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Club Car CARRYALL 272, Руководство по техническому обслуживанию и ремонту

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BODY AND TRIM

Front Body Repair

Page 4-2

2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual

4

FRONT BODY REPAIR

Read General Warning, Section 1, Page 1-1.

ABRASIONS AND HAZE

The original gloss can be restored by hand buffing with “Novus Plastic Polish”, “Mirror Glaze Professional For-
mula Number 17”, or similar polishing compounds. A buffing wheel with a small amount of automotive type
paste wax applied to the pad may also be used. Use a very light touch, because ABS/DR acrylic polishes eas-
ily. Johnson’s

®

 “J-Wax” or “Kit” may be applied as a final treatment.

LIGHT SCRATCHES

Ajax cleanser applied dry and hand-rubbed will rapidly smooth moderate scratches. Use a soft polishing com-
pound to restore gloss.
Scratches (up to 10 mils; the equivalent thickness of an average business card) can be removed by light
sanding. Start with wet silicone carbide abrasive paper (320 grit or finer). Use progressively finer grits (i.e.
400, 600, 800) to reduce sanding marks. Use Ajax cleanser (or equivalent) for final smoothing. A “Micro
Mesh” acrylic polishing kit with abrasive papers from 1800 to 8000 grit will provide the best final finish. Restore
gloss with soft polishing compound. It is not the intent of any of these processes to fill-in material removed due
to light scratches but rather to blend the finish of the surrounding area and the scratch together.

LARGE SCRATCHES AND ABRASIONS

Touch-up is not recommended. Replace the entire body part or have it repaired by a professional paint and
body repair shop with experience repairing ABS/DR acrylic bodies.

TUBE BUMPER/BRUSH GUARD

Read General Warning, Section 1, Page 1-1.

TUBE BUMPER/BRUSH GUARD REMOVAL

Remove the truss-head screws (14) and nuts (15) that secure the tube bumper or brush guard to the vehicle
frame 

(Figure 4-2, Page 4-6)

.

TUBE BUMPER/BRUSH GUARD INSTALLATION

Installation is the reverse of removal. Tighten the nuts (15) to 15 ft-lb (20.3 N·m) 

(Figure 4-2, Page 4-6)

.

Содержание CARRYALL 272

Страница 1: ...Manual Number 102907711 Edition Code 1007B0810A Turf 272 Carryall 272 Carryall 472 XRT 1200 and XRT1200 SE Gasoline Vehicles 2006 2010 Turf Carryall 272 472 XRT1200 SE Maintenance and Service Manual...

Страница 2: ......

Страница 3: ...lub Car distributor dealer representative or by a Club Car factory trained technician It is the policy of Club Car LLC to assist its distributors and dealers in continually updating their service know...

Страница 4: ...appear in future editions of this manual Damage to a vehicle or component thereof not resulting from a defect or that occurs due to unrea sonable or unintended use overloading abuse or neglect includi...

Страница 5: ...Identification 3 1 Storage 3 2 Preparing The Vehicle For Extended Storage 3 2 To Return Vehicle To Service 3 3 SECTION 4 BODY AND TRIM Cleaning the Vehicle 4 1 Front Body Repair 4 2 Abrasions and Haze...

Страница 6: ...14 Tailskirt 4 14 Tailskirt Removal 4 14 Tailskirt Installation 4 14 Trailer Hitch 4 15 Trailer Hitch Removal 4 15 Trailer Hitch Installation 4 15 Receiver Hitch 4 15 Receiver Hitch Removal 4 15 Recei...

Страница 7: ...ster Assembly Installation 6 17 Rear Brake Cluster Assembly Removal 6 18 Rear Brake Cluster Assembly Installation 6 19 Wheel Cylinder Replacement 6 19 Front Wheel Cylinder Removal 6 19 Front Wheel Cyl...

Страница 8: ...ustment 6 35 SECTION 7 STEERING AND FRONT SUSPENSION Steering Wheel 7 1 Steering Wheel Removal 7 1 Steering Wheel Installation 7 3 Steering Column 7 3 Steering Column Removal 7 3 Steering Column Disas...

Страница 9: ...tallation 9 1 Multi Leaf Springs 9 1 Multi Leaf Spring Removal 9 1 Multi Leaf Spring Installation 9 3 Snubber 9 4 Snubber Removal 9 4 Snubber Installation 9 4 SECTION 10 PERIODIC MAINTENANCE Periodic...

Страница 10: ...out Cam 12 28 Reverse Warning Buzzer 12 29 Reverse Buzzer Limit Switch 12 30 Oil Warning Light 12 30 Fuel Gauge Hour Meter 12 31 Fuel Level Sending Unit 12 32 RPM Limiter 12 33 Ignition Coil 12 34 Oil...

Страница 11: ...6 Governor Cable 14 7 Accelerator Cable 14 8 Closed Throttle or Idle Adjustment 14 9 Engine RPM Adjustment 14 10 Choke and Air Intake System 14 12 Choke Cable Removal 14 12 Choke Cable Installation 14...

Страница 12: ...eral Information 16 1 Lubrication 16 2 Axle Shaft 16 3 Axle Shaft Bearing and Oil Seal Removal 16 3 Axle Shaft Bearing and Oil Seal Installation 16 5 Unitized Transaxle Removal 16 6 Unitized Transaxle...

Страница 13: ...h Cleaning and Inspection 17 5 Drive Clutch Disassembly 17 6 Inspection of Drive Clutch Parts 17 7 Drive Clutch Assembly 17 10 Drive Clutch Installation 17 11 Driven Clutch 17 12 Driven Clutch Removal...

Страница 14: ......

Страница 15: ...mage GENERAL WARNING The following safety procedures must be followed whenever the vehicle is being operated repaired or ser viced Service technicians should become familiar with these general stateme...

Страница 16: ...ult in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Check the vehicle owner s manual for proper...

Страница 17: ...le on page 1 3 2 Disconnect the battery cables negative cable first as shown Figure 1 1 Page 1 3 3 Disconnect the spark plug wire s from the spark plug s CONNECTING THE BATTERY 1 Connect the battery c...

Страница 18: ...1...

Страница 19: ...ferential lock feature 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 Torque converter Automatic vari able speed dry type STEE...

Страница 20: ...t 31 1 in 79 cm Load bed size box bed inside dimensions 48 0 x 49 8 x 9 3 in 121 9 x 126 4 x 24 cm 13 0 cubic feet 48 0 x 49 8 x 10 9 in 121 9 x 126 4 x 27 6 cm 13 0 cubic feet 37 6 x 45 1 x 9 3 in 96...

Страница 21: ...ngine and key start with neutral rev See fol lowing NOTE NOTE 272 vehicles can be found custom ordered equipped with the non standard FE350 engine with pedal start SERIAL NUMBER IDENTIFICATION The ser...

Страница 22: ...he Forward Reverse handle is in the NEUTRAL position Chock the wheels 5 Drain carburetor and seal the fuel tank 6 Turn the fuel shut off valve to the closed OFF position Figure 3 4 Page 3 4 and Figure...

Страница 23: ...ERVICE 1 Make sure the key switch is OFF and the Forward Reverse handle is in the NEUTRAL position Remove the key Chock the wheels 2 Remove plug from vent tube and connect to tank vent Figure 3 2 Page...

Страница 24: ...ff Valve 49 State Fuel Tank Figure 3 5 Fuel Shut off Valve California Fuel Tank 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully opened or fully...

Страница 25: ...e grade No 00 steel wool Club Car does not recommend any type of pressure washing or steam cleaning Such a process will expose electrical components to moisture Moisture entering electrical components...

Страница 26: ...carbide abrasive paper 320 grit or finer Use progressively finer grits i e 400 600 800 to reduce sanding marks Use Ajax cleanser or equivalent for final smoothing A Micro Mesh acrylic polishing kit wi...

Страница 27: ...panel to access back of panel 4 Disconnect the wiring from components mounted in the dash panel 5 Remove five caps 1 from top of dashboard 2 Figure 4 2 Page 4 6 6 Remove screws 3 and special plastic w...

Страница 28: ...BODY AND TRIM Front Body Components Page 4 4 2006 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 4 Figure 4 1 Dash Panel Removal A B...

