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Club Car TURF 272 2005 Maintenance Service Manual

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2005
MAINTENANCE
SERVICE
MANUAL
TURF 272, CARRYALL 272, CARRYALL 472,
XRT 1200, and XRT 1200SE
GASOLINE VEHICLES
MANUAL NUMBER 102680406
EDITION CODE 0305A00000

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Summary of Contents for Club Car TURF 272 2005

  • Page 1 2005 MAINTENANCE SERVICE MANUAL TURF 272, CARRYALL 272, CARRYALL 472, XRT 1200, and XRT 1200SE GASOLINE VEHICLES MANUAL NUMBER 102680406 EDITION CODE 0305A00000...
  • Page 3 Club Car distributor/dealer representative or by a Club Car factory- trained technician. It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl- edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep- resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support.
  • Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc., is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    CONTENTS SECTION 1 – SAFETY General Warning ..........................SECTION 2 – VEHICLE SPECIFICATIONS General Information .......................... SECTION 3 – GENERAL INFORMATION General Information .......................... Engine Identification ......................... Serial Number Identification ......................Storage ............................. Preparing The Vehicle For Extended Storage ................To Return Vehicle To Service .......................
  • Page 6 Rear Seat Support ........................... Rear Seat Support Removal (Carryall 472/XRT 1200SE) ............Rear Seat Support Installation (Carryall 472/XRT 1200SE) ............Cargo Bed ............................Cargo Bed Removal ........................Cargo Bed Installation ........................4-11 Bed Stop Bumper Adjustment ...................... 4-12 Rear Fender ............................. 4-12 Rear Fender Removal ........................
  • Page 7 Brake Shoe Removal ........................Front Brake Shoe Removal ......................Rear Brake Shoe Removal ......................Brake Cluster Inspection and Cleaning .................... 6-10 Brake Shoe Installation ........................6-11 Front Brake Shoe Installation ....................... 6-12 Rear Brake Shoe Installation ......................6-12 Brake Drum Installation ........................6-14 Front Wheel Brake Drum Installation ....................
  • Page 8 Bleeding the Hydraulic Brake System ....................6-31 Purging the Hydraulic System ...................... 6-32 Filling the Hydraulic System ......................6-32 Park Brake System .......................... 6-33 Park Brake Cable Removal ......................6-33 Park Brake Cable Installation ....................... 6-34 Park Brake Handle Removal ......................6-35 Park Brake Handle Installation .....................
  • Page 9 SECTION 8 – WHEELS AND TIRES General Information .......................... SECTION 9 – REAR SUSPENSION Shock Absorbers ..........................Shock Absorber Removal and Inspection ..................Shock Absorber Installation ......................Multi-Leaf Springs ..........................Multi-Leaf Spring Removal ......................Multi-Leaf Spring Installation ......................Snubber ............................Snubber Removal .........................
  • Page 10 Diode ..............................12-12 Key Switch ............................12-14 Solenoid ............................12-15 Fuse ..............................12-16 Lockout Cam Limit Switch ........................ 12-17 Lockout Cam ............................ 12-17 Reverse Warning Buzzer ......................... 12-18 Reverse Buzzer Limit Switch ......................12-19 Oil Warning Light ..........................12-20 Fuel Gauge/Hour Meter ........................12-21 Fuel Level Sending Unit ........................
  • Page 11 SECTION 14 – FUEL SYSTEM General Information .......................... 14-1 Carburetor ............................14-1 Main Jet Elevation/Size Chart ...................... 14-2 Changing the Main Jet ........................14-2 Engine Control Linkage ........................14-6 General Information ........................14-6 Accelerator Rod ..........................14-6 Governor Cable ..........................14-8 Accelerator Cable .........................
  • Page 12 SECTION 15 – EXHAUST SYSTEM Muffler .............................. 15-1 Muffler Removal ........................... 15-1 Muffler Installation ........................15-1 SECTION 16 – MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK General 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 ................
  • Page 13 Driven Clutch ............................ 17-12 Driven Clutch Removal ......................... 17-12 Driven Clutch Disassembly ......................17-13 Driven Clutch Inspection ....................... 17-13 Driven Clutch Assembly ........................ 17-13 Driven Clutch Installation ......................17-17 SECTION i – INDEX 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page xi...

  • Page 15: Section 1 - Safety

    SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements contained within headings labeled DANGER, WARNING, CAUTION, or NOTE.
  • Page 16 SAFETY General Warning ý WARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and CAUTION statements in this manual as well as those on the vehicle. • 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.
  • Page 17 SAFETY General Warning AS SEEN FROM PASSENGER'S SIDE OF VEHICLE REMOVE NEGATIVE DISCONNECT BATTERY CABLES CABLE FIRST BEFORE WORKING ON VEHICLE GASOLINE VEHICLE BATTERY DISCONNECT Figure 1-1 Battery 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 1-3...

  • Page 19: Section 2 - Vehicle Specifications

    SECTION 2 – VEHICLE SPECIFICATIONS GENERAL INFORMATION SPECIFICATIONS TURF/CA 272 XRT 1200 CARRYALL 472 XRT 1200SE POWER SOURCE Engine: 4-cycle OHV, 400 cc, 13 hp rated, single-cylinder, air-cooled • • • • with pressure lubrication system Fuel system: Side-draft carburetor with float bowl, fixed jets, fuel filters •...
  • Page 20 VEHICLE SPECIFICATIONS General Information SPECIFICATIONS TURF/CA 272 XRT 1200 CARRYALL 472 XRT 1200SE Overall height (at steering wheel) 51 in. (130 cm) Wheelbase 80 in. (203 cm) 101 in. (256 cm) Ground clearance: (under differential) 6.6 in (17 cm) (under foot platform) 11.4 in (29 cm) Front wheel tread 43 in.

  • Page 21: Section 3 - General Information

    The dashboard must be removed to view this number. See following NOTE. NOTE: Always have the vehicle serial number at hand when ordering parts or making inquiries (Figure 3-1, Page 3-1). Club Car SERIAL NUMBER AD0501-583947 P O BOX 204658...

  • Page 22: Storage

    GENERAL INFORMATION Storage STORAGE ý DANGER • Read General Warning, Section 1, Page 1-1. ý WARNING • Read General Warning, Section 1, Page 1-1. ý CAUTION • Read General Warning, Section 1, Page 1-1. PREPARING THE VEHICLE FOR EXTENDED STORAGE 1.

  • Page 23: To Return Vehicle To Service

    GENERAL INFORMATION Storage TO RETURN VEHICLE TO SERVICE 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 3-3 or Figure 3-3, Page 3-3). 3.
  • Page 24 GENERAL INFORMATION Storage PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 3-6 Fuel Valve – Partially Closed Page 3-4 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 25: Section 4 - Body And Trim

    Club Car does not recommend any type of pressure washing or steam cleaning. Both can create water dam- age to electrical components and subsequent component failure. Normal residential water pressure is ade- quate for exterior cleaning.

