 20 7 2 4 Unscrew the p...

Page 356: ...ntations of the wave washer and of the primary and secondary weights to one another Figures 20 10 and 20 11 Page 20 8 Remove the plastic washers weights and wave washer from the pin Retain all parts Figure 20 8 Drive Button Mounting Figure 20 9 Weight Position Figure 20 10 Install Pin and Washer Figure 20 11 Install Secondary Weight Remove these items from ribs 10 24 SCREW FLAT WASHER DRIVE BUTTON...

Page 357: ...ly Figure 20 5 Page 20 6 See also Figure 20 13 Page 20 9 Discard the rings INSPECTION OF DRIVE CLUTCH PARTS 1 Inspect the idler bearing 6 for smooth rotation or seal damage Figure 20 5 Page 20 6 See follow ing NOTE NOTE It is normal for a small amount of grease to be present at the edge of seal 2 Inspect the bore of the moveable face assembly 14 for scarring or wear The moveable face assembly must...

Page 358: ... 7 ý CAUTION To avoid damaging the spiral back up rings be very careful when installing the moveable face 6 1 Rotate the moveable face assembly clockwise while installing it onto the shaft 6 2 Install the retaining ring 3 Figure 20 5 Page 20 6 7 Install the primary weights on the mounting pins Figure 20 10 Page 20 8 8 Install a wave washer on each mounting pin Make sure that the concave side of th...

Page 359: ...twelve o clock position as shown Figure 20 15 Page 20 11 14 Compress each take up spring and install the drive button over the rib and take up spring Figure 20 8 Page 20 8 15 Install a no 10 24 button retaining screw with flat washer through each button and into the rib Tighten the screws to 34 in lb 3 8 N m Figure 20 9 Page 20 8 16 Install the thrust washer 11 onto the moveable face assembly Figu...

Page 360: ...5 Connect battery cables positive cable first and tighten hardware to 144 in lb 16 N m See Figure 1 1 Page 1 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 6 Connect the spark plug wire to the plug 7 Drive the vehicle and check for proper operation DRIVEN CLUTCH See General Warning on page 1 1 DRIVEN CLUTCH REMOVAL 1 Remove the drive belt as instructed...

Page 361: ...If the bearing bore diameter is more than 1 384 inch 35 15 mm the entire moveable face assembly must be replaced 5 Inspect the shaft of the fixed face assembly There should be no noticeable wear Replace the shaft if it is worn scratched or damaged DRIVEN CLUTCH ASSEMBLY 1 Place the three drive buttons 6 in position Apply one drop of Loctite 222 to each of the socket head cap screws and then instal...

Page 362: ...TORQUE CONVERTER GASOLINE VEHICLE Driven Clutch Page 20 14 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual 20 Figure 20 18 Driven Clutch Assembly 2 3 4 5 6 7 8 11 12 1 10 9 TYPICAL 3 PLACES ...

Page 363: ...can be reused if the O D does not exceed 1 607 inches 40 82 mm otherwise it must be replaced with a new ring CCI P N 1014080 5 1 4 While holding onto the cam tap the end of the fixed face shaft lightly with a plastic mallet until the cam seats against the retaining ring See following CAUTION ý CAUTION Do not use a metal hammer to tap the fixed face hub A metal hammer will damage the shaft 5 2 Fiel...

Page 364: ...nto the keyed shaft Advance the press hub until it is firm against the shaft end 5 2 8 Remove the cam press hub 6 and installation tool and install the retaining ring NOTE The retaining ring can be reused if the O D does not exceed 1 607 inches 40 82 mm otherwise it must be replaced with a new ring CCI P N 1014080 DRIVEN CLUTCH INSTALLATION 1 To install the driven clutch reverse the removal proced...

Page 365: ...e accelerator is pressed This prevents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot If the Walk Away Braking function remains engaged for two seconds or more a warning buzzer will sound to alert the driver that motor braking has been activated ý WARNING Walk Away Braking will not limit vehicle speed to 1 mph 1 6 km h on very steep...

Page 366: ...OTENTIOMETER PIN 4 GRN WHT TO S O C PIN 5 LT BLUE TO OBC CONTROLLER LOCKOUT PIN 13 BLK WHT TO LOW SIDE OF MOTER SPEED SENSOR PIN 12 BLU WHT TO LOW SIDE OF SOLENOID COIL PIN 11 OPEN PIN 10 TAN TO KEY SWITCH SONIC WELD PIN 9 GRAY AUX 9 1 18_LT_GREEN W02 18_WHT W04 18_BLK_WHT W09 18_PUR_WHT W34 18_YEL W18 18_GRN W32 18_RED W19 18_GRN_WHT W30 10_BLK W49 10_BLU W63 6_GRN W64 MCOR SPEED SWITCH ASM THROT...

Page 367: ...VOLT BATTERIES MOTOR 3 PIN CONNECTOR 10_BLK W50 6_BLK W55 SONIC WELD 4 PIN NECTOR PROGRAMMER PLUG 18 BLK YEL 18 RED YEL 18 BLU YEL 18 GRN YEL FUSE BLOCK FUSE BLOCK 18_YEL W13 21 EEN W23 14_YEL W41 16_ORG W43 8_YEL_BLK_STP W44 10_ORG W61 6_WHT W62 16_BLK_WHT W71 NSOR 18_LT_GREEN W02 18_BLK_WHT W09 18_RED W19 18_GRN_WHT W30 10_BLK W49 10_BLU W63 6_GRN W64 ON BOARD 6_BLK W69 6_BLK W69 6_BLK W55 18_LT...

Page 368: ...r of energy units used by the vehicle 3 determines the number of energy units required to recharge the batteries and shuts the charger off when this number is reached 4 determines when to activate regen erative motor braking 5 locks out vehicle movement while the charger is plugged into the vehicle charger receptacle 6 stores operating data which can be read by the Communication Display Module CDM...

Page 369: ... SPEED PULSES menu item indicates that speed pulses are OFF when the vehicle is in motion or Diagnostic Menu SPEED SENSOR fault code Loose or disconnected motor speed sensor or broken wire Repair and or connect the three pin connector to the motor speed sensor Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controlle...

Page 370: ...or at the MCOR or broken wire Repair and or connect the three pin connector to the MCOR Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Failed MCOR Test Procedure 4 MCOR Voltage on page 21 12 Diagnostic Menu HW FAILSAFE Hardware Failsafe fault code Armature drive FET s field effect transistors inside speed...

Page 371: ...or pedal before turning key switch to the ON position or changing the selected direction with the Forward Reverse switch Diagnostic Menu LOW BATTERY fault code Batteries require charging Place batteries on battery charger and allow them to fully charge Improperly maintained or failed batteries Section 24 Batteries Electric Vehicles Diagnostic Menu OPEN ARMATURE fault code Loose or disconnected mot...