Страница 29: ...ets securing front fender 9 to frame Drill out two 3 16 x 5 8 pop rivets 10 and remove two washers 11 3 Use a 3 8 hex head socket to remove two screws 12 from fender frame support and remove fender FR...

Страница 30: ...vice Manual 4 Figure 4 2 Front Body Assembly 10 11 TYPICAL 4 PLACES 5 TYPICAL 5 PLACES 7 TYPICAL 2 PLACES 6 2 12 9 9 15 14 FENDER SUPPORT 1 3 4 7 TYPICAL 6 PLACES TYPICAL 5 PLACES 11 TYPICAL 4 PLACES...

Страница 31: ...ge 4 8 3 Adjust seat to preferred position Align holes in seat panel 3 with holes in seat 2 and secure with four bolts 4 and lockwashers 5 Tighten bolts to 96 in lb 10 8 N m See following WARNING WARN...

Страница 32: ...le unless the vehicle is fitted with a structural cab 3 Connect differential lock cable to differential lock handle See step 33 of Unitized Transaxle Installa tion Section 16 Page 16 21 4 Install park...

Страница 33: ...lifting the lower inside flange slightly across the entire seat area Push the trim toward the rear of the vehicle allowing the top flange to slide away from the seat frame toward the rear of the vehic...

Страница 34: ...06 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 4 Figure 4 4 Carryall 472 XRT 1200 SE Rear Seat Support 14 12 13 17 10 16 TYPICAL 4 PLACES 18 19 11 22 TYPICAL 10 PLAC...

Страница 35: ...3 8 inch hinge bolts 9 from the hinge assemblies 1 4 Raise rear edge of bed approximately 6 inches 15 2 cm and pull bed assembly toward rear of vehicle approximately 3 inches 7 6 cm to release bed lat...

Страница 36: ...age 4 12 2006 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 4 Figure 4 5 Turf CA 272 XRT 1200 Cargo Bed 4 3 25 11 2 17 TYPICAL 4 PLACES 16 19 TYPICAL 2 PLACES 18 10 TY...

Страница 37: ...d onto vehicle and align frame hinge brackets 3 with bed hinge brackets 4 2 3 Start the bolts 1 into left and right hinge assemblies Use an alignment tool if necessary 2 4 Use a small hammer to lightl...

Страница 38: ...ender washers 4 and 1 4 20 x 1 inch hex head bolts 3 attaching the fender wall 1 to the vehicle frame 4 Remove fender 1 from the vehicle 5 Repeat steps 1 through 4 for removal of the opposite fender i...

Страница 39: ...all 272 XRT 1200 1 1 Reverse the trailer hitch removal process and tighten bolts to 15 ft lb 20 3 N m Figure 4 7 Page 4 16 1 2 Install the tailskirt See Tailskirt Installation on page 4 14 RECEIVER HI...

Страница 40: ...aintenance and Service Manual 4 Figure 4 7 Turf 272 Carryall 272 XRT 1200 Rear Fender Tailskirt and Trailer Hitch 7 19 TYPICAL 2 PLACES 1 2 5 4 4 3 6 TYPICAL 2 PLACES 10 5 4 3 TYPICAL 4 PLACES 8 9 3 5...

Страница 41: ...1200 SE Maintenance and Service Manual Page 4 17 4 Figure 4 8 Carryall 472 XRT 1200 SE Rear Fender Tailskirt and Receiver Hitch 7 8 TYPICAL 2 PLACES 2 5 4 4 3 6 TYPICAL 2 PLACES 10 9 11 1 5 4 3 TYPICA...

Страница 42: ...he corner where the rear seat frame meets the floorboard and roll the mat corner toward the center of the vehicle from under the side support angle pulling it diagonally from the vehicle FLOOR MAT INS...

Страница 43: ...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 w...

Страница 44: ...arryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 5 Figure 5 1 Brake Pedal Assembly UND ER 16 STOP TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES FLOORBOARD REMOVED FOR CLARITY 1...

Страница 45: ...top jam nut 31 Figure 5 4 Page 5 3 4 Pull the brake pedal toward the rear of the vehicle until the brake stop bumper will not allow the pedal to travel any further Figure 5 5 Page 5 3 5 Holding the br...

Страница 46: ...crank assembly 11 Figure 5 1 Page 5 2 See following NOTE NOTE The spring 17 should not be under tension while the brake pedal is at rest 9 Install the bow tie locking pin 21 10 There should be at lea...

Страница 47: ...11 assem bly 7 Slide the spring retainer 11 off of the accelerator pivot rod 8 Inspect the pivot support bearing 9 inside the spring retainer for wear and replace if necessary 9 Remove locknut 26 from...

Страница 48: ...page 1 3 ACCELERATOR PEDAL ADJUSTMENT See General Warning Section 1 Page 1 1 1 Measure the distance from the top of the accelerator pedal to the floorboard If it is within the range of 5 3 4 inches 1...

Страница 49: ...r than 16 years old Do not leave childern unatten ded on vehicle UND ER 16 WAR NING WAR NING ROLLO VER OR FALLIN G OFF MAY CAUSE DEATH Read operato rs manual and operatin g instruct ions Remain seated...

Страница 50: ...10 Page 5 8 See following NOTE NOTE After the accelerator pedal and rod are adjusted the final governed engine RPM should be set to FE400 Engine 3850 30 RPM See Engine RPM Adjustment Section 14 Page 1...

Страница 51: ...2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual Page 5 9 5 Figure 5 11 Accelerator Pedal Assembly FLOORBOARD REMOVED FOR CLARITY TYPICAL 4 PLACES 26 22 21 24 TYPICAL 4 P...

Страница 52: ...5...

Страница 53: ...heavy pressure to the pedal and check for sponginess and excessive pedal travel The pedal should be firm and the back of the brake pedal should be a minimum of 2 inches from the floor If the brake pe...

Страница 54: ...r backing plate for signs of brake fluid leakage If so deter mine the cause of the leak and replace the brake hose or wheel cylinder See Wheel Cylinder Replacement on page 6 19 Also See Hydraulic Line...

Страница 55: ...prings Replace damaged items If the brake adjusters 3 are frozen requiring more than 65 in lb 7 4 N m to turn freely worn or loose replace the adjuster assemblies in pairs Figure 6 1 Page 6 2 See Brak...

Страница 56: ...b or axle seal and replace the brake shoes See Brake Shoe Removal on page 6 8 Glazed brake shoe linings Replace the brake shoes See Brake Shoe Removal on page 6 8 Damaged or distorted brake shoes Repl...

Страница 57: ...ings Sticking wheel cylinder piston Replace the wheel cylinder See Wheel Cylinder Replacement on page 6 19 Overly adjusted brake adjusters Adjust brake adjusters See Brake Shoe Adjuster Replacement on...

Страница 58: ...ge 6 7 4 2 Remove the castle nut 3 large flat washer 4 wheel bearing 5 and drum 8 If the brake drum was easily removed proceed to step 6 Rear brakes drag Binding park brake cables Adjust or replace ca...

Страница 59: ...adjuster bolts to increase the clearance between the brake shoe lining and the brake drum Figure 6 3 Page 6 7 See following NOTE NOTE If the adjusters require more than 65 in lb 7 3 N m of force to ro...

Страница 60: ...uire more than 65 in lb 7 3 N m of force to rotate they must be replaced See Brake Shoe Adjuster Replacement on page 6 21 5 3 Rotate the brake drum slightly to remove it from the brake shoe cluster as...

Страница 61: ...de the wheel bolt flange 22 off of the splined axle end 5 Use pliers or a brake tool to rotate the cup washer and compression spring assembly 90 and remove the cup and spring from each brake shoe Figu...

Страница 62: ...ake cluster assembly for proper operation 4 1 Locate the bolt heads of the two brake shoe adjusters on the back of each brake cluster assembly 4 2 Use a torque wrench and a Torx T 27 driver or hydraul...

Страница 63: ...equivalent on each of the six raised bosses on the back plate Figure 6 9 Page 6 11 See preceding WARNING 11 Brush a light coat of white lithium NLGI Number 2 grease Dow Corning BR2 Plus or equivalent...