  • Page 26: Light Scratches

    BODY AND TRIM Tube Bumper/Brush Guard LIGHT SCRATCHES Ajax cleanser applied dry and hand-rubbed will rapidly smooth moderate scratches. Use a soft polishing compound to restore gloss. Scratches (up to 10 mils; the equivalent thickness of an average business card) can be removed by light sanding.

  • Page 27: Dashboard Installation

    BODY AND TRIM Front Body Components DASHBOARD INSTALLATION 1. Reverse the dashboard removal process. 2. Tighten screws (5) to 11 in-lb (1.2 N·m) (Figure 4-2, Page 4-5). 3. Tighten Torx-head screws (3) with plastic washers (4) to 45 in-lb (5.1 N·m). 4.

  • Page 28: Front Body Removal

    BODY AND TRIM Seat FRONT BODY REMOVAL 1. Remove five caps (1) from top of dashboard (2) (Figure 4-2, Page 4-5). 2. Use a Torx #T-30 driver to remove the Torx-head screws (3) and washers (4) from top of front body (6). 3.
  • Page 29 BODY AND TRIM Seat TYPICAL 5 PLACES TYPICAL 6 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES FENDER SUPPORT TYPICAL 5 PLACES TYPICAL 4 PLACES TUBE BUMPER SHOWN. (SOME VEHICLES ARE EQUIPPED WITH A BRUSH GUARD) Figure 4-2 Front Body Assembly 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 4-5...

  • Page 30: Seat Adjustment

    BODY AND TRIM Front Seat Support Seat, Continued: Light Soiling – A solution of 10% liquid dish soap and warm water applied with a soft, damp cloth is recommended. A soft bristle brush may be used if necessary. Wipe off any residue with a water damp- ened cloth.
  • Page 31 BODY AND TRIM Front Seat Support 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 brake equalizer cable. See Equalizer Cable Installation, Section 6, Page 6-34. 5.

  • Page 32: Rear Seat Support

    BODY AND TRIM Rear Seat Support TYPICAL 4 PLACES TYPICAL 10 PLACES TYPICAL 4 PLACES Figure 4-4 Carryall 472/XRT 1200SE Rear Seat Support REAR SEAT SUPPORT Read General Warning, Section 1, Page 1-1. REAR SEAT SUPPORT REMOVAL (CARRYALL 472/XRT 1200SE) 1.

  • Page 33: Rear Seat Support Installation (Carryall 472/Xrt 1200Se)

    BODY AND TRIM Cargo Bed 3. Remove four 1/4-20 x 1 inch, phillips drive, truss-head machine screws (19) and lockwashers (18) from seat back support (22) and remove seat back (16) and seat back cap (17). 4. Remove four 5/16-18 flange locknuts (24) and four 5/16-18 x 3/4-inch carriage bolts (23) and remove seat back support (22).
  • Page 34 BODY AND TRIM Cargo Bed TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 4-5 Turf/CA 272/XRT 1200 Cargo Bed Page 4-10 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 35: Cargo Bed Installation

    BODY AND TRIM Cargo Bed Cargo Bed Removal, Continued: 2. Carryall 472/XRT 1200SE: 2.1. Remove two 3/8-16 nylon locknuts (2) from left and right cargo bed hinge/bolt assemblies (Figure 4-6, Page 4-11). 2.2. Apply slight upward pressure (by hand) on the rear of the bed to relieve pressure on the hinges, and remove the 3/8 x 3-3/8-inch hinge bolts (1) from the hinge assemblies.

  • Page 36: Bed Stop Bumper Adjustment

    BODY AND TRIM Rear Fender BED STOP BUMPER ADJUSTMENT 1. Turf 272/Carryall 272/XRT 1200: 1.1. Adjust the two front bumpers (16) by loosening the 1/4-20 nylon locknuts (17) and position so that when the cargo bed is lowered, both bumpers are centered on the bed frame weldments (Figure 4-5, Page 4-10).

  • Page 37: Tailskirt Installation

    BODY AND TRIM Trailer Hitch TAILSKIRT INSTALLATION 1. Installation is the reverse of removal. Tighten screws (7) to 55 in-lb (6.2 N·m) (Figure 4-7, Page 4-14 or Figure 4-8, Page 4-15). TRAILER HITCH Read General Warning, Section 1, Page 1-1. TRAILER HITCH REMOVAL 1.
  • Page 38 BODY AND TRIM Receiver Hitch TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 4-7 Turf 272/Carryall 272/XRT 1200 Rear Fender, Tailskirt, and Trailer Hitch Page 4-14 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 39 BODY AND TRIM Receiver Hitch TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 4-8 Carryall 472/XRT 1200SE Rear Fender, Tailskirt, and Receiver Hitch 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 4-15...

  • Page 40: Floor Mat

    BODY AND TRIM Floor Mat FLOOR MAT Read General Warning, Section 1, Page 1-1. FLOOR MAT REMOVAL 1. Turf 272/Carryall 272/XRT 1200: 1.1. Remove the brake and accelerator pedals. See Accelerator Pedal Removal, Section 5, Page 5-5. Also see Brake Pedal Removal, Section 5, Page 5-1. 1.2.

  • Page 41: Section 5 - Accelerator And Brake Pedal Assemblies

    SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. BRAKE PEDAL See General Warning, Section 1, Page 1-1. BRAKE PEDAL REMOVAL 1.
  • Page 42 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES CA 294/XRT 1200SE PLUG Figure 5-1 Brake Pedal Assembly Page 5-2 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 43: Brake Pedal Adjustment

    ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal Adjustment BRAKE PEDAL ADJUSTMENT See General Warning, Section 1, Page 1-1. 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.
  • Page 44 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal Adjustment Brake Pedal Adjustment, Continued: 6. Adjust the brake stop bumper (22) up to increase the distance between the pedal and the floorboard. or down to increase (Figure 5-4, Page 5-3). Proper brake pedal height is 6-5/8 inches ± 1/4 inch (16.8 cm ±...

  • Page 45: Accelerator Pedal

    ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal ACCELERATOR PEDAL See General Warning, Section 1, Page 1-1. ACCELERATOR PEDAL REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Remove the key. Chock the wheels. See following WARNING. ý...