Page 372: ...h Circuit on page 21 16 See also Test Procedure 4 MCOR Voltage on page 21 12 Forward Reverse rocker switch Test Procedure 15 Forward Reverse Rocker Switch on page 21 30 Solenoid loose wires Test Procedure 3 Solenoid Activating Coil on page 21 12 Solenoid failed coil Test Procedure 3 Solenoid Activating Coil on page 21 12 Solenoid failed solenoid diode Test Procedure 3 Solenoid Activating Coil on p...

Page 373: ...stment on page 6 8 Tires under inflated or flat tires See Section 8 Wheels and Tires Vehicle operates but motor braking function does not Wiring improperly wired Check vehicle wiring See Wiring Diagram on page 21 2 Speed sensor disconnected or failed Test Procedure 13 Motor Speed Sensor on page 21 29 Vehicle will run in forward but not in reverse or will run in reverse but not forward Forward Reve...

Page 374: ...ck Voltage Under Load 8 Key Switch and MCOR Limit Switch Circuit 9 16 Pin Connector 10 Onboard Computer Silicon Controlled Rectifier SCR Circuit 11 Onboard Computer Gray Wire and Fuse 12 Voltage at Charger Receptacle Red Wire Socket 13 Motor Speed Sensor 14 Solenoid Continuity 15 Forward Reverse Rocker Switch 16 Reverse Buzzer 17 Rebooting the Onboard Computer 18 Battery Warning Light TEST PROCEDU...

Page 375: ... Electric Vehicles for further details on battery testing TEST PROCEDURE 2 ONBOARD COMPUTER SOLENOID LOCKOUT CIRCUIT See General Warning on page 1 1 The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle Use the following procedure to test the solenoid lockout circuit 1 With batteries connected place the Tow Run switch in the RUN position 2 Set a mul...

Page 376: ...e with insulation piercing probe on the red 18 gauge wire located on the OBC side of the six pin connector The reading should be approximately 48 volts If the reading is incorrect test the Tow Run switch and connecting wires See Test Procedure 6 Tow Run Switch on page 21 15 6 2 Set a multimeter to 200 volts DC Place the black probe on the battery no 4 negative post and place the red probe with ins...

Page 377: ... batteries connected place Tow Run switch in RUN Using a multimeter set to 200 volts DC place red probe on battery no 1 positive post and place black probe with insulation piercing probe on the purple white wire at a point close to the three pin connector at the MCOR The reading should be approximately 48 50 volts full battery voltage 3 If reading is zero volts check the purple white wire continui...

Page 378: ...uld drop as the pedal is pressed When the pedal is all the way to the floor the multimeter should indicate approximately 1k ohms 8 9 If the MCOR does not operate as described replace the MCOR TEST PROCEDURE 5 A1 AND A2 MOTOR VOLTAGE See General Warning on page 1 1 1 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the fra...

Page 379: ...ted connect the black probe to the neg ative post of battery no 4 and connect red probe with insulation piercing probe on the light green wire close to the two pin connector on the Tow Run switch 2 With the Tow Run switch in the RUN position the reading should be approximately 48 50 volts With the switch in the TOW position the reading should be below approximately 5 volts 3 If the reading is abov...

Page 380: ... SCROLL DISPLAY buttons The hand set should indicate OFF when the key switch is in the OFF position 4 2 While monitoring the handset display screen turn the key switch to the ON position The handset should indicate ON 4 3 If the handset does not indicate that KEY INPUT is ON when the key switch is in the ON position proceed to the following procedure Key Switch and MCOR Limit Switch Circuit Test w...

Page 381: ...set to 200 volts DC place the black probe on the battery no 4 negative post and place the red probe with insulation piercing probe on the green wire close to the two pin connector on the MCOR 5 2 With Tow Run switch in the RUN position key switch in the ON position and Forward Reverse rocker switch in the NEUTRAL position the voltage reading should be zero volts When the accel erator pedal is pres...

Page 382: ...d to the controller A procedure is provided for testing each of the wires in the 16 pin connector Refer to the following chart for the appropriate procedure for each pin in the 16 pin connector If the results of any of the referenced procedures are different from those described in the procedure check the continuity of the wires in the wire harness and test the connected components with the approp...

Page 383: ... not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 With the accelerator pedal fully up not pressed the multimeter should read approximately 1k ohms 6 Slowly press the accelerator pedal while monitoring the multimeter The resistance should rise as the pedal is pressed When the pedal is all the way to the floor the multimeter should indicate between 5 67k ohms a...

Page 384: ... clip connect the black probe to the B terminal of the speed controller Figure 21 6 Page 21 20 CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m 6 Place the Tow Run switch in the RUN position 7 The multimet...

Page 385: ...r floor jack Position jack stands under the frame crossmember between the spring mount and side stringer just forward of each rear wheel See WARNING Lift only one end in General Warning on page 1 1 3 Disconnect the 16 pin connector at the speed controller 4 Set a multimeter to 200 volts DC insert the red probe of the multimeter into pin 6 green wire of the 16 pin connector See following CAUTION Us...

Page 386: ...page 1 1 Pin 7 in the 16 pin connector provides a connection point for the reverse buzzer to the speed controller 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 1 2 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame crossmember between the s...

Page 387: ...nector at the speed controller 4 Set a multimeter to 200 volts DC insert the red probe of the multimeter into pin 8 brown wire of the 16 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of the speed controller Figure 21 9 Page 21 24 CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 Place the Tow R...

Page 388: ... Procedure 6 Tow Run Switch on page 21 15 Test Procedure 9F Pin 9 See General Warning on page 1 1 Pin 9 in the 16 pin connector provides a connection point for the Tow Run switch to the speed controller The switch provides a 48 volt signal to the speed controller through pin 9 when the Tow Run switch is in the RUN position 1 Disconnect the battery cables as instructed See WARNING To avoid unintent...

Page 389: ... Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m 6 Place the Tow Run switch in the RUN position The multimeter should indicate full battery voltage approximately 48 volts 7 Place the Tow Run switch in the TOW position The multimeter should indicate zero volts DC at this time 8 If any other reading is obtained check ...

Page 390: ...r clip connect the black probe to the B terminal of the speed controller Figure 21 11 Page 21 26 CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m 6 With the Tow Run switch in the TOW position the multimete...

Page 391: ...ligator clip between the B terminal of the speed controller use alligator clip for this connection and pin 12 blue white wire of the 16 pin connector Figure 21 12 Page 21 27 See following CAUTION CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten ...

Page 392: ...puter gray wire and fuse See Test Procedure 11 Onboard Computer Gray Wire and Fuse on page 21 28 Red wire at the charger receptacle See Test Procedure 12 Voltage at Charger Receptacle Red Wire Socket on page 21 28 TEST PROCEDURE 11 ONBOARD COMPUTER GRAY WIRE AND FUSE See General Warning on page 1 1 1 With batteries connected and a multimeter set to 200 volts DC connect the red probe to the positiv...