Страница 64: ...to secure the brake shoe Figure 6 4 Page 6 9 6 After the shoes are installed move them together up and down approximately 1 4 to 3 8 inch 6 3 to 9 5 mm to make sure that they will slide easily withou...

Страница 65: ...g BR2 Plus or equivalent to both prior to assembly 8 1 Slide wheel bolt flange 22 onto splined axle Figure 6 5 Page 6 9 8 2 Slide the large flat washer 23 onto the end of the axle and up against the w...

Страница 66: ...NOTE Prior to installing the brake drum inspect the brake lines hoses drums and brake cluster assem blies See Brake System Inspection on page 6 1 Clean any residual grease from the friction area of th...

Страница 67: ...TION and NOTE WARNING Make sure to install and bend the cotter pin Failure to bend the cotter pin could result in the separation of the wheel from the spindle Loss of vehicle control could result caus...

Страница 68: ...and gen tly rotate the adjuster bolts to increase the clearance between the brake shoe lining and the brake drum Figure 6 14 Page 6 16 See following NOTE NOTE If the adjusters require more than 65 in...

Страница 69: ...DOT 5 brake fluid See Bleeding the Hydraulic Brake System on page 6 31 Worn or damaged brake drums must not be machined Replace as necessary Use only approved replacement brake drums designed for you...

Страница 70: ...REMOVAL 1 Remove rear brake drum See Rear Wheel Brake Drum Removal on page 6 8 2 Remove rear brake shoes See Rear Brake Shoe Removal on page 6 8 3 Remove park brake cable clip 1 hair spring cotter pi...

Страница 71: ...pin 3 and hair spring cotter pin 2 5 Install rear brake shoes See Rear Brake Shoe Installation on page 6 12 6 Install rear wheel brake drum See Rear Wheel Brake Drum Installation on page 6 16 7 Repea...

Страница 72: ...Hydraulic Brake System on page 6 31 7 Perform all of the brake system inspections See Brake System Inspection on page 6 1 REAR WHEEL CYLINDER REMOVAL 1 Remove rear wheel brake drum See Rear Wheel Brak...

Страница 73: ...kes must be bled after the correct installation of the brake components Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic system Use o...

Страница 74: ...nting post is to the top of the back plate 4 Grip adjuster arm 3 with a pair of locking pliers and tighten the bolt 4 to 115 in lb 13 N m 5 Repeat steps 1 through 4 for the remaining adjuster 6 Instal...

Страница 75: ...ystem must be opened As a result the brakes must be bled after the correct installation of the brake components Failure to bleed the brakes could result in decreased braking performance due to air bei...

Страница 76: ...t wrench to remove the brake line 4 from the T manifold block 1 Figure 6 20 Page 6 26 7 Remove the bolt 2 washer 13 and locknut 3 that secure the T manifold block 1 to the shock tower FRONT BRAKE HOSE...

Страница 77: ...6 1 2 Install the opposite end of the brake line to the master cylinder and tighten the flare nut fitting to 11 ft lb 14 9 N m Figure 6 20 Page 6 26 1 3 Repeat steps 1 1 through 1 2 for the opposite r...

Страница 78: ...from the rear brake hose at the I beam of the vehicle frame Figure 6 20 Page 6 26 or Figure 6 21 Page 6 27 6 Remove the horseshoe clip 12 that secures the rear brake hose 9 to the I beam frame and re...

Страница 79: ...200 SE Maintenance and Service Manual Page 6 27 6 Figure 6 21 Carryall 472 XRT 1200 SE Four Wheel Hydraulic Brake System TYPICAL 2 PLACES TYPICAL BOTH SIDES TYPICAL BOTH SIDES 5 7 8 14 14 9 2 18 17 10...

Страница 80: ...ll crank 2 Remove brake rod clevis pin 6 bow tie locking pin 8 and clevis 16 from the bell crank 13 Figure 6 22 Page 6 30 3 Remove the spring 18 from the bell crank 13 and master cylinder mounting bra...

Страница 81: ...master cylinder 1 Figure 6 22 Page 6 30 9 Remove master cylinder 1 from mounting bracket 19 push rod 3 and rubber boot 2 MASTER CYLINDER INSTALLATION 1 Install master cylinder 1 into mounting bracket...

Страница 82: ...ement Page 6 30 2006 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 6 Figure 6 22 Master Cylinder 1 5 4 7 TYPICAL 2 PLACES 18 19 20 11 8 TYPICAL 2 PLACES 3 6 13 2 8 12...

Страница 83: ...y of the adjuster bolts Over tightening the adjuster bolts could result in damage to the brake cluster components or the separation of the bolt 4 from the adjuster 3 Figure 6 1 Page 6 2 or Figure 6 19...

Страница 84: ...Brake System on page 6 31 2 Allow 1quart 0 9464 l of the brake fluid to be pulled into the vacuum type brake bleeder tool 3 With the vacuum still running tighten the two brake bleeder valves 4 Allow...

Страница 85: ...able See Park Brake Cable Removal on page 6 33 2 Remove the four 10 24 x 3 4 inch socket head screws 14 locknuts 18 and washers 17 from frame and remove the assembly Figure 6 27 Page 6 37 Wheel Brake...

Страница 86: ...6 27 Page 6 37 2 Assemble the equalizer bracket 10 onto the threaded end of the equalizer cable 9 3 Attach the conical nut 23 and equalizer jam nut 11 to the threaded end of the equalizer cable 4 Att...

Страница 87: ...on page 6 34 3 Adjust the park brake See Park Brake Adjustment on page 6 35 4 Perform all of the brake system inspections See Brake System Inspection on page 6 1 PARK BRAKE ADJUSTMENT CAUTION Perform...

Страница 88: ...d If the wheels move when the vehicle is pushed continue tightening the conical nut until the vehicle can no longer be pushed 7 Loosen the conical nut two full revolutions 8 Tighten the equalizer jam...

Страница 89: ...SE Maintenance and Service Manual Page 6 37 6 Figure 6 27 Park Brake System ClubCar 23 11 4 5 TYPICAL 2 PLACES 1 27 5 6 TYPICAL 2 PLACES TYPICAL EACH SIDE OF VEHICLE 15 20 TYPICAL EACH SIDE OF VEHICL...

Страница 90: ...6...

Страница 91: ...ositioning 5 Loosen the steering wheel nut 18 and back it off approximately 1 4 inch 6 mm Do not remove the nut 6 Use the steering wheel puller CC P N 102061201 to remove steering wheel 6 1 Place the...

Страница 92: ...ge 7 2 2006 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 7 Figure 7 3 Steering Column 17 16 TYPICAL 4 PLACES 15 TYPICAL 4 PLACES 13 14 19 18 24 11 10 10 9 8 7 6 5 1 3...

Страница 93: ...1 4 Remove dashboard See Dashboard Removal Section 4 Page 4 3 5 Remove the front body See Front Body Removal Section 4 Page 4 5 6 Remove the upper bolt 2 and lockwasher 3 from the steering universal j...

Страница 94: ...wedge 8 will ride against the inner race of the bearing 3 Install the wedge 8 spring 7 washer 6 and snap ring 5 onto the bottom end of the steering shaft 11 Figure 7 5 Page 7 5 4 Insert the shaft 11 f...

Страница 95: ...washers 16 and locknuts 17 Figure 7 3 Page 7 2 Tighten the four bolts in a crisscross pattern to 23 ft lb 31 2 N m 6 Tighten the bolt 2 on the upper steering universal joint 1 to 15 ft lb 20 N m 7 Che...

Страница 96: ...Replace the rack and pinion as an assembly if any is found In the event of an known impact and obvious visible damage is not found in the method described above dis connect the tie rods and or drag li...

Страница 97: ...tenance and Service Manual Page 7 7 7 RACK AND PINION DISASSEMBLY 1 Remove the two ball joints and inspect for excessive wear Figure 7 9 Page 7 7 2 Remove both drag links Figure 7 10 Page 7 7 Figure 7...