  • Page 46: Accelerator Pedal Adjustment

    ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment Accelerator Pedal Installation, Continued: 3. Tighten bolts (22) to 75 in-lb (8.5 N·m). 4. Install spacer (24), aligning the splined parts, and tighten the nylon locknut (26) to 18 ft-lb (24.5 N·m). 5.
  • Page 47 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment 1/2 IN. SOCKET 1/2 IN. WRENCH Correct pedal position is 5-3/4 in. ±1/4 in. (14.6 cm ±6 mm) from floormat to back of accelerator pedal Figure 5-7 Accelerator Pedal Height Figure 5-8 Accelerator Pedal Adjustment ACCELERATOR PEDAL ADJUSTMENT TOOL (CCI P/N 101871001)
  • Page 48 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment Accelerator Pedal Adjustment Continued: RETAINING PARALLEL NUTS WITH TOP VIEW OF THE ELECTRICAL COMPONENT Figure 5-10 Accelerator Cable and Electrical Box 8. Connect the accelerator rod at the accelerator pedal (Figure 5-11, Page 5-9). 8.1.
  • Page 49 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment FLOORBOARD REMOVED FOR CLARITY Figure 5-11 Accelerator Pedal Assembly 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 5-9...

  • Page 51: Section 6 - Mc012C-As00 Transaxle: Hydraulic And Park Brake Systems

    SECTION 6 – MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. BRAKE SYSTEM INSPECTION See General Warning, Section 1, Page 1-1. The hydraulic brake system and park brake system should be inspected immediately after any service to either of the brake systems.
  • Page 52 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Inspection REFERENCE FRONT TYPICAL BRAKE HOSE 2 PLACES BLEEDER TYPICAL VALVE 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 6-1 Front Hydraulic Brake Cluster Assembly Brake Line and Hose Inspection •...

  • Page 53: Brake System Troubleshooting

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting Brake Drum and Shoe Inspection • Remove and inspect each brake drum. The drum should not be cracked, warped or have excessive scores or heat checks. • Inspect the brake shoes. Shoes should not be distorted, cracked or have broken welds. •...
  • Page 54 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Low pedal – Pedal may go to the floor, Replace the worn hose. See Hydraulic continued Weak (bulging) brake hose Line and Hose Replacement on page 6-23.
  • Page 55 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle pulls to one side, continued Replace hub, axle seal or wheel cylinder Grease or brake fluid on the brake shoe and replace the brake shoes. See Brake linings Shoe Removal on page 6-8.

  • Page 56: Brake Drum Removal

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Removal TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Rear brakes drag Binding park brake cables Adjust or replace cables and adjust. Adjust shoes and repair the brake shoe Improper brake adjustment adjusters if necessary.
  • Page 57 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Removal Figure 6-2 Front Spindle and Brake Drum Assembly 5. To remove tight brake drums: 5.1. On the back of each brake cluster assembly, locate the heads of the two brake shoe adjusters. 5.2.

  • Page 58: Rear Wheel Brake Drum Removal

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Removal REAR WHEEL BRAKE DRUM REMOVAL ý WARNING • Use only approved replacement brake drums designed for your vehicle. For MC012C-AS00 transaxles, use CCI P/N 102264701. 1. Place chocks at the front wheels, release the park brake, loosen the rear wheel lug nuts and lift the rear of the vehicle with a chain hoist or floor jack.
  • Page 59 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Removal NOTE: It is recommended that the wheel bolt flange (22) be removed prior to brake shoe removal (Figure 6-5, Page 6-9). 2. Remove rubber boot (26), cotter pin (25), locking cap (27) and large flat washer (23) (Figure 6-5, Page 6-9).

  • Page 60: Brake Cluster Inspection And Cleaning

    NOTE: Factory installed brake shoes have non-asbestos linings (CCI P/N 102050201). When replacing brake shoes, Club Car, Inc., recommends non-asbestos replacement parts. 1. Remove the brake drum. See Front Wheel Brake Drum Removal on page 6-6, and Rear Wheel Brake Drum Removal on page 6-8.

  • Page 61: Brake Shoe Installation

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation 9.3. Disassemble the lever and strut by removing the C-clip and pin (Figure 6-8, Page 6-10). 9.4. Use a wire brush to remove corrosion and contaminants from the contact areas of the strut and lever.

  • Page 62: Front Brake Shoe Installation

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation FRONT BRAKE SHOE INSTALLATION 1. Install one shoe onto the back plate, positioning the bottom tip of the shoe into the brake shoe mounting block, and the top tip of the shoe into the wheel cylinder piston. 2.
  • Page 63 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation Lever is present on rear brake clusters only. TOP SLOTS BOTTOM SLOTS Figure 6-12 Brake Shoe Installation Figure 6-13 Slide Brake Shoes 4. Position the bottom tip of the remaining shoe into the mounting block and the top tip into the slot in the wheel cylinder piston.

  • Page 64: Brake Drum Installation

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation Rear Brake Shoe Installation, Continued: NOTE: Push the rubber boot onto the washer so that the washer edge fits into the boot-lip groove. 9. Install rear wheel brake drum. See Rear Wheel Brake Drum Installation on page 6-16. 10.
  • Page 65 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation 9. If the brake drum is difficult to push over the brake shoes, use the following procedure: 9.1. Locate the bolt heads of the two brake shoe adjusters on the back of the brake cluster plates. 9.2.

  • Page 66: Rear Wheel Brake Drum Installation

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation Rotate adjuster bolts Rotate adjuster bolts to loosen brake shoes. to tighten brake shoes. Hex-Head Bolt Wrench Torx-Head Bolt Wrench Torx Torx Figure 6-14 Loosen or Tighten Brake Adjusters REAR WHEEL BRAKE DRUM INSTALLATION NOTE: Prior to installing the brake drum, inspect the brake lines, hoses, drums and brake cluster assem- blies.

  • Page 67: Brake Cluster Assembly Replacement

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement 5. Install the wheel and finger-tighten the lug nuts (21) (Figure 6-19, Page 6-21). 6. Repeat steps 1 through 5 for the opposite rear wheel as required. 7. Lower the vehicle and finish tightening the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m). 8.

  • Page 68: Rear Brake Cluster Assembly Removal

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement Front Brake Cluster Assembly Installation, Continued: ý CAUTION • Do not substitute hex-head bolts for Torx-head bolts. Hex-head bolts can interfere with the proper operation of the brake shoe adjusters. 2.

  • Page 69: Rear Brake Cluster Assembly Installation

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement PLASTIC WIRE TIE FLEX BRAKE HOSE Figure 6-18 Rear Brake Hose With Plastic Bag REAR BRAKE CLUSTER ASSEMBLY INSTALLATION 1. Install the back plate to the axle tube flange with four new Torx-head bolts (16), washers (17) and lock- nuts (18).

  • Page 70: Front Wheel Cylinder Installation

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement Front Wheel Cylinder Removal, Continued: 3. Remove the banjo bolt (16) and two copper washers (17) (Figure 6-1, Page 6-2). 4. Lift the hose above the brake cluster assembly and place a plastic bag over the hose fitting to keep dirt and debris from entering the hydraulic brake system (Figure 6-15, Page 6-17).