Page 393: ...ack white wire terminal socket in the three pin connector The voltage reading should be 48 to 50 volts full battery voltage 3 2 If the reading is zero volts check the continuity of the black white wire from the 16 pin connector at the speed controller to the three pin connector at the motor speed sensor If the continuity is cor rect replace the speed controller 4 Check voltage at the red motor spe...

Page 394: ...ery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 1 3 Disconnect the yellow wire from the large post of the solenoid 4 Disconnect the resistor terminal from the same large post as the removed wire 5 Set a multimeter to 200k ohms Place the black probe on the solenoid large post with the 6 gauge yel low wire and place the red probe on the large post ...

Page 395: ...lectrical Components Electric Vehi cle 3 Disconnect the three wires from the rocker switch Using a multimeter set to 200 ohms place the black probe on the blue wire terminal 3 position on the rocker switch and place the red probe on the orange wire terminal 2 position With the switch in NEUTRAL or REVERSE there should be no conti nuity With the switch in FORWARD there should be continuity If the r...

Page 396: ...ossible the Onboard Computer OBC can become locked up causing the OBC solenoid lockout circuit to malfunction If this condition is suspected restart the computer as follows 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 1 See following NOTE NOTE Wait at least 90 seconds for the capacitors in the speed controller to discharge...

Page 397: ...the desired code is displayed will display the data Function codes and corresponding data are as fol lows F1 Battery voltage This displays the battery pack s current state of charge A reading of less than 48 volts indicates that the batteries need to be charged If a reading of less than 48 volts is obtained immediately after a charge cycle there may be a problem in the charge circuit F2 Energy uni...

Page 398: ...ing NOTE NOTE If by positioning CDM on seat bottom the CDM is unable to collect the data stream from the onboard computer hold CDM approximately 6 inches 15 2 cm from battery warning light 3 Wait approximately 30 seconds for a value to appear in the display window 4 If a value does not appear in the display window after 30 seconds try adjusting the aim of the CDM and repeating step 3 until a value...

Page 399: ...mprehensive information Figure 21 14 Flow Chart CDM Troubleshooting Guide CDM battery is discharged Replace CDM battery Failed CDM unit Replace CDM Failed OBC Replace OBC Remove battery lead and discharge the speed controller See the instructions in the WARNING on page 11 1 After a short time replace the lead and restart the OBC OBC program is locked up Restart OBC by driving vehicle or by connect...

Page 400: ...21 ...

Page 401: ...ISPLAY MODULE IQDM P Programming PLUGGING THE HANDSET INTO THE VEHICLE 1 Connect one end of the cable to the jack located on the bottom of the handset 2 Connect the cable adaptor to the IQDM cable 3 Find the IQDM jack on the vehicle Figure 22 1 Page 22 1 or Figure 22 2 Page 22 1 4 Remove the dust cap from the IQDM jack 5 Align the keyed portion of the plug with the IQDM jack and connect the plug t...

Page 402: ...eled 1 2 and 3 are BOOKMARK BUTTONS Figure 22 3 Page 22 3 These buttons allow the user to bookmark up to three specific screens for rapid return to those screens To bookmark a specific display screen have the desired screen displayed and simply press and hold a bookmark button until the statement bookmark set is displayed When it is necessary to go back to the bookmarked screen rapidly press and r...

Page 403: ...ion The information menu displays the model number serial number manufacturer date and software version of the speed controller See Information on page 22 14 Programmer Setup The programmer setup menu allows the user to set the LCD contrast display the fault history of the program mer as well as various other information pertaining to the handset such as model number serial number OEM information ...

Page 404: ... can be monitored when the key switch is in the ON or OFF position Batt Voltage Displays the current battery voltage at the speed controller Heatsink Displays the temperature in degrees Celsius of the speed controller heatsink During normal operating con ditions the heatsink temperature should be below 85 C 5 C 185 F 9 F See following NOTE NOTE Improper brake adjustment can sometimes cause the ope...

Page 405: ...itch is placed in the REVERSE position the handset should indicate that the reverse input is on Main Cont Displays the current solenoid main contactor state When the contactor is activated the handset indicates that the solenoid is on When the contactor is not activated the handset indicates that the solenoid is off Key Input Displays the position of the key switch OFF or ON Password Tries IQDM P ...

Page 406: ...ses of Faults Some common causes of faults are Loose broken or disconnected wires or connectors Failed components Improper adjustment or installation of electrical or mechanical components examples brake adjust ment improper MCOR installation Improper wiring of electrical components As shown above there are many possible causes for faults to occur and the speed controller has a pro grammed reactio...

Page 407: ...AILSAFE A B C THROTTLE FAULT 1 A SPEED SENSOR D MAIN WELDED D MAIN DRIVER ON D MAIN DRIVER OFF A C MAIN CONT DNC B MAIN COIL FAULT A FIELD MISSING A B C HPD A PROC WIRING A OVERVOLTAGE A B G UNDERVOLTAGE E THERMAL CUTBACK E MOTOR STALL F MAIN DROPOUT A C OPEN ARMATURE A MAX PASSWORD TRIES no action taken INCORRECT PASSWORD no action taken HIGH SPEED WALKAWAY D KEY SWITCH SRO C ...

Page 408: ...rmature current If the speed controller detects a failure of the armature drive FET s or circuitry a hardware failsafe fault is detected CONTROLLER FAULT CONTROLLER ATTEMPTS TO RECOVER HW FAILSAFE When key switch is cycled THROTTLE FAULT 1 When condition clears SPEED SENSOR When condition clears MAIN WELDED When condition clears MAIN DRIVER ON When condition clears MAIN DRIVER OFF When accel pedal...

Page 409: ...lenoid did not close fault is detected when the speed controller has sent voltage to the solenoid activating coil but the solenoid contacts are not closed Main Coil FAULT If the speed controller determines that the solenoid is not closing as a result of a solenoid coil failure a main coil fault is detected Field Missing If the speed controller is operating at a duty cycle of greater than 90 almost...

Page 410: ... password tries fault is indicated the speed controller must be removed and shipped to Club Car before it can ever be placed in private speed mode See Code A Code B and Code C on page 29 3 See also Password Tries IQDM P only on page 22 5 Fault History The fault history menu can be useful in determining the cause of a vehicle problem however the fault history alone should not be the factor that det...

Page 411: ...UTRAL position and lock the park brake 3 Plug the handset into the vehicle 3 1 Connect one end of the cable to the jack located on the bottom of the handset 3 2 Connect the cable adaptor to the IQDM cable 3 3 Remove the dust cap from the IQDM jack 3 4 Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack Figure 22 4 Page 22 12 or Figure 22 5 Page 22 12 4 Scroll to...

