Club Car XRT 1500 2005 Page 44 Owner'S Manual Download | Manualshive

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Air Intake System

Page 42

2005 XRT 1500 Gasoline and Diesel Vehicle Owner’s Manual

AIR INTAKE SYSTEM

CAUT ION

• Do not drill into the driver-side frame. Failure to heed this caution could damage the engine by

allowing excessive contamination to enter the air intake system.

AIR FILTER REPLACEMENT

The air filter should be inspected periodically and replaced when necessary. Filter changes should not exceed
the recommended interval.

See Periodic Service Schedule on page 30.

More frequent service may be

required in extremely dirty operating environments. In the event of a loss of power, sluggish acceleration, or
a roughly running engine, service the air filter immediately.

Air Filter Removal

1. Release both canister tab lock

(Figure 33)

2. Pull the canister cap away from the canister.

3. Remove the air filter cartridge.

See following NOTE.

NOTE:

The air filter cartridge is specifically designed for this engine. It only fits into the canister one way.
Use only the Club Car part (CCI P/N 102498601) designed for this engine.

Air Filter Installation

1. Push the new air filter cartridge onto the inside canister nozzle.

2. Place the canister cap, marked TOP, on the top center of the canister.

3. Secure the canister cap with both tab locks.

4. Push the yellow tab lock in to secure canister cap.

Figure 33 Air Filter Cartridge

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Summary of Contents for XRT 1500 2005

Page 1: ...Owner s Manual 2005 XRT 1500 Vehicles Gasoline and Diesel ...

Page 2: ......

Page 3: ...quential damages that result from the use of the material in this manual This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consent of Club Car Inc The information contained in this document is subject to change without notice Club Car Inc rese...

Page 4: ...nd that you ask them to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your Club Car vehicle needs repairs or service we recommend that your local authorized Club Car representative perform them For the name and address of the Club Car representative nearest you logon to our w...

Page 5: ...Pre Operation and Daily Safety Checklist 19 Driving Instructions 20 Bed Latch and Prop Rod 23 Front Shock Absorbers 24 Loading and Unloading 24 Towing with the Vehicle 25 Transporting on a Trailer 26 Storage 26 Maintenance 29 Periodic Service Schedule 30 Periodic Lubrication Schedule 33 Brake Fluid Reservoir 34 Engine Oil 35 Gearcase Lubrication 40 Engine Coolant Diesel Vehicles 41 Air Intake Syst...

Page 6: ... CCI 102621101 WARNING VEHICLE LOADING Read owner s manual and warnings on dash Maximum gross vehicle weight 2750 lb 1247 kg Maximum cargo load 800 lb 363 kg Includes cargo bed load and gross trailer weight Maximum cargo load is reduced by the weight of optional equipment Maximum trailer hitch tongue weight 150 lb force 667 N PREVENT VEHICLE ROLL OVER Place cargo forward in the cargo bed and distr...

Page 7: ...l Reverse Buzzer will sound Release park brake and slowly press accelerator pedal to increase speed All wheel drive will automatically drive appropriate wheel s as required TOSTO PVE HICL E Release accelerator pedal and push brake pedal After stopping firmly set park brake Turn key to OFF position remove key and place shift lever in neutral position when not in use F N N R WARNING CAN CAUSE SEVERE...

Page 8: ...nd load Avoid stopping on or backing down steep hills Avoid top heavy loads See owner s manual CCI 102682301 HIGH CAPACITY VEHICLE LOADING Read owner s manual and warnings on dash CCI 102459601 Maximum gross vehicle weight 3012 lb 1366 kg Maximum cargo load 1050 lb 476 kg Includes cargo bed load and gross trailer weight Maximum cargo load is reduced by the weight of optional equipment Maximum trai...

Page 9: ...ct shift lever position Forward Neutral Reverse Buzzer will sound Release park brake and slowly press accelerator pedal to increase speed All wheel drive will automatically drive appropriate wheel s as required TOSTO PVE HICL E Release accelerator pedal and push brake pedal After stopping firmly set park brake Turn key to OFF position remove key and place shift lever in neutral position when not i...