  • Page 71: Brake Shoe Adjuster Replacement

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Adjuster Replacement REFERENCE BRAKE HOSE BLEEDER VALVE TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL TYPICAL 4 PLACES 2 PLACES Figure 6-19 Rear Hydraulic Brake Cluster Assembly BRAKE SHOE ADJUSTER REPLACEMENT See General Warning, Section 1, Page 1-1.

  • Page 72: Front Brake Shoe Adjuster Removal

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Adjuster Replacement FRONT BRAKE SHOE ADJUSTER REMOVAL 1. Remove front wheel brake drum. See Front Wheel Brake Drum Removal on page 6-6. 2. Remove front brake shoes. See Front Brake Shoe Removal on page 6-8. 3.

  • Page 73: Hydraulic Line And Hose Replacement

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement 2. Apply a light coat of grease to the Bellville washer (5) and install the washer onto the bolt (4) and against the inside surface of the back plate (1). 3.

  • Page 74: Front Brake Hose Assembly Removal

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement Front Brake Line Installation, Continued: 4. Tighten the flare nut (4) to the master cylinder to 11 ft-lb (14.9 N·m). 5. Tighten the flare nut (4) to the T-manifold block (1) to 11 ft-lb (14.9 N·m). 6.

  • Page 75: Rear Brake Line Installation

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement 1.5. Use a 3/8-inch flare nut wrench to remove the same brake line (10 or 11) from the rear brake hose at the I-beam of the vehicle frame. 1.6.
  • Page 76 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement Rear Brake Hose Removal, Continued: 4. Use a 3/8-inch flare nut wrench to remove the brake hose from the wheel cylinder (Figure 6-17, Page 6-18). 5. Use a 3/8-inch flare nut wrench to remove the rear brake line (10 or 11) 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).
  • Page 77 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement TYPICAL BOTH SIDES TYPICAL 2 PLACES REFERENCE REFERENCE FRONT SUSPENSION MASTER CYLINDER REFERENCE FRONT BRAKE ASSEMBLY TYPICAL BOTH SIDES REFERENCE REAR BRAKE ASSEMBLY Figure 6-21 Carryall 472/XRT 1200SE Four-Wheel Hydraulic Brake System 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-27...

  • Page 78: Rear Brake Hose Installation

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement REAR BRAKE HOSE INSTALLATION 1. Install brake hose (9) through the oval-shaped hole in the vehicle I-beam, and install the horseshoe clip (12) that secures the brake hose to the I-beam frame (Figure 6-20, Page 6-26 or Figure 6-21, Page 6-27).

  • Page 79: Master Cylinder Installation

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement 1. Chock the wheels and release the park brake and access the master cylinder. 2. Place a pan below the vehicle to collect the brake fluid. 3. Remove the two wires from the master cylinder pressure switch (4) (Figure 6-22, Page 6-30). 4.
  • Page 80 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement Turf-Carryall PLUG TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 6-22 Master Cylinder Page 6-30 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 81: Bleeding The Hydraulic Brake System

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System BLEEDING THE HYDRAULIC BRAKE SYSTEM See General Warning, Section 1, Page 1-1. The hydraulic system must be free of air. Air enters the hydraulic system whenever the system is opened and will result in a “spongy”...

  • Page 82: Purging The Hydraulic System

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System PURGING THE HYDRAULIC SYSTEM In some cases it may be necessary to completely drain the front, rear or entire hydraulic brake system of brake fluid. To completely purge the hydraulic system, perform the following procedure. 1.

  • Page 83: Park Brake System

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Ful l Lev el Safe Le vel Lev el Figure 6-24 Master Cylinder Reservoir PARK BRAKE SYSTEM See General Warning, Section 1, Page 1-1. PARK BRAKE CABLE REMOVAL Equalizer Cable Removal 1.

  • Page 84: Park Brake Cable Installation

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System PARK BRAKE CABLE INSTALLATION Park Brake Pulley Installation 1. Align the equalizer cable pulley assembly (13) with the mounting holes in the frame (Figure 6-27, Page 6-37). 2. Install the four 10-24 x 3/4-inch socket-head screws (14), flat washers (17) and locknuts (18) and tighten to 54 in-lb (6.1 N·m).

  • Page 85: Park Brake Handle Removal

    MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System 5. Pull the end of the brake cable (8) up and into a keyhole opening in the park brake equalizer bracket (10). 6. Adjust the park brake. See Park Brake Adjustment on page 6-35. 7.
  • Page 86 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Park Brake Adjustment, Continued: 5. With the park brake released (down), tighten the conical nut (23) until significant resistance is observed in the equalizer cable in order to fully lock the brakes (Figure 6-27, Page 6-37). 6.
  • Page 87 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL EACH SIDE OF VEHICLE TYPICAL EACH SIDE OF VEHICLE Figure 6-27 Park Brake System 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-37...

  • Page 89: Section 7 - Steering And Front Suspension

    SECTION 7 – STEERING AND FRONT SUSPENSION ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. STEERING WHEEL See General Warning, Section 1, Page 1-1. STEERING WHEEL REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Chock the wheels.
  • Page 90 STEERING AND FRONT SUSPENSION Steering Wheel TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-3 Steering Column Page 7-2 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 91: Steering Wheel Installation

    STEERING AND FRONT SUSPENSION Steering Column STEERING WHEEL INSTALLATION NOTE: To minimize corrosion, apply a small amount of oil or anti-seize compound to steering shaft splines and taper before installing the steering wheel. 1. Install the steering wheel (25) on the splines of the steering shaft (11) (Figure 7-3, Page 7-2). Align the match marks placed on the wheel and steering column shaft in step 5, Steering Wheel Removal on page 7-1.

  • Page 92: Steering Column Assembly

    STEERING AND FRONT SUSPENSION Steering Column Figure 7-4 Steering Joint Assembly STEERING COLUMN ASSEMBLY 1. Insert bearing seat (10) into both ends of steering tube (14). Place a block of wood on bearing seat and tap lightly on block until bearing seat (10) is fully seated in steering tube (14) (Figure 7-5, Page 7-5 and Figure 7-6, Page 7-5).

  • Page 93: Rack And Pinion

    STEERING AND FRONT SUSPENSION Rack and Pinion COLUMN RETAINING TOOL (CCI P/N 1014259) STEP 1 STEP 1 BEARING BEARING PRESS TOOL PRESS TOOL (CCI P/N 1014264) 5.1-5.4 cm (CCI P/N 1014264) 2 in.-2 1/8 in. STEP 2 WEDGE SEATING WEDGE SEATING INTO THE INNER INTO THE INNER RACES OF BEARING...
  • Page 94 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Removal, Continued: 3. Remove the lug nuts from the front wheels. 4. Remove the cotter pins (18) and ball joint retaining nuts (24) (Figure 7-19, Page 7-10). 5. Remove the ball joints (23) from the spindle assemblies. Figure 7-7 Rack and Pinion Bolts 6.