Page 412: ...andset that has the desired speed controller settings See Speed Con troller Cloning Transferring Settings from the Vehicle to the Handset on page 22 11 2 Locate a vehicle that does not have the desired speed controller settings 3 Turn the key switch to the OFF position place the Forward Reverse handle in the NEUTRAL position and lock the park brake 4 Plug the handset into the vehicle 4 1 Connect o...

Page 413: ...2 13 11 Repeat this procedure for additional vehicles that need to be programmed with the same handset set tings RESET ALL SETTINGS In the event that a mistake was made and one or more changes should not have been made with the handset the speed controller settings can be reverted to the original settings from the beginning of the session when the handset was plugged into the vehicle This function...

Page 414: ...to scroll to information and pressing the right arrow key to activate the menu This menu selection displays information pertaining to the speed controller The information provided from this menu selection includes Model Number Displays the model number of the speed controller Serial Number Displays the serial number of the speed controller MFG Date Displays the date the speed controller was manufa...

Page 415: ...will erase the history of faults that are stored in the handset INFORMATION This menu selection displays information pertaining to the handset The information provided in this menu selection includes model number serial number the date the handset was manufactured the handset soft ware version etc CODE NUMBER TEXT DISPLAYED 9 Time out error detect no response from controller 14 Communication error...

Page 416: ...2 Handset Cord Adaptor on page 22 18 IQDM jack on vehicle F R switch has failed Test Procedure 3 IQDM Jacks on page 22 18 Contrast Setting is too light See Program on page 22 14 Onboard computer is in power down mode Drive the vehicle for a short distance and reconnect the handset to the vehicle Onboard computer malfunction See Section 21 Electrical System and Testing Electric Vehicle Loose vehicl...

Page 417: ...uare plug 2 Place the black probe on each of the pins one at a time on the plug on the other end of the cord 3 The multimeter should indicate continuity on only one pin If any other reading is obtained the cord must be replaced 4 Repeat the procedure three more times each time with the red probe inserted into a different terminal on the end of the cord with the square plug Handset is locked up but...

Page 418: ...1 1 Test Procedure 3A IQDM Jack Located on F R Switch Housing 1 Turn the key switch to the OFF position place the Forward Reverse control in the NEUTRAL position and lock the park brake 2 Place the Tow Run switch in the TOW position disconnect the batteries negative cable first and wait 90 seconds for the speed controller capacitors to discharge See General Warning on page 1 1 3 Check the IQDM jac...

Page 419: ...f the electrical com ponents mounted on the dash panel Do not allow wires to touch See following NOTE NOTE Take care to prevent key switch terminals and wires from touching the metal frame around the dash 3 2 Disconnect the IQDM jack four pin connectors 4 and 5 and visually inspect the contacts for dam age and corrosion Inspect the IQDM jack mounted to the bottom of the dash panel Repair and repla...

Page 420: ...set cord to the handset 3 5 Connect the other end of the handset cord without the adapter 4 to the four pin connector of the speed controller 2 Figure 22 10 Page 22 20 3 6 Connect the vehicle batteries positive cable first 3 7 If the handset functions when connected directly to the speed controller the adapter plug or vehicle wire harness should be thoroughly tested See Test Procedure 2 Handset Co...

Page 421: ...s completely as shown in Detail A Figure 23 1 Page 23 2 3 2 Remove Tuflok screws from instrument panel as shown in Detail B 3 3 Pull forward on top of instrument panel to access back side of key switch 3 4 Disconnect the wire connectors from the key switch 4 Remove the key switch 4 1 Remove the key switch nut 1 Figure 23 2 Page 23 2 4 2 Remove key switch 2 from back side of instrument panel Key Sw...

Page 422: ...itch in the TOW position 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 3 Remove the center dash panel Figure 23 3 Page 23 3 3 1 Remove the plastic cap 1 covering the mounting screw 2 on each side of the center dash panel 3 Figure 23 3 Page 23 3 3 2 Loosen but do not remove the screw 2 on each side of the center dash panel...

Page 423: ... not allow wires to touch See following NOTE NOTE Take care to prevent key switch terminals and wires from touching the metal frame around the dash 4 Slide center dash panel up steering column by snapping top out and then rotating the panel out and up 5 Disconnect the wires from the key switch Do not allow wires to touch 6 From the back of the dash panel push down on the retaining tabs surrounding...

Page 424: ...N 1014305 3 Install center dash by reversing removal procedure Make sure key switch terminals 7 do not touch frame and that the center dash panel is properly seated and snapped into place Figure 23 4 Page 23 4 4 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Pr...

Page 425: ...rocker switch housing 2 to body Tighten to 20 in lb 2 3 N m Figure 23 5 Page 23 5 4 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 5 Place the Tow Run switch in the RUN position 6 Inspect the vehicle for pro...

Page 426: ...witch into dash panel Figure 23 6 Page 23 7 2 Connect the 18 gauge brown orange and blue wires to the rocker switch exactly as shown in the wiring diagram See Wiring Diagram on page 12 6 3 Install center dash by reversing removal procedure Make sure key switch terminals do not touch frame and that the center dash panel is properly seated and snapped into place 4 Connect the battery cables positive...

Page 427: ... 23 7 3 Remove Tow Run switch 10 and nut 9 from bracket 5 4 Disconnect the two pin connector 7 and remove switch Tow Run Switch Installation 1 Installation is reverse of removal Make sure groove on switch is aligned with tang on bracket Tighten Tow Run switch boot hex nut 6 to 16 in lb 1 8 N m Figure 23 5 Page 23 5 and Figure 23 6 Page 23 7 2 Place the Tow Run switch in the TOW position and connec...

Page 428: ...on page 1 2 2 Place chocks at rear wheels and lift the front of the vehicle with a chain hoist or floor jack Place jack stands under the round tube crossmember of the frame to support vehicle See WARNING Lift only one end in General Warning on page 1 1 3 Disconnect the two pin and three pin connectors 1 from the MCOR 2 Figure 23 7 Page 23 8 4 Remove the hex head screws 3 connecting the MCOR to the...

Page 429: ...connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion REVERSE BUZZER See General Warning on page 1 1 Testing the Reverse Buzzer See Test Procedure 16 Section 21 Page 21 31 Reverse Buzzer Removal 1 Disconnect the battery cables as instructed See WARNING To avoid u...

Page 430: ...en both solenoid mounting screws 12 4 2 Lift the solenoid 3 up and off of the component mounting plate 5 Slot mounted solenoid Figure 23 9 Page 23 10 5 1 Slide solenoid up to disengage the mounting tabs and remove from component mounting plate Solenoid Installation 1 Mount solenoid onto component mounting plate with screws 12 Figure 23 8 Page 23 10 or by engaging slot Figure 23 9 Page 23 10 2 Tigh...

Page 431: ...al Warning on page 1 2 2 Remove rear body access panel and unplug the six pin connector 16 at the OBC Figure 23 10 Page 23 11 or Figure 23 11 Page 23 11 3 Remove the two screws 5 from the speed controller cover 1 and remove the cover Figure 23 12 Page 23 13 4 Remove the wire tie 3 securing the speed controller wires to the mounting plate 5 Remove black 6 gauge wire 14 from the speed controller B t...