Страница 98: ...the bolt and then sliding off the uni versal joint Figure 7 12 Page 7 8 7 Remove the dust seal Figure 7 13 Page 7 8 8 Remove the snap ring Figure 7 14 Page 7 9 9 Install the universal joint back onto...

Страница 99: ...3 Remove the ball joint 9 from the rack 2 Figure 7 19 Page 7 10 12 Remove the rack 2 from housing 1 13 Inspect the bushing 17 and needle bearing 14 for excessive wear If wear is excessive replace the...

Страница 100: ...6 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 7 Figure 7 19 Steering Gear 13 4 15 17 22 3 16 2 23 12 19 12 11 10 24 9 18 TYPICAL 4 PLACES TYPICAL 2 PLACES 20 21 5 6...

Страница 101: ...bber mallet See following CAUTION CAUTION Do not force the pinion bearing assembly into the housing The gear teeth or the small bearing could be damaged 4 Install the snap ring 4 5 Use a socket to app...

Страница 102: ...re 7 19 Page 7 10 Nuts will be tightened during toe in adjustment procedure 18 Apply a light coat of anti seize lubricating compound to the drag link threads 19 Loosely install the two nuts 12 and bal...

Страница 103: ...e 1 1 WHEEL ALIGNMENT Wheel alignment is limited to adjusting the toe in of the front wheels See Toe in Adjustment on page 7 13 See following NOTE NOTE Prior to making any front suspension adjustments...

Страница 104: ...ball joint to the end of the threads on each drag link Figure 7 26 Page 7 14 6 4 Tighten the locknuts 24 to 40 ft lb 54 N m Figure 7 19 Page 7 10 7 Check the toe in If toe in is not adjusted properly...

Страница 105: ...0 off of the A arm 13 9 Repeat steps 1 through 8 for the opposite front wheel if necessary KINGPIN AND STEERING SPINDLE INSTALLATION 1 Inspect all parts and replace them as necessary 2 Inspect the kin...

Страница 106: ...e lower shock absorber mounting bolt 2 nut 3 and steering stop bracket 34 8 Remove the two bolts 10 two nuts 11 and the A arm 13 from the suspension mounting plate 9 Repeat steps 1 through 8 for the o...

Страница 107: ...Suspension 15 TYPICAL 2 PLACES 14 TYPICAL 4 PLACES 16 32 33 2 34 22 1 35 2 TYPICAL 2 PLACES 4 TYPICAL 4 PLACES 3 6 TYPICAL 2 PLACES TYPICAL 2 PLACES 13 13 20 7 TYPICAL 2 PLACES TYPICAL 2 PLACES 10 TYP...

Страница 108: ...nd lift the front of the vehicle with a chain hoist or floor jack See WARNING Lift only one end in General Warning Section 1 Page 1 2 2 Place jack stands under the outer front frame I beams and lower...

Страница 109: ...able movement of the wheel and hub on the spindle remove dust cap 1 and cotter pin 2 and then tighten the spindle nut 3 until both bearings 5 fully seat in the bearing cups 7 Figure 7 30 Page 7 19 4 L...

Страница 110: ...7...

Страница 111: ...les should not come in contact with the tires or wheels NOTE An air leak could be due to a punctured tire faulty valve core improperly seated valve stem or improperly seated tire bead Small holes in t...

Страница 112: ...8...

Страница 113: ...E When installing shock absorbers make sure front shocks have identical part numbers and rear shocks have identical part numbers 1 To install reverse the removal procedure 2 Tighten nut 2 until rubber...

Страница 114: ...Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 9 Figure 9 1 Rear Suspension for MC012C BS00 Transaxle 7 8 8 7 6 1 14 12 24 23 18 13 25 19 23 24 23 17 22 REAR BRAKE CABLE 21...

Страница 115: ...U bolts 13 to the shock mount bracket 14 Figure 9 1 Page 9 2 8 Remove bolt 16 and locknut 17 attaching the leaf spring 18 to the rear shackles 19 9 Allow rear of leaf spring 18 to rest on the ground a...

Страница 116: ...o 35 ft lb 47 5 N m 6 Install shock absorber See Shock Absorber Installation on page 9 1 SNUBBER See General Warning Section 1 Page 1 1 SNUBBER REMOVAL 1 Support the powertrain with a floor jack under...

Страница 117: ...lems are found during scheduled inspection or service do not operate vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or dea...

Страница 118: ...ation whichever comes first Battery Clean terminals and wash dirt from casing check electrolyte level Add distilled water if necessary See Battery Section 12 Page 12 39 Front wheel alignment and toe i...

Страница 119: ...Front suspension 2 fittings Chassis Lube EP NLGI Grade 2 Annually by trained technician only every 100 hours of operation whichever comes first Check fill transaxle to plug level MC012C BS00 29 oz 85...

Страница 120: ...BRAKE FLUID Brake fluid level should be within 1 4 inch 6 mm from top of reservoir Figure 10 2 Also brake fluid should be clean with no residue in bottom of reservoir or other evidence of contaminati...

Страница 121: ...e key Place the Forward Reverse handle in the NEUTRAL position Chock the front wheels 2 Access the engine compartment See WARNING For vehicles with cargo beds on page 1 2 Turf 272 Carryall 272 XRT1200...

Страница 122: ...his will allow the oil filter more clearance under the electrical component box Figure 10 6 9 Relocate the oil drain pan to a position under the engine oil filter Figure 10 7 10 Remove the engine oil...

Страница 123: ...all the oil filter onto the engine oil filter port Figure 10 8 See following NOTE NOTE Use only Club Car oil filters CC P N 1016467 designed for this engine 13 Hand tighten 2 3 to 3 4 turn after filte...

Страница 124: ...Reverse handle in the NEUTRAL position run engine for 3 minutes and check for leaks Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks If filter leaks tighte...

Страница 125: ...enger seat 2 Remove fuel cap and fill tank with fresh unleaded gasoline only See preceding DANGER and CAU TION NOTE Whenever possible avoid using oxygenated fuels and fuels that are blended with alcoh...

Страница 126: ...res infrequent checks Figure 10 13 Electrolyte level should be checked semiannually 1 Turn the key switch to the OFF position and remove the key Place the Forward Reverse handle in the NEUTRAL positio...

Страница 127: ...onal injury Be sure battery hold down clamp is properly tightened Tighten to 144 in Ib 16 N m A loose clamp may allow the battery to become damaged from vibration or jarring If battery appears weak ha...

Страница 128: ...10...

Страница 129: ...ting and Electrical System FE400 Key Start Engine Test Procedures 14 15 and 16 Intermittent ignition coil failure Section 11 Troubleshooting and Electrical System FE400 Key Start Engine Test Procedure...

Страница 130: ...too lean check main jet size Section 14 Fuel System Engine pre ignites Excessive carbon deposits on piston head or in combustion chamber See the Engines and Transaxles manual CC P N 102396501 Spark p...

Страница 131: ...ating Section 11 Troubleshooting and Electrical System FE400 Key Start Engine Test Procedure 8 Starter generator failed Section 11 Troubleshooting and Electrical System FE400 Key Start Engine Test Pro...

Страница 132: ...ng nuts or bolts are loose Section 13 FE400 Engine Snubber on frame is worn or damaged Section 13 FE400 Engine Misaligned muffler mounting clamp Section 15 Exhaust System Damaged drive belt or starter...

Страница 133: ...accelerator pedal when the Forward Reverse handle is in the NEUTRAL position See Section 13 FE400 Engine LOCKOUT CAM This key start vehicle is equipped with a lockout cam that allows the engine to be...

Страница 134: ...LK W50 18_BLK W35 18_ORG W23 18_WHT_BLK W18 18_BLK W34 18_YEL W33 10_RED W30 16_BLK W32 18_RED W24 18_YEL W26 18_YEL W26 16_BLK W19 16_BLK W9 18_GRN_WHT W17 18_YEL W54 18_BLK W55 16_BRN W44 6_RED W28...

Страница 135: ...W2 18_BLK W38 18_BRN W45 18_WHT W20 18_YEL W21 18_BRN W22 18_RED W36 18_RED W25 18_RED W37 6_BLK W3 6_GREEN_HIGH_TEMP W31 6_RED W28 6_BLK W29 10_NON_INSUL W27 16_BLK W5 18_BLK W53 18_BRN W52 6_WHT W1...