  • Page 95: Rack And Pinion Disassembly

    STEERING AND FRONT SUSPENSION Rack and Pinion 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 7-9 Ball Joint Figure 7-10 Drag Link 3.
  • Page 96 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly, Continued: 6. Remove the universal joint assembly from the pinion by removing 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.
  • Page 97 STEERING AND FRONT SUSPENSION Rack and Pinion 10. If the ball bearing (15) (Figure 7-19, Page 7-10) has been damaged, remove the c-type stop ring (16) (Figure 7-14, Page 7-8) and press the bearing off (Figure 7-16, Page 7-9). 11. Inspect the ball joints (9) for wear. If one or both of the ball joints (9) are excessively worn, remove and replace the ball joint from the rack (Figure 7-19, Page 7-10).
  • Page 98 STEERING AND FRONT SUSPENSION Rack and Pinion TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-19 Steering Gear Page 7-10 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 99: Rack And Pinion Assembly

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY 1. Apply a liberal amount of EP grease to the teeth of the rack (2), then slide the rack through the bushing (17) and housing (1) (Figure 7-19, Page 7-10). CAUT ION •...

  • Page 100: Rack And Pinion Installation

    STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Assembly, Continued: 11. Insert a 3/8-inch, 1/4-drive, deep-well socket into the steering column end of the universal joint (2) and tighten the bolts (1) to 15 ft-lb (20.3 N·m) (Figure 7-22, Page 7-12). 12.

  • Page 101: Front Suspension

    STEERING AND FRONT SUSPENSION Front Suspension 4. Install remaining bolt and lockwasher on the upper universal joint and tighten it to 15 ft-lb (20 N·m). 5. Check all universal joint bolts for proper torque of 15 ft-lb (20 N·m). 6. Adjust the toe-in. See Toe-in Adjustment on page 7-13. FRONT SUSPENSION See General Warning, Section 1, Page 1-1.

  • Page 102: Front Suspension Components

    STEERING AND FRONT SUSPENSION Front Suspension Components Toe-in Adjustment, Continued: 4. Measure the distance between the marks on the forward-facing surfaces of the tires (Figure 7-24, Page 7-13). See following NOTE. NOTE: The front measurement must be less than the rear measurement. 5.

  • Page 103: Kingpin And Steering Spindle Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components 4. Rest the brake cluster on the A-arm as shown (Figure 7-27, Page 7-15). Ensure that there is no strain on the brake hose. See following WARNING. ý WARNING • Strain on the brake hose or the brake hose fittings can result in damage to the hose or fittings, causing a leak in the hydraulic system, diminished brake performance, or brake failure.

  • Page 104: A-Arm Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components Kingpin and Steering Spindle Installation, Continued: 9. Install a new cotter pin (18) and bend it to secure it to the ball joint. 10. Use a grease gun and apply grease to the grease fitting (17) in the A-arm (13) (Figure 7-28, Page 7-17). See Lubrication on page 7-13.
  • Page 105 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL TYPICAL 4 PLACES TYPICAL 2 PLACES 4 PLACES TYPICAL 4 PLACES TYPICAL...

  • Page 106: Shock Absorber Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components A-Arm Installation, Continued: 12. Install the brake cluster. See Front Brake Cluster Assembly Installation, Section 6, Page 6-17. 13. Install the wheel and tighten the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m). 14.

  • Page 107: Front Wheel Bearings And Hubs

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS See General Warning, Section 1, Page 1-1. FRONT WHEEL FREE PLAY INSPECTION 1. Chock rear wheels, loosen the front wheel lug nuts and lift the front of the vehicle with a chain hoist or floor jack.

  • Page 109: Section 8 - Wheels And Tires

    SECTION 8 – WHEELS AND TIRES ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION • Keep tires properly inflated as follows: Front: 7-11 psi (.48-.76 Bars) All Terrain Tread Rear: 14-18 psi (.97-1.24 Bars) Front: 12-16 psi (.83-1.10 Bars)

  • Page 111: Section 9 - Rear Suspension

    SECTION 9 – REAR SUSPENSION ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. SHOCK ABSORBERS See General Warning, Section 1, Page 1-1. SHOCK ABSORBER REMOVAL AND INSPECTION 1. Check shock absorbers (1) for damage or fluid leakage around the housing and replace if necessary (Figure 9-1, Page 9-2).
  • Page 112 REAR SUSPENSION Multi-Leaf Springs TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE AXLE SADDLE Figure 9-1 Rear Suspension for MC012C-AS00 Transaxle Page 9-2 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 113: Multi-Leaf Spring Installation

    REAR SUSPENSION Multi-Leaf Springs Multi-Leaf Spring Removal, Continued: 4. Position jack stands under the two side stringers as shown (Figure 9-3, Page 9-3). Lower the floor jack to let the jack stands support the vehicle. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2.

  • Page 114: Snubber

    REAR SUSPENSION Snubber Multi-Leaf Spring Installation, Continued: 3. Align opposite end of leaf spring with spring shackles (19). Insert bolt (16) through shackles and leaf spring eye. Attach locknut (17) and tighten to 15 ft-lb (20.3 N·m). Lower transaxle onto leaf spring (18) (Figure 9-1, Page 9-2).

  • Page 115: Section 10 - Periodic Maintenance

    SECTION 10 – PERIODIC MAINTENANCE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. PERIODIC SERVICE SCHEDULE ý WARNING • Service, repairs, and adjustments must be made per instructions in this maintenance and service manual.

  • Page 116: Periodic Lubrication Schedule

    PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Annual service by Check for leaks around gaskets, fill plugs, etc. Engine trained technician only Inspect, clean and gap spark plug; replace if necessary. (or every 100 hours of operation, whichever Check air filter element;...

  • Page 117: Master Cylinder

    PERIODIC MAINTENANCE Master Cylinder FLOORBOARD Fuel tank is located under front passenger seat on Carryall 472. Figure 10-1 Turf 272/Carryall 272/XRT 1200 and Carryall 472/XRT 1200SE Lubrication Points MASTER CYLINDER The master cylinder is located under the passenger seat toward the center of the vehicle (Figure 10-2, Page 10-3).

  • Page 118: Brake Fluid

    PERIODIC MAINTENANCE Engine Oil BRAKE FLUID Brake fluid level should be within 1/4-inch (6 mm) from top of reservoir (Figure 10-2, Page 10-3). Also, brake fluid should be clean with no residue in bottom of reservoir or other evidence of contamination. See following WARNING.