Page 432: ... Figure 23 10 Page 23 11 or Figure 23 11 Page 23 11 5 Connect the black 10 gauge wire 8 to the charger receptacle Figure 23 10 Page 23 11 or Figure 23 11 Page 23 11 Tighten to 23 in lb 2 6 N m 6 Connect the gray wire fuse holder to the charger receptacle 7 Early OBC Only Connect the black 10 gauge wire 6 and the black 10 gauge wire 5 to the accessory mounting terminal Install the nut on the access...

Page 433: ...ntroller cover 1 and remove the cover Figure 23 12 Page 23 13 4 Disconnect all wires and multi pin connectors from the speed controller Figure 23 13 Page 23 14 5 Remove the three self tapping screws 17 that hold the controller 6 to the component mounting plate and remove the controller from the vehicle Speed Controller Installation 1 Install the three self tapping screws 17 that hold the controlle...

Page 434: ...onnect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 6 Place the Tow Run switch in the RUN position 7 Inspect the vehicle for proper operation Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position ...

Page 435: ...Warning on page 1 2 2 Remove the 10 gauge red wire 4 from the positive post of battery no 1 Figure 23 14 Page 23 16 3 Remove black 10 gauge OBC wire 5 from charger receptacle 4 Disconnect the gray wire 9 from the receptacle at the yellow fuse holder 5 Remove the four screws 1 that secure the charger receptacle bezel 7 to the receptacle backing plate 8 and to the vehicle body 6 Move the receptacle ...

Page 436: ...ove the fuse link 6 from the charger receptacle 7 by removing the two nuts and washers used to secure the 10 gauge black wire 5 from the computer and the 10 gauge black wire to the receptacle Figure 23 14 Page 23 16 2 Remove the fuse link 6 from the charger receptacle Receptacle Fuse Link Installation 1 Insert the two fuse link mounting posts into the mounting holes in the charger receptacle 2 Pla...

Page 437: ...tentionally starting in General Warning on page 1 2 2 Remove instrument panel See Key Switch Removal on page 23 1 3 Disconnect the two wires from the battery warning light 4 Press the two retaining tabs 11 and remove the light from the instrument panel Battery Warning Light Installation 1 Install in reverse order of removal 2 Place the Tow Run switch in the TOW position and connect the battery cab...

Page 438: ...23 ...

Page 439: ...working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring ý WARNING 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 Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shortin...

Page 440: ...above 9 3V and within 0 7V All readings below 9 3V but within 0 7V Check electrical system and charger for problems SeeTroubleshooting Guide If problem is not found go to on charge voltage test Any reading below 9 3 volts and not within 0 7 volts of those batteries above 9 3 volts replace battery Replace any battery with a variation of more than 50 points of specific gravity between cells or has a...

Page 441: ...ace the red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 4 Figure 24 4 Page 24 9 Record reading Then set multimeter to 20 volts DC and place the red probe on the positive post and the black probe at the negative post of each battery Record the readings The on charge voltage for the set should be between 56 0 volts and 63 0 volts depending on the...

Page 442: ...rd the reading and return the electrolyte to the cell from which it was taken Replace vent cap 7 Repeat steps 2 through 6 on all cells Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 F 26 7 C The readings obtained as described above must be corrected for temperature For each 10 F 5 6 C above 80 F 26 7 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 26 7 C s...

Page 443: ...vel is correct in all cells 2 Connect the tester leads to the positive post of battery no 1 and negative post of battery no 4 Figure 24 3 Page 24 5 VEHICLE NO BATTERY NO ELECTROLYTE TEMPERATURE CORRECTION FACTOR CORRECTED SPECIFIC GRAVITY REQUIRED ACTION CELL 1 CELL 2 CELL 3 CELL 4 CELL 5 CELL 6 12 1 20 F 6 6 C 0 024 1 275 0 024 1 251 1 280 0 024 1 256 1 280 0 024 1 256 1 275 0 024 1 251 1 280 0 0...

Page 444: ... discharge times are low less than 60 minutes replace batteries below 10 05 volts 3 In general battery sets that discharge in less than 60 minutes at 78 F 25 6 C on the discharge test will typically not hold a charge for an entire work shift However discharge time is dependent on the elec trolyte temperature The table shown gives the discharge times at various temperatures of a set of bat teries t...

Page 445: ...ischarge test which lasted 45 minutes battery no 1 is clearly shown to be the problem Battery no 4 should be watched a little more closely but appears to be okay Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad battery due to its performance The battery charger test sho...

Page 446: ...ice life from new batteries restrict vehicles with new batteries to one hour of operation between charges for the first two months vehicle is in service Batteries should be fully charged before first use of new vehicle before first use of a vehicle after storage and before use each day 6 If the battery cables are to be reused inspect them for broken or frayed wires damaged terminals or worn insula...

Page 447: ...water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off bat teries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CCI P N 1014305 See Self Discharge on page 24 10 3 Maintain proper electrolyte level See Electrolyte Level on page 24 10 4 Batteries should be properly ch...

Page 448: ... below the level of the plates If the electrolyte level is below the level of the plates add just enough water to cover the plates and then charge the batteries After charging fill with water to the level indicator Filling a battery to the level indicator before charging will result in overfilling because the electrolyte level will rise during charging and some of the electrolyte may bubble out of...

Page 449: ...d to 40 in lb 4 5 N m Excessive vibration causes the plates to shed prematurely and shortens the life of the battery It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts The acid which is lost reduces the capacity of the battery and cannot be replaced Battery hold downs should NOT be so tight as to crack or buckle the battery case This may cause ...

Page 450: ...hicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person immediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if The plug is too loose or does not make a good connection The plug an...

Page 451: ...t period 10 minutes The charger is automatic and will turn off when batteries are fully charged If the charger does not seem to be oper ating properly or if the batteries seem weak contact your local Club Car distributor dealer PLUG AND RECEPTACLE The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring t...

Page 452: ...ed check the batteries for state of charge Any battery with a specific gravity lower than 1 250 will need a catch up charge If the problem continues after a catch up charge has been performed check the battery charger Refer to the appropriate battery charger maintenance and service manual See Section 25 Battery Charger Electric Vehicle DEEP DISCHARGE Never discharge batteries to the point the vehi...

Page 453: ...e first ones out in the morning Spread the workload evenly giving all vehicles the same amount of use This will keep your fleet in balance and will not overwork certain sets of batteries See following NOTE NOTE When vehicles are being rotated the CDM Communication Display Module can be a very helpful service tool Monitoring the value of function 3 with the CDM simplifies vehicle usage scheduling S...