Page 10: ...ng the vehicle we urge you to review the information in this manual Understand and become familiar with the DANGER WARNING and CAUTION state ments and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life PROPOSITION 65 STATE OF CALIFORNIA ý WARNING This product contains or emits ...

Page 11: ... followed If any of the operation or warning decals on the vehicle become damaged have been removed or cannot be easily read they should be replaced immediately to avoid possible property damage personal injury or death Contact your Club Car dealer ý DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death ý WARNING A WARNING indicates an immediate hazard t...

Page 12: ...ply with state and local laws pertaining to child safety The driver and passenger must be restrained at all times with the safety belts provided to help prevent injury in the event of sudden braking collision or roll over No more than one person per seat at one time Do not allow people to ride in any part of the vehicle that is not equipped with a seat and a safety belt Do not allow a passenger to...

Page 13: ...frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component Wear safety glasses or approved eye protection when servicing the vehicle 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 v...

Page 14: ...be removed to view this decal See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries CONTROLS AND INDICATORS See General Warnings on page 10 ý WARNING Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures Do not tamper with the governor on the gasoline vehicle or the high idle speed ...

Page 15: ...engine starts release the key and it will return to the ON position The engine will idle in neutral The engine will continue to idle until the key is turned to the OFF position See following WARNING CAUTION and NOTE Turn the key to PREHEAT position if the temperature falls below 23 F 5 C Do not hold the key in the PREHEAT position longer than 20 seconds ý WARNING Moving parts Keep clear of the eng...

Page 16: ... Vehicle Owner s Manual Figure 4 Instrument Panel Gasoline Vehicles Figure 5 Instrument Panel Diesel Vehicles WARNING WARNING ON OFF START 0 1 2 1 1 10 P 3 4 5 6 1 8 7 2 A C B F N R 10 WARNING WARNING PREHEAT ON OFF START 0 1 2 1 1 10 P 9 A C B 4 5 6 1 8 7 2 F N R 10 ...

Page 17: ...dal until it latches into place To disen gage pull the park brake release handle Figure 7 See following WARNING ý WARNING The park brake has multiple locking positions and should be firmly locked to prevent the vehicle from rolling LOW OIL WARNING LIGHT The low oil warning light 8 is located on the instrument panel just to the left of the steering column Figure 4 or Figure 5 If the warning light c...

Page 18: ...ired position pull up on the steering adjustment lock lever to firmly lock the steering column in position ý WARNING Ensure that the steering wheel lock is fully engaged prior to operating the vehicle ELECTRIC BED LIFT Vehicles with Electric Bed Lift Option The electric bed lift switch 10 is located on the instrument panel to the right of the key switch Figure 4 or Figure 5 To lift the bed pull up...

Page 19: ...ans forward too quickly A slow easy motion will allow the belt to extend and the person can move around freely If the safety belt can not be pulled out of the retractor firmly pull the belt and release it It should then pull smoothly out of the retractor To release the safety belt press the buckle release button 1 and allow the belt to retract If the belt does not retract smoothly pull it out and ...

Page 20: ...ts should be replaced immediately Do not disassemble or modify the system Keep safety belts clean and dry If cleaning is necessary use a mild soap and lukewarm water solution Do not use bleach dye or abrasive cleaners as they may severely weaken the safety belts Do not insert coins clip etc in the buckle as this may prevent the tab from locking into the buckle properly If the safety belt does not ...

Page 21: ...g condition and in conjunction with the Periodic Service Schedule on page 30 Any problems should be corrected by a Club Car dealer distributor or a trained technician General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight Check hose clamps for tight fit Safety and information decals Check to ensure that all safety and information decals are...

Page 22: ...uld not have any play in the steering wheel Be sure the steering wheel adjustment lever is locked into position Accelerator After starting the engine with the key switch and placing the Forward Reverse handle in the FORWARD position the vehicle should accelerate smoothly to full speed as the accelerator pedal is pressed When the pedal is released it should return to the original position and the e...