  • Page 119: Engine Oil And Filter Change

    PERIODIC MAINTENANCE Engine Oil ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 100 hours of operation, then every 200 hours of oper- ation. 1. Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Chock the front wheels.
  • Page 120 Corning® BR2-Plus or equivalent), or new engine oil to the rubber seal of the filter before installation. This will help seal the filter to the oil mounting bracket (Figure 10-8, Page 10-6). See following NOTE. NOTE: Use only Club Car oil filters (CCI P/N 1016467) designed for this engine. Figure 10-8 Oil Filter Seal...

  • Page 121: Oil Viscosity

    PERIODIC MAINTENANCE Fueling Instructions 12. Tighten the oil filter by hand until tight. Do not use a band wrench or channel lock pliers to tighten. 13. Lower the vehicle and remove the floor jack from under the rear of the vehicle. 14.

  • Page 122: Battery

    PERIODIC MAINTENANCE Battery Fueling Instructions, Continued: NOTE: Whenever possible, avoid using oxygenated fuels and fuels that are blended with alcohol. Vehicles to be stored for extended periods should be prepared for storage as instructed in Section 3 of this manual. 1.
  • Page 123 PERIODIC MAINTENANCE Battery The battery in a Club Car vehicle is a 12-volt, low-maintenance battery that requires infrequent watering (Figure 10-14, Page 10-9). 1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position.

  • Page 125: Section 11 - Troubleshooting And Electrical System: Fe400, Key-Start Engine

    SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difficulties should they occur. The guide includes the symptom, probable cause(s) and suggested checks.
  • Page 126 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine turns but fails to start. Fuel tank is empty Section 14 – Fuel System Fuel line or filters clogged Section 14 – Fuel System Fouled spark plug Section 13 –...
  • Page 127 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Spark plug fouls repeatedly, continued. Section 11 – Troubleshooting and Ignition coil failed Electrical System: FE400, Key-Start Engine, Test Procedures 14, 15, and 16 Rings are heavily worn, low cylinder See the Engines and Transaxles manual pressure...
  • Page 128 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Starter/Generator does not charge Starter/generator belt is loose or slipping Belt Tension Adjustment on page 12-10 battery, continued. Section 11 – Troubleshooting and Voltage regulator failed Electrical System: FE400, Key-Start Engine, Test Procedure 12 Section 11 –...

  • Page 129: Electrical System

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Electrical System ELECTRICAL SYSTEM The electrical system on the FE400 key-start vehicles is 12 volts DC with negative ground to frame. It consists of ten circuits that are easily identified: • Starter Circuit •...

  • Page 130: Wiring Diagrams

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagrams WIRING DIAGRAMS FUELTANK SENDING UNIT 18_ORG(W23) HEAD LIGHT RIGHT CENTER DASH PANEL ASSEMBLY OIL SENDING FNR LIMIT OIL LIGHT UNIT SWITCHES REVERSE FUEL/HOUR BUZZER FRONT METER GUAGE POS (+) NEG (-) 6_WHT(W1) P/N 1014948 WHITE...
  • Page 131 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagrams BATTERY YELLOW BROWN OPTIONAL BLACK TALL LIGHT BARE 10_NON_INSUL(W27) ENGINE 6_RED(W28) 6_WHT(W1) STARTER GENERTOR 6_RED(W28) 18_BLK(W53) BLACK BROWN OPTIONAL WHITE TALL LIGHT 18_RED(W25) 18_YEL(W26) 18_RED(W36) 18_WHT(W20) UNDER 18_RED(W37) DASH ELECTRICAL COMPONENT BOX BRAKE LIGHT PRESSURE SWITCH...
  • Page 132 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagrams FUEL TANK SENDING UNIT ORANGE BLACK CENTER DASH PANEL ASM. LIGHT SWITCH YELLOW YELLOW OIL LIGHT OIL SENDING UNIT BLUE HEADLIGHT RIGHT YELLOW BLACK BLUE ORANGE POS (+) RED/WHT NEG (-) REVERSE BUZZER BLUE WHITE...
  • Page 133 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagrams OPTIONAL TAILLIGHT YELLOW BROWN FNR LIMIT SWITCHES BLACK BLACK BLACK GREEN RED/WHT BATTERY BARE ENGINE ORANGE ORANGE RED/WHT RED/WHT POS (+) NEG (-) YELLOW WHITE REVERSE BUZZER STARTER/GENERATOR BLACK P/N 1014948 WHITE BLUE BLUE...