Page 454: ...C will discharge very little over a four month period Batteries stored at 80 F 26 7 C will have to be recharged every few weeks 5 48 volt electric vehicles and compatible battery chargers are designed to be left connected with AC power to the charger ON during off season storage The storage charge feature will automatically charge the batteries as needed throughout the storage period CHARGING A BA...

Page 455: ...2007 2008 XRT 800 810 and 850 Maintenance and Service Manual Page 25 1 25 SECTION 25 BATTERY CHARGER ELECTRIC VEHICLE Refer to the appropriate Battery Charger Maintenance and Service Manual ...

Page 456: ...25 ...

Page 457: ... can be performed without disassembling the motor using a multimeter or continuity tester NOTE Tag the motor wires for identification before disconnecting TEST PROCEDURE 1 INTERNAL SHORT CIRCUITS See General Warning on page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 2 Disconnect wires from terminals on motor using ...

Page 458: ... F2 terminal The multimeter should indicate continuity If the reading is incorrect a possible open field coil or bad connections at the terminals may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 26 2 MOTOR See General Warning on page 1 1 Motor Removal 1 Disconnect the battery cables as instructed See WARNING To avo...

Page 459: ...as it will go If more room is needed remove the jack from beneath the transaxle and allow the springs to rest on the floor Figure 26 3 Page 26 3 9 Remove the four bolts that mount the motor to the transaxle Figure 26 18 Page 26 14 See following CAUTION ý CAUTION Do not position fingers under motor when sliding motor off of the input shaft in step 9 Fingers may get pinched when motor disengages 10 ...

Page 460: ...5 Remove two screws 11 attaching brush rigging 12 to the stator shell 2 Figure 26 9 Page 26 8 6 Mark the brush terminal posts A1 and A2 13 to identify their positions in the stator shell then remove the nuts 6 and flat washers 5 Figure 26 9 Page 26 8 From the outside push the posts through the stator shell wall into the interior of the stator shell 7 Carefully remove the brush rigging and the term...

Page 461: ...determine original cause of failure Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper See following CAUTION and NOTE CAUTION Do not use emery cloth to polish the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes NOTE Oil on the commutator may indicate a faulty tra...

Page 462: ...spect the brush springs 14 Figure 26 9 Page 26 8 Replace springs that are discolored from heat light gold or blue tinted Replace springs which apply a force of less than 16 oz Figure 26 7 Page 26 7 See following CAUTION and NOTE CAUTION When checking brush spring tension do not over extend the spring Using excessive force will damage the spring NOTE When installing new brushes remove and replace b...

Page 463: ...a press is not available secure a bearing puller CCI P N 1012811 to the bearing and pull the bear ing off of the end of the armature shaft Support the shaft so it will not drop when the bearing is removed Figure 26 10 Page 26 10 Discard the bearing and speed sensor magnet See following NOTE NOTE The speed sensor magnet will be pressed off by the bearing when the bearing is removed BEARING INSTALLA...

Page 464: ...08 XRT 800 810 and 850 Maintenance and Service Manual 26 Figure 26 9 Motor Model 5BC59JBS6390 16 15 18 4 6 5 3 F 1 A 1 F 2 A 2 22 29 9 TYPICAL 2 PLACES TYPICAL 2 PLACES 11 10 24 21 7 8 TYPICAL 4 PLACES 28 27 2 1 25 26 TYPICAL 3 PLACES 14 13 17 12 30 ...

Page 465: ...ONDITIONING THE MOTOR See General Warning on page 1 1 Motor reconditioning must be performed by a qualified motor repair technician The use of proper tools and procedures is absolutely essential for successful motor reconditioning Motor Specifications Any rework must be performed by a qualified technician Motor service specifications are listed in the follow ing table ITEM SERVICE LIMIT Commutator...

Page 466: ...apart from each other 2 1 With brush rigging facing down and held slightly above stator shell insert the two terminal posts through insulators in stator shell wall at the A1 and A2 positions Insert brush holder screws through the holes in the brush rigging and into the threaded holes in the mounting bracket Figure 26 11 Page 26 11 Tighten the screws to 20 in lb 2 3 N m 2 2 One at a time push brush...

Page 467: ...oles in the bearing retainer with the two mating holes in the end shield and installing the screws 9 Figure 26 9 Page 26 8 Tighten the screws to 17 in lb 1 9 N m See following NOTE NOTE Use a long screw with the same thread specifications as the mounting screws to maintain hole alignment while starting the first mounting screw Figure 26 12 Page 26 11 3 2 Align the match marks on the end shield and...

Page 468: ...from the end of the shaft and working back toward the transaxle away from the end of the shaft Figure 26 14 Page 26 12 2 4 The grease should be evenly distributed in the grooves to a width of approximately 3 8 inch 9 5 mm 2 5 Use a flat screwdriver to clean the grease out of one of the grooves and allow air to escape when the motor is pushed onto the input shaft 2 6 Check the chamfer and end of th...

Page 469: ...TE Failure to install and tighten the motor mounting bolts in the proper sequence and to the proper tightness may result in motor noise during operation 4 4 Tighten the right bolt 1 to 65 in lb 7 3 N m 4 5 Tighten the left bolt 2 to 65 in lb 7 3 N m 4 6 Tighten the center bolt 3 to 65 in lb 7 3 N m Figure 26 18 Page 26 14 4 7 Tighten the bolt 4 inserted through the tab to 155 in lb 17 5 N m Figure...

Page 470: ...h in the TOW position and connect the batteries positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 11 Place the Tow Run switch in the RUN position 12 Inspect the vehicle for proper operation See following WARNING ý WARNING Make sure that the vehicle operates in the forward direction whe...

Page 471: ...igure 26 19 Page 26 15 3 Using a screwdriver gently pry the motor speed sensor 21 from recessed area on the motor end shield Motor Speed Sensor Installation 1 Position the motor speed sensor 21 as shown and firmly press the speed sensor into the motor end shield Sensor should fit flush against the motor Figure 26 19 Page 26 15 2 Connect the three pin connector 22 to the vehicle wire harness 3 Plac...

Page 472: ...26 ...

Page 473: ...STING The following tests can be performed without disassembling the motor using a multimeter or continuity tester NOTE Tag the motor wires for identification before disconnecting TEST PROCEDURE 1 INTERNAL SHORT CIRCUITS See General Warning on page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning on page 1 2 2 Disconnect wires from ...

Page 474: ...inal The multimeter should indicate continuity If the reading is incorrect a possible open field coil or bad connections at the terminals may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 27 2 MOTOR See General Warning on page 1 1 MOTOR REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unint...

Page 475: ... it will go If more room is needed remove the jack from beneath the transaxle and allow the springs to rest on the floor Figure 27 3 Page 27 3 9 Remove the four bolts that mount the motor to the transaxle Figure 27 24 Page 27 15 See following CAUTION ý CAUTION Do not position fingers under motor when sliding motor off of the input shaft in step 9 Fingers may get pinched when motor disengages 10 Ca...