Страница 136: ...R METER 2006 to mid 2007 DETAIL FUEL GUAGE HOUR METER Mid 2007 and Newer See Detail for Previous Guage 6 7 1 4 2 RED WHT RED WHT BROWN BLUE YELLOW BLK WHT BLACK BLUE BLACK BLUE HEADLIGHT LEFT BLUE BLA...

Страница 137: ...BRAKE LIGHT PRESSURE SWITCH OPTIONAL TAILLIGHT BROWN BLACK OPTIONAL TAILLIGHT WHITE BROWN BLACK BLACK BROWN YELLOW COM N0 YELLOW 2 COM NO NC NO COM 1 FNR LIMIT SWITCHES F1 F2 DF A1 A2 BATTERY YELLOW R...

Страница 138: ...Limit Switch 8 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 R...

Страница 139: ...2 Check for loose or corroded battery terminal connections Clean tighten and replace connections as necessary Hydrometer Test A hydrometer CC P N 1011478 measures the specific gravity The higher the...

Страница 140: ...ch up charge or it may be a weak cell When the variations between cells reach 0 050 or more the battery should be replaced Voltage Test 1 Place the red probe of a multimeter set at Volts DC 20 volt ra...

Страница 141: ...DURE 2 FUSE See General Warning Section 1 Page 1 1 The fuse red 10 amp is located in the electrical component box 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the N...

Страница 142: ...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...

Страница 143: ...16 See Key Switch Removal Section 12 Page 12 24 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...

Страница 144: ...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 11 Page 11 16 The reading should be conti...

Страница 145: ...uity 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 th...

Страница 146: ...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 14 Test Solenoid Continuity Figure 11 15 Test Solenoid Groun...

Страница 147: ...eading is incorrect it indicates a possible grounded 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 D...

Страница 148: ...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 intake hose to the carburetor at the carburetor intake por...

Страница 149: ...lectrical Control Box and Diode Orientation Figure 11 20 Diode Test Figure 11 21 Diode Test Probes Reversed 2 3 1 ANGLED I BEAM OUTER I BEAM 5 7 6 WHITE FROM DIODE RED FROM BATTERY RED FROM DIODE RED...

Страница 150: ...wire to the DF terminal on the starter generator TEST PROCEDURE 12 VOLTAGE REGULATOR See General Warning Section 1 Page 1 1 NOTE Perform Test Procedures 10 and 11 before proceeding with this test pro...

Страница 151: ...gine Kill Wire on page 11 31 See following WARNING WARNING When the white black engine kill wire is disconnected the engine will not stop running after the key switch is turned to the OFF position It...

Страница 152: ...onnecting The Battery on page 1 3 3 Disconnect both of the bullet terminals Figure 11 25 Page 11 25 4 Using a multimeter set to 200 ohms place the red probe on the brown ground wire and place the blac...

Страница 153: ...the RPM limiter Figure 11 25 Page 11 25 Place the red probe of the meter on the male bullet terminal of the wire connecting to the ignition coil under the fan housing and place the black probe on a cl...

Страница 154: ...ry coil must be tested independently from each other 5 Test the spark plug cap separately from the secondary coil 5 1 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the s...

Страница 155: ...11 31 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 bench test the ignition coil 7 If the prec...

Страница 156: ...e ignition coil 3 Using a multimeter set to 20k ohms measure the resistance of the secondary coil and spark plug cap together 3 1 Place the red probe of the meter into the end of the spark plug cap th...

Страница 157: ...istance Bench Test Figure 11 34 Secondary Coil 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 2 1 2m 2...

Страница 158: ...nce is between 6 0k 11 0k ohms the secondary coil is within acceptable limits If the resis tance is not between 6 0k 11 0k ohms the ignition coil has failed and must be replaced 6 If the preceding pro...

Страница 159: ...OFF and remove the key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Move the Forward Reverse handle to REVERSE and listen for an audible click from the limit switch If...

Страница 160: ...he key Place the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting The Battery on page 1 3 3 Remove the center dash assembly...

Страница 161: ...4 If all of the test results are good and the voltage reading is zero there may be a broken or damaged 6 gauge white wire from the solenoid to the starter generator See Test Procedure 8 Starter Gener...

Страница 162: ...Page 12 32 8 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 Procedure 26 Fuel Gau...

Страница 163: ...timeter to 20 volts DC and place the red probe of the multimeter on the 2 terminal of the fuel gauge hour meter with the blue wire Place the black probe on the 3 terminal of the fuel gauge hour meter...

Страница 164: ...f the fuel gauge hour meter where the blue wire w25 is connected Place the black probe on the 1 terminal of the fuel gauge hour meter with the black wire w22 Figure 11 41 Page 11 37 7 Connect battery...

Страница 165: ...eels 2 Turn the key switch ON to verify the display appears 3 Start the engine and let it idle See following DANGER DANGER Do not operate vehicle in an enclosed area without proper ventilation The eng...

Страница 166: ...e the Forward Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting The Battery on page 1 3 3 Remove the center dash assembly See Key Sw...

Страница 167: ...h the front body trim or other parts of the vehicle frame Place a dry towel between the body trim and the center dash to prevent an electrical short circuit 6 Connect battery and spark plug wire s See...

Страница 168: ...y 12 volts replace the head light bulb 6 If there is no voltage reading at the wire harness check continuity of the 16 gauge blue wire from the headlight to the light switch Using a multimeter set to...

Страница 169: ...all 272 472 and XRT 1200 1200 SE Maintenance and Service Manual Page 11 41 11 Figure 11 45 Check Voltage to Headlight Socket BLACK WIRE BLUE WIRE LEFT HEADLIGHT WIRE HARNESS 2m 20 m 200 m 2k 200 200 2...

Страница 170: ...11...

Страница 171: ...ion 1 Page 1 1 Testing the Starter Generator See Test Procedure 8 Section 11 Page 11 19 Also See Test Procedure 11 Section 11 Page 11 22 Starter Generator Removal 1 Disconnect battery and spark plug w...

Страница 172: ...brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will help prevent them from sliding back towards the center Figure 12...

Страница 173: ...commutator Lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover to avoid interference The springs will rest on the sides of th...

Страница 174: ...1 Wipe the carbon dust from the two bearings Inspect bearings by spinning them by hand and checking for both axial A and radial B play Figure 12 8 Page 12 5 2 Replace the bearing if it is noisy does n...

Страница 175: ...off of the output end of the shaft Figure 12 7 Page 12 4 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 th...

Страница 176: ...r Commutator Cleaning and Inspection 1 Clean the carbon dust dirt and oil from the commutator Slight roughness of the commutator can be pol ished away with 400 grit or finer sandpaper See following CA...

Страница 177: ...armature core The reading should be no continuity If the reading is incorrect replace the armature and the two bearings Figure 12 12 Page 12 7 Visual Inspection of Field Coils Burned blackened charred...

Страница 178: ...ces to the inside of the housing to retain the field wires Tighten screws to 9 ft lb 12 2 N m Figure 12 10 Page 12 6 4 Slide the bearing retainer onto the output end of the armature shaft 33 so that i...

Страница 179: ...ounting bracket with the heads of the bolts facing towards the driver side of the vehicle Position the starter generator in the mounting bracket so that the bolts will go through the starter generator...

Страница 180: ...e 12 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 12 13 Page 12 10 See following CAU...

Страница 181: ...gure 12 17 Page 12 12 Pull back each brush spring and pull the 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 sli...

Страница 182: ...ion and Replacement 1 Visually inspect brushes Replace brushes that are cracked or severely chipped 2 Check the length of each brush If the overall length of any brush is less than 0 79 inch 20 mm rep...

Страница 183: ...excessive force or pushing brush springs beyond their normal maximum extension point will damage springs Starter Generator Assembly 1 To prevent contact between the brushes and commutator as the commu...

Страница 184: ...m the field coil housing first remove the two securing bolts 43 Carefully remove armature and output end cover assembly from the field coil housing so components are not damaged 3 To separate armature...

Страница 185: ...faces Do not remove the 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 to...