  • Page 134: Test Procedures

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURES INDEX OF TEST PROCEDURES 1. Battery 2. Fuse 3. Ground Cables 4. Key Switch (Starter Circuit) 5. Key Switch (Accessory Terminal) 6. Solenoid 7. Lockout Cam Limit Switch 8. Starter/Generator (Starter Function) 9.
  • Page 135 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 1 – BATTERY See General Warning, Section 1, Page 1-1. ý DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working around a battery.
  • Page 136 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 1 – Battery, Continued: 7. Record the reading. 8. Return the electrolyte to the cell from which it was taken. Replace vent cap. 9. Repeat steps 2 through 8 on all cells. BATTERY PLATES 1.250...
  • Page 137 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures NOTE: A fully charged battery that is in good condition should have a specific gravity of at least 1.225 in all cells, and the difference in the specific gravity of any two cells should be less than 50 points. Open circuit voltage should be at least 12.4 volts.
  • Page 138 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 3 – GROUND CABLES See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
  • Page 139 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Place black (–) probe on frame. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Disconnect the 6 gauge black wire from the battery. Place red (+) probe on disconnected end of wire. Figure 11-10 Battery Ground Cable Test TEST PROCEDURE 4 –...
  • Page 140 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- 1000 --- FUSED FUSED 750V 750V Reading with key switch Reading with key switch in the ON position in the START position Figure 11-11 Key Switch Test –...
  • Page 141 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 6 – SOLENOID See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2.
  • Page 142 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 7 – Lockout Cam Limit Switch, Continued: SOLENOID SOLENOID WAVETEK WAVETEK 1000 1000 2000 2000 200k ELECTRICAL 200k COMPONENT 200nA 200nA ELECTRICAL 1000 --- FUSED 1000 --- 750V FUSED 750V COMPONENT BOX FRAME...
  • Page 143 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 8 – STARTER/GENERATOR (STARTER FUNCTION) See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
  • Page 144 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 8 – Starter/Generator (Starter Function), Continued: 8. With the wires still disconnected, using a multimeter set to 200 ohms, place the red (+) probe on the DF terminal and the black (–) probe on the F1 terminal. The reading should be between 4.5 and 5.5 ohms. If the reading is incorrect, a possible grounded DF terminal and/or grounded field coil may be the cause.
  • Page 145 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 7. If the diode tests good, reconnect the diode leads. See Diode Installation, Section 12, Page 12-12. See also following WARNING. ý WARNING • Incorrect wiring could result in severe injury or death. •...
  • Page 146 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 11 – STARTER/GENERATOR (GENERATOR FUNCTION) See General Warning, Section 1, Page 1-1. NOTE: Perform Test Procedure 10 before proceeding with this test procedure. Keep the battery connected while performing this test procedure. 1.
  • Page 147 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-22 Test Voltage Regulator TEST PROCEDURE 13 – GROUNDED KILL WIRE See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1.
  • Page 148 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 14 – Ignition Spark, Continued: 2.1. Adjust the tester probes to approximately to 18,000 volts (18 Kv) setting (SE – Small Engine Setting on the Thexton 404 tool). Connect the tester to the spark plug wire, and connect the alligator clip to a solid engine ground.
  • Page 149 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK FEMALE BULLET KILL CIRCUIT WIRE TERMINAL BLACK WIRE Figure 11-25 RPM Limiter Ignition Coil – In Vehicle Test 1.
  • Page 150 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 16 – Ignition Coil, Continued: 4. Using a multimeter set to 20k ohms, measure the resistance of the secondary coil and spark plug cap together. 4.1. Place the red (+) probe of the meter into the end of the spark plug cap that normally connects to the spark plug and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 11-27, Page 11-26).
  • Page 151 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Figure 11-28 Ignition Coil and Cap Figure 11-29 Spark Plug Cap Removal WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-30 Spark Plug Cap Test 6. Test the secondary coil separately from the spark plug cap. 6.1.
  • Page 152 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Ignition Coil – Bench Test 1. Remove the coil from the engine. See Ignition Coil Removal, Section 12, Page 12-23. 2. Using a multimeter set to 200 ohms, measure the primary coil resistance. 2.1.
  • Page 153 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK SECONDARY COIL 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 1000 --- FUSED 750V 200nA 1000 --- FUSED 750V Figure 11-32 Primary Coil Resistance – Bench Test Figure 11-33 Secondary Coil and Cap Resistance – Bench Test WAVETEK 1000...
  • Page 154 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 16 – Ignition Coil, Continued: 4. If not previously tested, test the spark plug cap separately from the secondary coil. 4.1. Remove the rubber gasket (1) on the plug cap (2) by rolling back the gasket onto the spark plug wire (3) (Figure 11-28, Page 11-27).
  • Page 155 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 18 – ENGINE KILL WIRE See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
  • Page 156 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 21 – OIL LEVEL SENSOR See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
  • Page 157 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 24 – BATTERY TEST (UNDER LOAD) See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
  • Page 158 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 25 – Fuel Level Sending Unit, Continued: 6. If the readings are within the specifications listed above, the fuel level sending unit is working properly. If the readings are incorrect, the fuel level sending unit has failed and the fuel tank must be replaced. See Fuel Tank Removal, Section 14, Page 14-22.
  • Page 159 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 8. Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded earlier. If not, check the continuity of the blue and black wires (Figure 11-37, Page 11-35). 9.
  • Page 160 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 28 – Light Switch, Continued: 4. Using a multimeter set on 20 volts DC, place alligator clips on the multimeter probes. Connect the red (+) probe to the light switch terminal with the blue wire connected to it (Figure 11-39, Page 11-36). ý...
  • Page 161 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 5. Loosen the black wire connector (on the end of the long black wire) at the headlight diode assembly just enough to maintain the connection and yet expose part of the metal terminal in the connector. Place black (–) probe on the connector (Figure 11-40, Page 11-37).
  • Page 162 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 30 – Voltage at Headlight Socket, Continued: 3. Remove the wire harness from the headlight (Figure 11-41, Page 11-38). 4. Using a multimeter set to 20 volts DC, place the black (–) probe of multimeter into the black wire terminal of the wire harness.
  • Page 163 SECTION 12 – ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. STARTER/GENERATOR See General Warning, Section 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.
  • Page 164 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator A1 TERMINAL TERMINAL TERMINAL TO BATTERY GROUND POST Figure 12-1 Starter/Generator Removal Disassembly of the Starter/Generator to Service the Brushes 1. Remove the two bolts (20) and pull commutator end cover (23) free of starter/generator housing (24) (Figure 12-2, Page 12-2).
  • Page 165 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Brush Inspection and Replacement 1. Visually inspect brushes. Replace brushes that are cracked or severely chipped. 2. Check the wear line on the side of the brush. If the end of the brush is within 1/16-inch (1.6 mm) of the wear line, replace all four brushes (Figure 12-4, Page 12-3).
  • Page 166 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Starter/Generator Assembly 1. Connect the brush wires to the holders using four lockwashers (26) and four screws (25). Make sure the crossover leads are also connected. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12-3, Page 12-2). 2.
  • Page 167 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Figure 12-7 Armature and Output End Cover Assembly Figure 12-8 Bearing Play Inspection Bearing Removal 1. Place the wedge attachment tool (CCI P/N 1012812) between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller (CCI P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
  • Page 168 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator WEDGE ATTACHMENT BEARING PRESS RAM USE A 1/2-INCH TOOL PULLER SUPPORT SOCKET OR PIPE TOOL INNER RACE OF BEARING PRESS ON ARMATURE SHAFT USE A WEDGE 1/2-INCH ATTACHMENT SOCKET TOOL OR PIPE NOTE: BEARING IS SECTIONED FOR CLARITY Figure 12-9 Bearing Removal POLE PIECE SCREW...