Page 476: ...n on page 27 9 3 Loosen but do not remove the two screws securing the end cap to the motor frame Figure 27 5 Page 27 4 4 Orient the motor so that the splined end of the armature is facing down 5 Inspect the area where the end cap mates with the motor frame If the end cap appears to be loose where it connects to the motor frame proceed to step 6 otherwise disengage the end cap from the motor frame ...

Page 477: ... disengaged from the end cap bearing NOTE Replacement of the end cap bearing is recommended if the armature is removed 9 1 Place the end cap in a press with the armature facing down 9 2 Place a bearing press tool with an outer diameter smaller than that of the armature shaft between the press ram and the armature shaft Figure 27 8 Page 27 6 9 3 Have an assistant support the armature while the pres...

Page 478: ...ve the motor from the vehicle See Motor Removal Section 27 Page 27 2 2 Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 27 4 Visual Inspection Burned charred or cracked insulation Improperly cured varnish Thrown solder Flared armature windings Damaged armature core laminations Figure 27 8 Armature Removal Figure 27 9 A1 and A2 Terminals Figure 27 10 Brus...

Page 479: ... are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes NOTE Oil on the commutator may indicate a faulty transaxle input shaft oil seal Armature Ground Test CAUTION Do not submerge the armature in solvent NOTE Before testing the armature wipe it clean with a clean cloth Remove any carbon dust and metal particles from between the commutato...

Page 480: ...brush as shown Figure 27 13 Page 27 9 4 3 Gently pull the scale to obtain the spring tension reading See following CAUTION CAUTION When checking brush spring tension do not over extend the spring Using excessive force will damage the spring 4 4 Replace springs which require a force of less than 35 oz 990 grams Figure 27 13 Page 27 9 See following NOTE NOTE When installing new brushes remove and re...

Page 481: ...or determining general bearing failure 1 Remove the motor from the vehicle See Motor Removal Section 27 Page 27 2 2 Remove the bearing by performing steps 1 through 14 of Motor Disassembly on page 27 4 3 Use a clean cloth to wipe the carbon dust off of the bearing Inspect the bearing by spinning it by hand and checking for both axial A and radial B play Figure 27 14 Page 27 9 4 Replace the bearing...

Page 482: ...8 XRT 800 810 and 850 Maintenance and Service Manual 27 Figure 27 15 Motor Model EJ4 4001 10 24 23 25 4 5 6 7 9 12 8 14 13 15 16 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES 16 11 19 20 22 21 1 2 17 18 TYPICAL 3 PLACES 3 TYPICAL 2 PLACES 30 ...

Page 483: ...od ensures the terminals and brushes will be properly positioned in the rigging When replacing brushes replace all four brushes Never replace only two Install the brushes in the same rigging 180 apart from each other 2 1 Insert the brushes into the brush rigging as shown Figure 27 16 Page 27 12 2 2 Insert the two terminal posts through insulators 4 in the end cap 11 wall at the A1 and A2 posi tion...

Page 484: ...he weight of the commutator The brushes can be easily damaged by this weight 4 Gently press each brush with a small screwdriver until the spring rests on the end of each brush as shown Figure 27 19 Page 27 12 5 Align the match marks on the end cap and the motor frame 1 and secure with two bolts 16 Figure 27 15 Page 27 10 Tighten bolts to 130 in lb 14 7 N m 6 Install the speed sensor magnet 24 with...

Page 485: ...m the end of the shaft and working back toward the transaxle away from the end of the shaft Figure 27 21 Page 27 13 2 4 The grease should be evenly distributed in the grooves to a width of approximately 3 8 inch 9 5 mm 2 5 Use a flat screwdriver to clean the grease out of one of the grooves and allow air to escape when the motor is pushed onto the input shaft 2 6 Check the chamfer and end of the i...

Page 486: ...o install and tighten the motor mounting bolts in the proper sequence and to the proper tightness may result in motor noise during operation 4 4 Tighten the right bolt 1 to 65 in lb 7 3 N m 4 5 Tighten the left bolt 2 to 65 in lb 7 3 N m 4 6 Tighten the center bolt 3 to 65 in lb 7 3 N m Figure 27 24 Page 27 15 4 7 Tighten the bolt 4 inserted through the tab to 155 in lb 17 5 N m Figure 27 24 Page ...

Page 487: ...the Tow Run switch in the TOW position and connect the batteries positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 11 Place the Tow Run switch in the RUN position 12 Inspect the vehicle for proper operation See following WARNING ý WARNING Make sure that the vehicle operates in the forw...

Page 488: ...27 ...

Page 489: ...ked on a level surface the lubricant level should be even with the bottom of the hole The lower plug 22 is for draining the lubricant When draining the lubricant the upper plug should be removed so the lubricant will drain faster Be sure the drain plug is installed before filling See following NOTE NOTE Recycle or dispose of used oil or lubricant in accordance with local state and federal regulati...

Page 490: ...age the inside surfaces of the tube when removing the oil seal and adapter ring A damaged tube might have to be replaced NOTE Do not discard the adapter ring If the adapter ring is lost or damaged the axle tube will have to be replaced 6 2 Use a press to separate the axle oil seal 15 from the adapter ring 39 Figure 28 3 Page 28 2 Retain the adapter ring and discard the oil seal 7 Inspect the axle ...

Page 491: ...aft 2007 2008 XRT 800 810 and 850 Maintenance and Service Manual Page 28 3 28 Figure 28 5 Axles And Tubes 1 3 14 15 39 24 26 13 33 36 32 8 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29 2 3 8 36 27 30 28 37 38 5 6 4 15 39 TYPICAL 6 PLACES ...

Page 492: ...le shaft assembly 1 or 2 must be replaced Figure 28 5 Page 28 3 2 1 Insert the shaft splined end first through the seal and into the axle tube Be careful not to damage the seal on the inside of the axle tube hub Advance the shaft through to the bearing on the shaft then rotate it to align the shaft splines with the splined bore of the differential side gear 27 Figure 28 5 Page 28 3 Continue advanc...

Page 493: ...st forward of each rear wheel Lower the vehicle to let the jack stands support the vehicle Figure 28 6 Page 28 5 See WARNING Lift only one end of the vehicle in General Warning on page 1 1 3 Remove the rear wheels then thread one lug nut onto a stud on each rear hub This will keep the brake drums on the hubs 4 Remove the bow tie pins 1 brake cable clevis pins 2 and cable retaining E clips 3 Discon...

Page 494: ...rs under motor when sliding motor off of the input shaft Fingers may get pinched when motor disengages 10 Carefully remove the motor from the transaxle Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft then lift motor out See preceding WARNING 11 If a floor jack was used pull floor jack from beneath the transaxle and allow the springs to rest on...