Страница 186: ...uring the visual inspection can aid in diagnosing the original cause of the failure Items to look for are listed below Burned charred or cracked insulation Improperly cured varnish Thrown solder Flare...

Страница 187: ...side diameter is less than 1 60 inches 40 6 mm replace the armature and bearings Figure 12 25 Page 12 17 Armature Ground Test CAUTION Do not submerge armature in solvent NOTE Before testing wipe the a...

Страница 188: ...are listed in the following table Starter Generator Assembly 1 Slide the bearing retainer 32 onto the output end of the armature shaft 33 Figure 12 21 Page 12 14 Figure 12 26 Armature Ground Test 1 20...

Страница 189: ...tches 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 in the openings in the commutator end cover 23 Figure...

Страница 190: ...n place around the drive clutch pulley install the starter generator belt 3 around the pulley 10 on the end of the starter generator 5 Position a pry bar 13 between the top of the starter generator mo...

Страница 191: ...egulator 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 12 29 Page 12 21 2 Connect the vo...

Страница 192: ...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...

Страница 193: ...to the solenoid posts in the electrical component box See following WARNING WARNING Incorrect wiring could result in severe injury or death Diode and solenoid connections must have correct polarity Ke...

Страница 194: ...Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting The Battery on page 1 3 3 Remove the dash panel 3 1 Loosen seven Tuflok screws but do not remove screws completely as show...

Страница 195: ...e handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting The Battery on page 1 3 3 Remove the air intake hose from the carburetor 4 Remove electr...

Страница 196: ...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 firm...

Страница 197: ...e 12 34 Page 12 28 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 li...

Страница 198: ...ecting The Battery on page 1 3 2 Remove the external snap ring 14 Figure 12 35 Page 12 28 3 Remove the plastic washer 12 and the spring 13 4 Remove the cam 11 Lockout Cam Installation 1 Install the ca...

Страница 199: ...he screw 3 nut 4 lockwasher 5 and flat washer 6 securing the front buzzer to the vertical frame support 7 Remove the screws nuts lockwashers and flat washers securing the rear buzzer to the cross fram...

Страница 200: ...ch Installation 1 Install the reverse buzzer limit switch 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 tight...

Страница 201: ...y and spark plug wire s See Connecting The Battery on page 1 3 FUEL GAUGE HOUR METER See General Warning Section 1 Page 1 1 Testing the Fuel Gauge Hour Meter See Test Procedure 26 Section 11 Page 11 3...

Страница 202: ...lternate pulling the lower and upper tabs away from the gauge housing to remove clip Pull gauge meter from the instrument panel Fuel Gauge Hour Meter Installation 1 Install a new gauge meter into hole...

Страница 203: ...2 38 Page 12 33 RPM Limiter Installation 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...

Страница 204: ...nerator See Starter Generator Removal on page 12 1 See following NOTE NOTE The crankshaft has left hand threads at the clutch mounting hole 2 Remove the muffler See Muffler Removal Section 15 Page 15...

Страница 205: ...4 from 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 12 41 Page 12 36 6 Slide the gasket 1 onto the end o...

Страница 206: ...xle housing Loosely attach the two nuts 6 finger tight See Figure 13 1 Section 13 Page 13 4 17 Attach the engine to the bottom of the engine mounting plate using the bolts 1 washers 2 and nuts 5 Tight...

Страница 207: ...11 Page 11 40 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 battery and spark plug wire s...

Страница 208: ...TRAL posi tion Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting The Battery on page 1 3 3 Remove the center dash panel See Key Switch Removal on page 12 24 4 Disconnect wi...

Страница 209: ...e dash panel with nut 2 on the outside of the dash and tighten the nut to 14 in lb 1 6 N m Figure 12 45 Page 12 38 3 Push the light switch shaft in Screw the knob onto the end of the shaft until the k...

Страница 210: ...prevent future corrosion 2 The battery should be kept clean and dry to prevent self discharge Any dirt grime or acid spillage should be removed Wash the battery with a bristle brush using water and b...

Страница 211: ...ght washers 9 and four locknuts 10 from the armrests See Figure 4 3 Section 4 Page 4 8 3 2 Remove the two armrests 11 and 12 from the vehicle 3 3 Carefully lift and rotate the seat support 90 counterc...

Страница 212: ...in any direction can allow a small amount of electrolyte to leak out of the vent hole Do not exceed this 45 angle when lifting carrying or installing battery The battery acid could cause severe perso...

Страница 213: ...ating it 90 clockwise Install the armrests using four bolts eight washers and four locknuts Tighten bolts 8 to 13 ft lb 17 6 N m See Figure 4 3 Section 4 Page 4 8 4 2 Check the park brake and differen...

Страница 214: ...st 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...

Страница 215: ...uctions 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 hav...

Страница 216: ...gs valve guides cylinder wall etc Also examine the spark plug wire Remove rubber boot and inspect internal spring for damage Inspect spark plug wire for damage and be sure spring coil is securely atta...

Страница 217: ...ow caused by the piston moving up and down Air can flow out of the crankcase but the one way reed valve blocks return flow It thus maintains a vacuum in the crankcase Oil laden air in the crankcase pa...

Страница 218: ...ine oil properly CRANKCASE COVER REMOVAL 1 Remove yellow jumper wire 11 from cord connector 12 Figure 13 2 Page 13 5 2 Remove nuts and clamps at two ended bolts 1 and 2 Figure 13 3 Page 13 5 3 Remove...

Страница 219: ...cover and remove the oil level sensor and bracket 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 an...

Страница 220: ...asher by turning it counterclockwise Figure 13 7 Page 13 7 See following CAUTION CAUTION The flywheel nut has right hand threads Turn it clockwise to tighten or counterclockwise to loosen Do not damag...

Страница 221: ...Page 13 8 4 Tighten the cover mounting bolts 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 2...

Страница 222: ...Belt Installation Section 17 Page 17 3 4 Install muffler See Muffler Installation Section 15 Page 15 1 5 Install starter generator and belt See Starter Generator Model G425419 Section 12 Page 12 1 6 I...

Страница 223: ...2 Add Engine Oil ITEM SIZE FE400 LIMITS Flywheel retaining nut M18 100 ft lb 135 N m Crankcase cover to block bolts M8 22 ft lb 31 N m Starter Generator bracket to block bolts M8 16 5 ft lb 23 N m Oil...

Страница 224: ...13...

Страница 225: ...er operating condition Check the following items Spark plug and gap condition See Spark Plug Section 13 Page 13 2 Air filter element See Air Filter on page 14 18 Fuel filters See Fuel Filters on page...

Страница 226: ...line 26 at the carburetor end only Temporarily plug the end of the fuel line to prevent fuel leakage 1 8 Chock the front wheels and place a floor jack under the engine mounting plate and raise the en...

Страница 227: ...2 in lb 1 4 N m See following CAUTION and NOTE CAUTION Do not remove the valve spring assembly from the float assembly Doing so will damage the spring NOTE Inspect the main jet nozzle 7 and pilot jet...

Страница 228: ...arburetor Page 14 4 2006 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 14 Figure 14 2 Carburetor Installation 1 2 3 4 13 15 12 21 26 10 21 11 19 TYPICAL 2 PLACES 18 22...

Страница 229: ...ry and spark plug wire s See Connecting The Battery on page 1 3 23 Test drive the vehicle Figure 14 3 Changing the Main Jet Drain carburetor over a catch basin by turning bowl drain screw 11 countercl...

Страница 230: ...accelerator push rod do the following Turn key switch OFF place Forward Reverse handle in the NEUTRAL position and remove key before servicing the vehicle Disconnect battery and spark plug wire s See...

Страница 231: ...the limit switch lever is bent replace the switch NOTE Use the inside hole location or hole closest to the bell crank shaft as shown 8 Confirm proper accelerator rod operation before tightening jam n...

Страница 232: ...Accelerator Cable 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 battery and spark plug wire s See Discon...

Страница 233: ...governor arm Figure 14 8 Page 14 11 4 Install cable 7 in accelerator cable bracket 17 and push down to snap into bracket slot to secure 5 Confirm that the engine RPM adjustment is correct See Engine R...