Page 23: ...y to inattentive passengers and or damage to the vehicle avoid sudden starts sudden stops and abrupt turns To help avoid the possibility of losing control of or overturning the vehicle reduce speed for adverse driving conditions such as wet grass or rough terrain Do not use the vehicle on public roads It is neither designed nor intended for street use and should not be licensed for use on public r...

Page 24: ... wheel drive will automatically drive appropriate wheel s as required See following WARNING ý WARNING Operator must control vehicle speed when going downhill Never shift the vehicle out of the FORWARD position while going downhill If you do you will not be able to shift into the REVERSE position or back into the FORWARD position until stopped Press the brake pedal as necessary and press the accele...

Page 25: ...k brake Make sure it is fully engaged This will prevent the vehi cle from rolling 2 Turn the key switch to the OFF position remove the key and place the Forward Reverse handle in the NEUTRAL position Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position when the vehicle is not in use Figure 12 Page 27 See also Figure 34 and Figure 35 on page 43 BED LATCH AND PROP ROD See G...

Page 26: ...o not recommend adjusting the shock absorbers unless the vehicle will be equipped with a cab enclosure or snow plow In that event please refer to the cab installation instructions for the shock absorber adjustment procedure LOADING AND UNLOADING ý WARNING Firmly engage park brake before loading vehicle Do not allow riders in the cargo bed Reduce vehicle load and speed when driving up or down slope...

Page 27: ...le See following NOTE NOTE A standard vehicle with a cab accessory weighing 235 lb 107 kg must reduce its maximum pay load capacity by 235 lb 107 kg to 565 lb 256 kg TOWING WITH THE VEHICLE ý WARNING Do not tow a vehicle or trailer on public streets or highways Normal vehicle operating speed should be reduced when towing Extreme caution should be used when towing Do not allow riders in the vehicle...

Page 28: ...er tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer The vehicle to be transported should be tied securely to the trailer with the Forward Reverse handle in the NEUTRAL position the key switch in the OFF position and the park brake firmly engaged Because of the added length of the trailer use caution when making turns Do not transport t...

Page 29: ...27 Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode ý CAUTION Batteries in a low state of charge will freeze at low temperatures Figure 12 Fuel Shut off Valve Closed Position Figure 13 Fuel Shut off Valve Open Position Figure 14 Fuel Valve Partially Closed Position CLOSED OFF POSITION SELECTOR IS ALIGNED WITH OFF MARKINGS ON ...

Page 30: ... vent line from the fuel tank vent nipple Figure 35 Page 43 6 3 Plug the fuel tank vent nipple so that it is air tight Club Car recommends using a slip on vinyl cap 7 Change engine oil See Engine Oil and Filter Change on page 36 All vehicles 8 Disconnect the battery cables negative cable first See WARNING To avoid unintentionally start ing on page 11 9 Batteries should be clean and free of corrosi...

Page 31: ...ealer distributor for repairs and semiannual and annual periodic service ý WARNING Only trained technicians should service or repair the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation If any problems are found during s...

Page 32: ...se approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When servicing the vehicle with part of the vehicle on jack stands do not operate the engine with the Forward Reverse handle in either the FORWARD or REVERSE position The all wheel drive system will engage any wheel s front or rear with traction See Figure 2 on page 11 PERIODIC SE...

Page 33: ...ntials Check lubricant levels Add if necessary See Lubrication Level Check for Front Differential Transmission and Rear Differential on page 40 General vehicle Wash engine compartment and underside of vehicle Do not wash engine when hot FIrst adjustment after 20 hours addi tional every 100 hours of operation Engine Gasoline vehicles Adjust valve clearance See Honda GX620 Service Manual CCI P N 102...