Page 495: ...alves 4 Remove input pinion gear 17 by pulling gear out while rocking intermediate gear assembly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 28 5 Page 28 3 See following CAUTION CAUTION Do not damage gears Use extreme care when handling them 5 Use a bearing puller or arbor press to remove bearings 16 from the input pinion gear If the oil seal 10 is ...

Page 496: ...e the two bolts 8 4 Remove the differential pin 31 by pushing pin through differential gear case from one side Figure 28 5 Page 28 3 See also Figure 28 15 Page 28 9 8 5 Remove the idler gears and thrust plates 1 and 2 Figure 28 16 Page 28 9 8 6 Remove the differential gears and thrust plates 3 and 4 8 7 Inspect the bearings 13 of the differential case 26 and replace them if they are damaged Figure...

Page 497: ...CI P N 1014161 The lip of the oil seal should face the inside of the transaxle housing Make sure the seal is firmly seated 6 Install the differential assembly the intermediate gear assembly and the input pinion gear simulta neously Be sure all bearings are seated properly in the housing Rotate the input shaft to check for smooth gear operation Figure 28 11 Page 28 6 7 Install both dowel pins 25 in...

Page 498: ...parate from the transaxle and damage the axle assembly and other components Loss of vehicle control could result in severe personal injury or death 12 Make sure the drain plug 22 is installed in the transaxle and tightened to 23 ft lb 31 N m Fill the tran saxle through the level indicator hole with 22 ounces of SAE 30 API Class SE SF or SG oil a higher grade may also be used Install and tighten th...

Page 499: ...er bushings expand to the same size as the cup washers 10 Install the rear wheels and finger tighten the lug nuts 11 Lift the vehicle and remove the jack stands 12 Lower vehicle and tighten the lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 13 Inspect the vehicle to check for proper operation See following WARNING ý WARNING Make sure that the vehicle operates in the forward direction whe...

Page 500: ...28 ...

Page 501: ...EHICLE 1 Connect one end of the cable to the jack located on the bottom of the handset 2 Connect the cable adaptor to the IQDP P cable 3 Find the IQDM jack on the vehicle Figure 29 1 Page 29 1 or Figure 29 2 Page 29 1 4 Remove the dust cap from the IQDM jack 5 Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack Figure 29 1 IQDM Jack On F R Switch Housing Figure ...

Page 502: ... handset from the program menu SPEED SETTING The vehicle s top speed can be changed by selecting values 1 through 3 Figure 29 4 Page 29 2 If a value of 4 is displayed for the speed setting a special access code has been entered to place the vehicle in private speed mode A speed setting of 4 cannot be selected with the speed setting menu item For additional infor mation on speed setting 4 refer to ...

Page 503: ... on the slope of the incline See Speed Setting on page 29 2 SPEED CAL The speed cal speed calibration menu item allows the user to fine tune the vehicle speed This feature can not be used to increase the vehicle speed The range for speed calibration is 0 to 10 Each time the number is increased the top speed will be decreased by 0 12 mph 0 2 km h The top vehicle speed will be deter mined by the spe...

Page 504: ...29 ...

Page 505: ...er calibration 24 4 maintenance preventive 24 9 see also batteries electrolyte replacement 24 8 self discharge 24 10 storage 24 15 testing 24 3 discharge test 24 5 interpreting test results 24 6 hydrometer test 24 3 interpreting results 24 4 on charge voltage test 24 3 voltage test 21 10 voltage test under load 21 15 troubleshooting examples 24 7 vibration damage 24 11 battery hydrometer test 11 9...

Page 506: ...ng brake assembly 6 5 seat 4 1 vehicle body 4 1 clutch torque converter troubleshooting 20 1 clutch drive see drive clutch clutch driven see driven clutch column steering see steering column communication display module CDM function codes 21 33 retrieving data from 21 34 troubleshooting 21 35 commutator see starter generator connector 16 pin see test procedures crankcase cover installation 15 5 re...

Page 507: ...32 fuel level sending unit testing 12 31 hour meter circuit testing 11 35 hour meter circuit testing 12 33 installation 14 21 operation 13 21 removal 14 21 fuel gauge hour meter gasoline vehicles hour meter circuit testing 12 33 operation 13 21 fuel level sending unit 14 22 testing 11 32 fuel level sending unit testing 12 31 fuel lines 16 25 fuel pump 16 19 assembly 16 20 cleaning and inspection 1...

Page 508: ...12 23 1 23 2 starter circuit testing 11 13 starter circuit testing pedal start 12 13 testing 21 16 kill circuit engine testing 11 28 12 19 12 28 kill limit switch installation 14 16 removal 14 15 kill limit switch engine testing 12 27 kill wire engine testing 11 29 L leaf spring see suspension front and suspension rear lockout cam limit switch 11 15 testing 11 31 lockout cam circuit function 11 5 ...

Page 509: ... 21 34 testing 21 11 21 28 P park brake adjustment electric MCOR 5 17 gasoline vehicle 5 12 installation 5 4 removal 5 3 pedal group adjustment electric MCOR 5 16 gasoline vehicle 5 11 R rack and pinion assembly 7 10 disassembly 7 7 installation 7 12 removal 7 7 rear suspension see suspension rear receptacle see charger receptacle regenerative braking 21 1 repair front and rear body gouges punctur...

Page 510: ...n 14 7 disassembly 14 2 14 4 field coil inspection 13 8 14 8 removal 14 6 installation 13 9 14 10 removal 13 1 14 1 rework 14 8 testing 11 17 11 20 12 16 12 18 steering adjustment 7 6 rack and pinion assembly 7 10 disassembly 7 7 installation 7 12 removal 7 7 steering column assembly 7 4 disassembly 7 4 installation 7 5 removal 7 2 steering wheel installation 7 2 removal 7 1 storage electric vehic...

Page 511: ...eptacle 21 28 13 speed sensor motor 21 29 14 solenoid 21 30 15 Forward Reverse rocker switch 21 30 16 reverse buzzer 21 31 17 OBC rebooting 21 32 18 battery warning light 21 32 test procedures gasoline vehicle battery 11 9 11 31 diode 11 18 engine kill circuit 11 29 fuel gauge 11 33 fuel level sending unit 11 32 fuse 11 11 ground cables 11 12 headlight 11 37 12 35 headlight diode 11 37 12 35 headl...

Page 512: ...ommunication display module CDM 21 35 IQDM and IQDM P handset 22 16 torque converter 20 1 troubleshooting guide 1 21 5 troubleshooting guide 2 21 8 vehicle troubleshooting guide 12 1 U unitized transaxle installation 18 13 19 14 lubrication 18 2 19 2 removal 18 6 19 6 service 18 1 19 1 V voltage regulator installation 14 12 removal 14 11 testing 11 20 12 18 W walk away braking 21 1 WARNING definit...

Page 513: ...Clarity of Illustrations 4 Index Usability 5 Troubleshooting Chart Usability Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in the following catgories Your Comments Are Appreciated Please select your category Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other ____...

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Page 516: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808 ...

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