Страница 234: ...dal pressed to the floor the tachometer should read 4 1 After the accelerator pedal and rod are adjusted the final governed engine RPM should be set to 3850 30 RPM 5 To reduce RPM loosen the accelerat...

Страница 235: ...Engine Control Linkage 2006 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual Page 14 11 14 Figure 14 8 Governor and Accelerator Cables 3 18 6 4 5 19 7 8 3 17 1 2 TYPICAL...

Страница 236: ...crew 17 to secure cable to air box Tighten screw to 18 in lb 2 0 N m 5 Carryall 472 XRT 1200 SE 5 1 Attach a new wire tie 23 around the cable and air duct Figure 14 11 Page 14 16 AIR BOX REMOVAL 1 Tur...

Страница 237: ...ration INTAKE DUCT REPAIR If the intake duct is badly torn or has large holes it will need to be replaced INTAKE DUCT REMOVAL NOTE This procedure is best accomplished using two people 1 Turn the key s...

Страница 238: ...second person removes each bolt from their respective shock and shock tower and gently allow the A arm assembly to rest in a suspended condition 2 10 Roll the floormat from underneath the dashboard a...

Страница 239: ...Maintenance and Service Manual Page 14 15 14 Figure 14 10 Turf 272 Carryall 272 XRT 1200 Air Intake and Choke Assemblies 30 29 TYPICAL 3 PLACES 22 23 13 TYPICAL 2 PLACES 24 14 25 TYPICAL 2 PLACES 25 2...

Страница 240: ...472 and XRT 1200 1200 SE Maintenance and Service Manual 14 Figure 14 11 Carryall 472 XRT 1200 SE Air Intake and Choke Assemblies 14 28 27 26 21 20 19 TYPICAL 3 PLACES 23 TYPICAL 3 PLACES 24 25 13 16...

Страница 241: ...ocations of the strip plate 27 using bolts 28 and locknuts Do not tighten Figure 14 10 Page 14 15 6 2 Position the top edge of the strap plate 27 onto the frame and install the two bolts 26 flat wash...

Страница 242: ...ilter fits correctly and that the wire latches are not caught between lid and air box 7 Fasten wire latches 3 and make sure latches securely engage the bottom half of the box See follow ing CAUTION CA...

Страница 243: ...ped install the secondary fuel filter 22 in reverse of removal Use new clamps 16 3 Turn the fuel shut off valve to the ON position Figure 14 20 Page 14 28 4 Connect battery and spark plug wire s See C...

Страница 244: ...build kit is available from Club Car CC P N 1014524 1 Remove four screws 24 and lockwashers 25 from front of the fuel pump Figure 14 12 Page 14 20 2 Remove the front cover of the fuel pump while holdi...

Страница 245: ...screws 24 on the assembly Be sure the arrows on the front cover point from the fuel inlet to the fuel outlet Figure 14 13 Page 14 20 Tighten the screws to 26 in lb 3 0 N m FUEL PUMP INSTALLATION 1 Con...

Страница 246: ...fuel lines is used up and the engine stalls 4 Disconnect battery and spark plug wire s See Disconnecting The Battery on page 1 3 5 Remove the four bolts 8 eight washers 9 and four locknuts 10 from the...

Страница 247: ...e center stud of the sending unit See following WARN ING WARNING Make sure the key switch is OFF and key removed before disconnecting wiring 10 Loosen clamp 16 and remove the fuel line 1 from fuel tan...

Страница 248: ...e Manual 14 Figure 14 16 Turf 272 Carryall 272 XRT 1200 Fuel and Vent Lines 13 12 11 16 See Above Gas Tank Fuel Pickup Tube No Longer Used For 2009 and 2010 Model Year For Vehicles Without Carbon Cani...

Страница 249: ...e Manual Page 14 25 14 Figure 14 17 Carryall 472 XRT 1200 SE Fuel and Vent Lines 12 16 See Above Gas Tank Fuel Pickup Tube 1 16 6 13 8 15 7 16 5 3 7 16 20 14 16 16 17 22 21 25 2 16 18 10 14 20 4 No Lo...

Страница 250: ...N m 2 3 Return the seat support 1 to its original position by rotating it 90 counterclockwise Figure 14 14 Page 14 22 2 4 Install the seat support and seat handles and tighten bolts 8 to 13 ft lb 17...

Страница 251: ...rom the fuel tank to the primary fuel filter 17 Arrow indicates flow Figure 14 16 Page 14 24 or Figure 14 17 Page 14 25 Fuel line no 2 runs directly from the primary fuel filter 17 to the fuel inlet o...

Страница 252: ...Page 1 1 WARNING If the carbon canister is damaged replace it Do not attempt to repair it See the following canister removal procedure CARBON CANISTER REMOVAL 1 Disable the vehicle See Disabling The V...

Страница 253: ...push pull the canister 1 into bracket Figure 14 22 Page 14 29 Force it in until fully seated 2 Attach hoses 5 7 and 8 to appropriate locations on carbon canister and secure with hose clamps 6 3 Instal...

Страница 254: ...FUEL SYSTEM Carbon Canister If Equipped Page 14 30 2006 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 14...

Страница 255: ...the governor cable bracket 13 6 Remove the hex nuts 10 and lockwashers 11 from the manifold 7 Remove the muffler 1 from the vehicle MUFFLER INSTALLATION NOTE Any time the muffler is removed from the...

Страница 256: ...the NEUTRAL position start the engine and check for exhaust leaks and proper engine operation See following DANGER 10 Start the engine and check for exhaust leaks and proper engine operation See follo...

Страница 257: ...n therefore the engine and clutches are not subjected to reversing loads This reduces maintenance requirements on the engine and clutches With the unitized transaxle power is transferred from the engi...

Страница 258: ...plug is used for draining When draining lubricant both plugs should be removed to allow the lubricant to drain faster Be sure the drain plug and gasket are cleaned and installed before filling the tra...

Страница 259: ...al Warning Section 1 Page 1 1 Removal of the unitized transaxle is not required for servicing or replacing axle shafts axle bearings or axle shaft oil seals If the unitized transaxle is to be removed...

Страница 260: ...end 6 Use a 90 internal snap ring pliers 0 090 inch tip to remove internal retaining ring from axle tube Figure 16 5 Page 16 4 7 Carefully pull the axle shaft and bearing straight out of the axle tube...

Страница 261: ...omponents before axle installation Use a small brush and carefully apply a light coat of white lithium NLGI Number 2 grease Dow Corning BR2 Plus or equivalent to splined components before assembly 5 1...

Страница 262: ...being trapped in the hydraulic system Use only DOT 5 brake fluid See Bleeding the Hydraulic Brake System Section 6 Page 6 31 1 Turn the key switch OFF and remove the key Place the Forward Reverse hand...

Страница 263: ...the fuel pump 5 Remove the differential lock cable 5 1 Place differential lock handle in the disengaged direction 5 2 Use a pair of pliers and apply pressure to the locking tabs of the cable end 1 whe...

Страница 264: ...it from the box Figure 16 15 Page 16 9 5 8 Disconnect the engine ground wire from the oil filler tube mounting bracket Figure 16 16 Page 16 9 Figure 16 12 Differential Lock Cable Bracket Figure 16 13...

Страница 265: ...5 11 Loosen nut 3 and bolt 7 on transaxle shifter lever 6 and remove lever from shaft 5 12 Remove woodruff key 9 from shifter shaft 5 13 Mark for reference then disconnect the 6 gauge white wire F2 po...

Страница 266: ...s 7 1 Remove the park brake cable clip 1 hair spring cotter pin 2 and clevis pin 3 Figure 16 22 Page 16 11 7 2 Remove the cable from the cable support bracket Figure 16 22 Page 16 11 7 3 Remove the up...

Страница 267: ...he vehicle I beam frame to rest on the jack stands but allow the jack to remain under and in contact with the transaxle case guard Figure 16 26 Page 16 12 10 Remove the bolts securing the leaf springs...

Страница 268: ...2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 16 Unitized Transaxle Removal Continued Figure 16 24 Shock Absorbers Figure 16 25 Raise Vehicle Figure 16 26 Position Jac...