Page 34: ... See authorized Club Car dealer or trained technician for service Diesel vehicles Check the v belt for proper tension or damage Adjust or replace if necessary Diesel vehicles Change engine coolant See Section 15 Radiator and Cooling System in the maintenance and service manual Radiator Diesel vehicles Check clamps for tightness check hoses for cracks Replace if necessary Engine air intake system R...

Page 35: ...emiannually by owner or trained technician or every 50 hours of operation whichever comes first Check add brake fluid Use only DOT 5 silicone brake fluid Rear suspension 2 fittings Chassis Lube EP NLGI Grade 2 First change 50 hours additional change every 100 hours of operation or annually whichever comes first Change front differential lubricant 5 oz 150 mL Mobil 424 Exxon Hydraul 560 or Esso Hyd...

Page 36: ...xterior surface of the master cylinder indicates a leak The brake fluid reservoir diaphragm located in the cap should not have holes or other damage Figure 16 Lubrication Points Diesel Vehicles Figure 17 Brake Fluid and Coolant Access Door Figure 18 Brake Fluid Reservoir 6 7 4 1 3 5 2 2 4 FLOORBOARD 1 2 W A R N I N G U S E O N L Y D O T 3 F L U I D F R O M A S E A L E D C O N T A I N E R MAX MIN U...

Page 37: ...t to the back side of the front panel Inlet and outlet oil carrying hoses enable oil circulation to and from the engine See following NOTE NOTE The normal oil pressure value stated in the Honda engine manual is 28 psi at idle however the remote filter design causes oil pressure to be 18 psi which is normal for this type of oil circulation design ENGINE OIL LEVEL CHECK 1 Remove the oil level dipsti...

Page 38: ...nges under the drain plug Figure 21 or Figure 23 5 From the underside of the vehicle use a socket or box end do not use an open end wrench to remove the drain plug 1 Turn the plug counterclockwise and drain the engine oil into the pan See following WARNING ý WARNING Do not attempt to change engine oil when the engine is hot or even warm Hot engine oil can cause skin burns Wear safety glasses or ap...

Page 39: ...Drain the engine oil See Engine Oil Draining on page 36 2 Place the oil drain pan under the engine oil filter 2 Figure 22 or Figure 23 3 Remove the engine oil filter Turn it counterclockwise and drain the residual oil in the filter port and filter into the oil drain pan See following NOTE Figure 21 Engine Oil Drain Plug and Pan Gasoline Vehicles Figure 22 Replace Engine Oil Filter Gasoline Vehicle...

Page 40: ...an Dispose of used oil according to the environmental laws and regulations for your area 4 Use a clean lint free rag to wipe the oil filter port flange surface clean where the oil filter gasket seats 5 To help seal the new oil filter to the oil port flange 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 out...

Page 41: ...or Spray CCI P N 1014305 3 With the Forward Reverse handle in the NEUTRAL position start and run the engine for a few minutes Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks If a leak is detected check the tightness of the oil filter and drain plug Tighten repair and or replace components as necessary NOTE Wait five minutes after turning off the engine...

Page 42: ...NOTE Front differential Clean and install the drain plug 2 and washer before filling the front differential with new lubricant Figure 30 Tighten the drain plug to 9 ft lb 12 N m Use a funnel when filling the gearcase through the lubri cant level indicator hole 1 See Periodic Lubrication Schedule on page 33 Tighten the level indicator plug to 10 ft lb 14 N m Transmission Clean and install the drain...

Page 43: ...r plug and tighten to 21 ft lb 28 N m ENGINE COOLANT DIESEL VEHICLES ENGINE COOLANT LEVEL CHECK The coolant reserve tank is located under the dashboard next to the brake fluid reservoir Figure 17 Raise the access panel located on top of the dashboard to check the coolant level before every operation 1 Check the coolant level of the reserve tank 2 If the coolant is at or below the LOW mark add wate...

Page 44: ...n the event of a loss of power sluggish acceleration or a roughly running engine service the air filter immediately Air Filter Removal 1 Release both canister tab lock Figure 33 2 Pull the canister cap away from the canister 3 Remove the air filter cartridge See following NOTE NOTE The air filter cartridge is specifically designed for this engine It only fits into the canister one way Use only the...