Страница 269: ...gure 16 30 Page 16 13 15 Place blocks under the engine pan so they will completely support the engine and keep it level to the floor Figure 16 31 Page 16 14 See following NOTE NOTE Place the blocks so...

Страница 270: ...The governor cable and the accelerator cable should remain attached to the governor arm 21 Remove the two bolts that secure the differential lock cable bracket to the transaxle housing and unhook the...

Страница 271: ...ngs See Multi Leaf Spring Installation Section 9 Page 9 3 3 Position the transaxle mounting plate on the two mounting studs at the rear of the engine and install the two mounting nuts Figure 16 37 Pag...

Страница 272: ...6 38 Page 16 16 8 Install the governor cable bracket on transaxle case and tighten the mounting screws to 134 in lb 15 1 N m Figure 16 39 Page 16 17 9 Loosely install governor lever arm on governor sh...

Страница 273: ...nd install the grade eight bolts and locknuts and tighten to 15 ft lb 20 3 N m Figure 16 42 Page 16 18 See fol lowing CAUTION CAUTION Use only grade eight bolts for the front leaf spring supports 16 A...

Страница 274: ...zed Transaxle Installation Page 16 18 2006 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 16 Unitized Transaxle Installation Continued Figure 16 41 Shock Absorber Figur...

Страница 275: ...een restored See following WARNING WARNING The brakes must be bled after the correct installation of the brake components Failure to bleed the brakes could result in decreased braking performance due...

Страница 276: ...N m Figure 16 35 Page 16 15 26 2 Place the woodruff key 9 on the shifter shaft 26 3 Place the shifter lever 6 aligned with the woodruff key onto the Forward Reverse shaft 15 26 4 Install the nut 3 wa...

Страница 277: ...age 16 21 31 Connect air intake hose to carburetor and secure hose clamp Figure 16 54 Page 16 21 32 Connect carburetor vent tube to carburetor and secure with hose clamp Figure 16 55 Page 16 22 33 Con...

Страница 278: ...wiring is secured properly See following WARNING 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...

Страница 279: ...g the cable to the vehicle When installed cable must be routed and secured as it was originally 1 Remove the ball joint socket 2 from the Forward Reverse shifter assembly ball stud 3 Figure 16 59 Page...

Страница 280: ...shifter cable support bracket at the Forward Reverse assembly and tighten nuts to 22 ft lb 29 8 N m 4 Install the ball joint socket 10 on the shifter lever ball stud 11 on the transaxle 5 Install the...

Страница 281: ...uld result in loss of vehicle control and severe personal injury DIFFERENTIAL LOCK SYSTEM INSPECTION The differential lock system should periodically be inspected for proper operation 1 Place chocks a...

Страница 282: ...es to the cable mounting bracket 2 at the transaxle 8 Pull cable 5 toward the front of the vehicle to remove the cable from the bracket 2 and vehicle DIFFERENTIAL LOCK CABLE INSTALLATION 1 Route the c...

Страница 283: ...intenance and Service Manual Page 16 27 16 Figure 16 60 Differential Lock Cable Routing ClubCar WARNING 1 Rotate the cable connector toward the passenger side of the vehicle to connect the cable to th...

Страница 284: ...16...

Страница 285: ...s at the drive clutch the driven clutch is forced open as the diameter of its belt loop decreases At governed top speed the ratio of drive clutch to driven clutch is 0 92 to 1 On steep grades or when...

Страница 286: ...th clutches does not solve the problem disassemble and thoroughly clean all parts in the drive clutch Be sure to clean the plastic drive buttons 10 Figure 17 7 Page 17 8 Figure 17 1 Torque Converter T...

Страница 287: ...battery and spark plug wire s See Disconnecting The Battery on page 1 3 3 Grasp the belt midway between the drive and driven clutches Lift upward on the belt to force the sheaves of the driven clutch...

Страница 288: ...d adjusting hardware and then remove the starter belt See WARNING Moving parts Do not in General Warning on page 1 2 5 Remove the drive clutch retaining bolt 18 and flat washer 19 Figure 17 7 Page 17...

Страница 289: ...s Solvents will damage the lubricating characteristics of the bushings 2 Inspect the belt contact surfaces of the clutch sheaves for wear If any area of a sheave contact surface has wear of 0 060 inch...

Страница 290: ...touches the clutch hub or the bolt bottoms out then back the bolt out one half turn Figure 17 6 Page 17 6 NOTE The stop nut has been mechanically crimped and locked into position acting as an integra...

Страница 291: ...e it with a new bearing 9 Use a scribe or small pick to remove the spiral backup rings 12 from each end of the bore in the fixed face assembly Figure 17 7 Page 17 8 See also Figure 17 11 Page 17 9 Dis...

Страница 292: ...ER Drive Clutch Page 17 8 2006 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 17 Figure 17 7 Drive Clutch Assembly 1 8 7 6 5 4 3 2 11 12 12 15 14 13 9 16 17 18 19 TYPIC...

Страница 293: ...Position Figure 17 10 Remove Idler Bearing Figure 17 11 Spiral Back up Rings Remove these items from ribs 10 24 SCREW FLAT WASHER DRIVE BUTTON DRIVE BUTTON TAKE UP SPRING RIBS WEIGHT SLOTS IN HUB CAS...

Страница 294: ...all the primary weights on the mounting pins Figure 17 12 Page 17 10 8 Install a wave washer on each mounting pin Make sure that the concave side of the washer faces the side of the primary weight wit...

Страница 295: ...nstall the hub assembly 8 on the moveable face assembly and align the match marks made before dis assembling the clutch Press the hub assembly on by hand 18 Replace the three plastic plugs 9 into the...

Страница 296: ...ard Reverse handle in the NEUTRAL posi tion Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting The Battery on page 1 3 3 Remove the drive belt as instructed See Drive Belt R...

Страница 297: ...e on the fixed and moveable face assemblies Assemblies must be replaced if surfaces are worn more than 0 060 inch 1 5 mm 4 Inspect the bronze bearing in the moveable face If the bearing bore diameter...

Страница 298: ...UE CONVERTER Driven Clutch Page 17 14 2006 2010 Turf Carryall 272 472 and XRT 1200 1200 SE Maintenance and Service Manual 17 Figure 17 16 Driven Clutch Assembly 2 3 4 5 6 7 8 11 12 1 10 9 TYPICAL 3 PL...

Страница 299: ...in position when the cam installation tool is removed providing for the assembly of the retaining ring The retaining ring can be reused provided the O D does not exceed 1 607 inches 40 82 mm Otherwis...

Страница 300: ...16 5 2 5 Place the cam press hub 6 onto the cam installation bolt and thread it down onto the cam hub centering the press hub onto the cam hub 5 2 6 Hold the fixed face assembly of the clutch 5 and r...

Страница 301: ...that the washer 12 is mounted with the flat portion of the washer against the driven clutch as shown Figure 17 16 Page 17 14 Secure with a new bolt 11 See following NOTE NOTE The bolt 11 must be repl...

Страница 302: ...17...

Страница 303: ...stallation 6 25 master cylinder see master cylinder pedal inspection 6 1 troubleshooting 6 3 wheel cylinder front removal 6 19 brush guard removal 4 2 bumper tube installation 4 2 removal 4 2 C cargo...

Страница 304: ...brake cluster 6 3 brake pedal 6 1 differential lock 16 25 starter generator armature 12 16 bearing 12 15 brush spring 12 12 brushes 12 12 commutator 12 16 field coils 12 8 12 18 K key switch engine ki...

Страница 305: ...g column assembly 7 4 steering wheel installation 7 3 removal 7 1 storage vehicle storage 3 2 suspension front a arm installation 7 16 kingpin and steering spindle installation 7 15 toe in adjustment...

Страница 306: ...tube bumper see bumper tube V voltage regulator testing 11 22 W WARNING definition of 1 1 wheel cylinder see brakes wheel cylinder wire continuity testing 11 20 wiring diagram 11 6...

Страница 307: ...Finding Information 3 Clarity of Illustrations Photos 4 Index Usability In order to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent...

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Страница 309: ...Club Car R NOTES...

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Страница 312: ...Club Car LLC 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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