Page 45: ...an up any spilled fuel before operating the vehicle 1 Remove the fuel cap and fill the tank with fuel Gasoline vehicles have a black fuel cap diesel vehicles have a green fuel cap See preceding DANGER and following NOTE NOTE Gasoline vehicles Use unleaded gasoline only Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Diesel vehicles Use only diesel fuel grade ...

Page 46: ...til water begins to stream from the filter 4 Drain the water until it changes color to fuel See following WARNING ý WARNING Clean up spilled fuel Keep sparks and flames away from the vehicle and service area Failure to heed this warning could result in an explosion or fire resulting in severe personal injury or death 5 Close the valve by rotating it counterclockwise until the valve is firmly seale...

Page 47: ... immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately ý WARNING Do not jump start a dead battery using another battery and jumper cables The battery in a Club Car vehicle is a 12 volt low maintenance battery that requires infrequent checks Figure 37...

Page 48: ...essary do not leave discharged overnight CLEANING THE VEHICLE Each vehicle is equipped with an ABS DR acrylic front body and an all aluminum rear body The vehicle has a powder coated steel cargo bed Use commercial automotive cleaning solutions with a sponge or soft cloth for normal cleaning A garden hose at normal residential water pressure is adequate To remove oxidation or discoloration from alu...

Page 49: ...to enter the air intake system ELECTRIC WINCH ACCESSORY If your vehicle is equipped with an electric winch read and follow all manufacturer safety warnings and instructions in the winch operator manual as well as the following WARNING and CAUTION statements Make sure a winch warning decal is affixed to the vehicle on the seat support panel next to the receptacle for the remote operation switch See...

Page 50: ... 204658 Augusta Georgia 30917 4658 Attention Vehicle Registration VEHICLE SPECIFICATIONS SPECIFICATIONS GASOLINE VEHICLES DIESEL VEHICLES POWER SOURCE Engine 4 cycle OHV 614 cc 20 hp rated twin cylinder air cooled with pressure lubrication system Engine 4 cycle OHV 719 cc 20 hp rated three cylinder liquid cooled with pressure lubri cation system Fuel system Side draft carburetor with float bowl fi...

Page 51: ...cubic feet Maximum payload capacity level surface only 800 lb 363 kg High capacity option 1050 lb 476 kg Vehicle rated capacity payload driver and passenger level surface only 1200 lb 544 kg High capacity option 1450 lb 658 kg Maximum gross vehicle weight fully loaded vehicle including accessories 2750 lb 1247 kg High capacity option 3012 lb 1366 kg Standard seating capacity 2 LIQUID CAPACITIES En...

Page 52: ...iorate or fail due to exposure or ordinary wear and tear Batteries battery charger onboard computer and solid state speed controller are covered under separate CLUB CAR warranties Also excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including unreasonable or unintended strain or use improper installation of accessories installation...

Page 53: ... WAY VARIES THE TERMS OF THIS WARRANTY 7 NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE VEHICLE LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of in...

Page 54: ... low altitudes have your servicing dealer return the carburetor to original factory specifications Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are col lectively referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use an oxygena...

Page 55: ...e to oper ate outside its design parameters Problems That May Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring under load After burning backfiring Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on...

Page 56: ...ny you warranty coverage if vehicle engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting vehicle engine to a CLUB CAR distribution center as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and...

Page 57: ...MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 5 NO CONSEQUENTIAL DAMAGES In no event shall Club Car be liable for any incidental or consequential damages including but not limited to loss related to property other than the vehicle loss of use loss of time inconvenience or any other economic...

Page 58: ...ity of Illustrations 4 Periodic Service and Periodic Lubrication Schedules 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 y our ca tegory Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other ____...

Page 59: ......

Page 60: ...b Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl l 1 706 863 3000 Fax 1 706 863 5808 Publication Part Number 102680211 Edition Code 0704C1004B ...

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