  • Page 169 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator 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 CAUTION. CAUT ION •...
  • Page 170 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator ARMATURE WAVETEK 1000 2000 200k COMMUTATOR 200nA 1000 --- FUSED 750V ARMATURE SHAFT Figure 12-12 Armature Ground Test Starter/Generator Rework Any rework must be performed by a qualified technician. Starter/Generator service specifications are listed in the following table.
  • Page 171 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator CAUT ION • Route the field terminal wires so that they will not contact the armature. 3. Install the four pole pieces into the housing. Use the four screws to secure pole pieces to the inside of the housing to retain the field wires.
  • Page 172 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Starter/Generator Installation, Continued: 6. Install the white wire from the solenoid to the F2 terminal on the starter/generator. Install the black wire from the frame to the A2 terminal on the starter/generator. Install a flat washer, lockwasher and nut onto each terminal, and tighten the nut to 48 in-lb (5.4 N·m).
  • Page 173 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Voltage Regulator VOLTAGE REGULATOR See General Warning, Section 1, Page 1-1. Testing the Voltage Regulator See Test Procedure 12, Section 11, Page 11-22. Voltage Regulator Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
  • Page 174 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Diode DIODE See General Warning, Section 1, Page 1-1. Testing the Diode See Test Procedure 10, Section 11, Page 11-20. Diode Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
  • Page 175 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Diode RIGHT ANGLED Some wires SUPPORT omitted CARRYALL 472 for clarity. AND XRT 1200SE RED FROM VOLTAGE REGULATOR RED FROM DIODE RED FROM WHITE FROM FUSE BLOCK DIODE WHITE FROM STARTER/ RED FROM GENERATOR BATTERY ANGLED I-BEAM OUTER...
  • Page 176 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Key Switch Diode Installation, Continued: 6. Connect the intake hose to the carburetor and secure the hose with the hose clamp. 7. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16.3 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305).
  • Page 177 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Solenoid Figure 12-19 Center Dash Panel Removal SOLENOID See General Warning, Section 1, Page 1-1. Testing the Solenoid See Test Procedure 6, Section 11, Page 11-17. Solenoid Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
  • Page 178 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuse Solenoid Installation, Continued: 2. Connect all wires as indicated. 2.1. Connect the 6-gauge white wire from the starter/generator, 18-gauge red wire from the voltage reg- ulator, and the 12-gauge white wire from the diode to the large post on the solenoid. See Wiring Diagrams, Section 11, Page 11-6.
  • Page 179 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Lockout Cam Limit Switch LOCKOUT CAM LIMIT SWITCH See General Warning, Section 1, Page 1-1. Testing the Lockout Cam Limit Switch See Test Procedure 7, Section 11, Page 11-17. Lockout Cam Limit Switch Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
  • Page 180 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Reverse Warning Buzzer FORWARD/REVERSE FORWARD/REVERSE ASSEMBLY ASSEMBLY REVERSE BUZZER LOCKOUT LIMIT SWITCH LIMIT SWITCH Figure 12-20 Lockout Cam and Reverse Buzzer Figure 12-21 Lockout Cam Limit Switches Lockout Cam Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
  • Page 181 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Reverse Buzzer Limit Switch 6. Remove the 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 frame sup- port between the bed hinges under the rear of the bed.
  • Page 182 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Oil Warning Light Reverse Buzzer Limit Switch Removal, Continued: 4. Remove the nuts (2) and washers (6) from the lockout cam limit switch (5) and slide the lockout cam limit switch off of the screws. Do not disconnect the wires. 5.
  • Page 183 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuel Gauge/Hour Meter Figure 12-23 Fuel Gauge/Hour Meter and Oil Warning Light Assembly 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 11-34. Also see Test Procedure 27 – Hour Meter on page 11-35.
  • Page 184 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuel Level Sending Unit Fuel Gauge/Hour Meter Installation, Continued: 3. Connect the orange wire from the fuel level sending unit to the no. 1 terminal, the blue wire to the no. 2 terminal, the white wire to the No. 4 terminal and the black wire to the No. 3 terminal on the gauge/meter. See Wiring Diagrams, Section 11, Page 11-6.
  • Page 185 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ignition Coil DAMPER RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK KILL CIRCUIT WIRE FEMALE BULLET TERMINAL BLACK WIRE Figure 12-24 RPM Limiter Assembly IGNITION COIL See General Warning, Section 1, Page 1-1. The ignition coil is located under the flywheel shroud of the engine.
  • Page 186 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ignition Coil Ignition Coil Removal, Continued: 7. Remove the pan head bolts (5) securing the fan shroud (8) to the fan housing (9) (Figure 12-25, Page 12-24). 8. Loosen, but do not remove, three bolts (6) attaching the fan housing as shown. 9.
  • Page 187 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ignition Coil 8. Install the gasket (1) on the cap (2). 9. Position the ignition coil (7) onto the cast mounting bosses on the engine crankcase and tighten the two mounting bolts (6) finger-tight. 10. Rotate the flywheel (8) until the magnet is positioned directly under the ignition coil. Use a 0.012 inch (0.304 mm) bronze feeler gauge to set the air gap between the ignition coil and the flywheel magnet.
  • Page 188 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Oil Level Sensor Ignition Coil Installation, Continued: 21. Install the starter/generator and belt. See Starter/Generator Installation on page 12-9. 22. Connect the spark plug wire to the spark plug. 23. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16.3 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305).
  • Page 189 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Headlight Diode Headlight Bulb Installation NOTE: When handling halogen bulbs, do not touch glass portion of bulb. Oil from finger tips can cause premature failure of bulb. 1. Connect wire harness (4) to the halogen bulb assembly (6). The retaining tab should lock onto the halo- gen bulb assembly (Figure 12-29, Page 12-26).
  • Page 190 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Light Switch Headlight Diode Installation, Continued: 3. Connect the solid black wire from the ground terminal block to the positive (+) terminal on the diode. 4. Install the dash panel in reverse order of removal. See Key Switch Removal on page 12-14. 5.
  • Page 191 Club Car recommends a group 70, side-post battery (CCI P/N 1012328), with a 650 cranking amp rating at 32 °F (0 °C) (500 CCA at 0 °F (-17.8 °C)) and a reserve capacity of at least 105 minutes. The group 70 classifi- cation indicates battery size: 8-1/4 inches W x 6-1/2 inches D x 7-1/4 inches H (21.0 cm W x 16.5 cm D x 18.4...
  • Page 192 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Battery Vibration Damage The battery hold-down clamp should always be tight enough to keep the battery from bouncing. Battery life may be severely shortened if the clamp is too loose. Excessive vibration shortens the life of the battery. It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts.
  • Page 193 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Battery 5. Remove the battery hold-down clamp from the battery and remove. See following WARNING. ý WARNING • Keep the battery in an upright position to prevent electrolyte leakage. Tipping the battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak out of the vent hole.
  • Page 194 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Battery Battery Installation See General Warning, Section 1, Page 1-1 and DANGER on page 12-28. 1. Place the battery into the vehicle with the battery posts facing the engine. 2. Secure the battery to the vehicle with the clamp and install bolt, washer and locknut and tighten to 12 ft- lb (16.3 N·m).
  • Page 195 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ground Cables ý WARNING • Do not jump-start a dead battery using another battery and jumper cables. GROUND CABLES Testing the Ground Cables See Test Procedure 3, Section 11, Page 11-14. 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-33...
  • Page 197 SECTION 13 – FE400 ENGINE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION See General Warning, Section 1, Page 1-1. The Turf 272, Carryall 272, Carryall 472, XRT 1200 and XRT 1200SE model vehicles are powered by an FE400 engine with key-start.
  • Page 198 FE400 ENGINE General Information SPARK PLUG Spark plugs are selected to suit specific engine design and vehicle operating conditions. The spark plug (CCI P/N 101881101) is designed for FE400 engines, providing maximum life and efficient combustion of fuel. The spark gap should be set to 0.027 - 0.031 inches (0.69 - 0.79 mm). Spark Plug Removal See General Warning, Section 1, Page 1-1.
  • Page 199 FE400 ENGINE Cylinder CYLINDER See General Warning, Section 1, Page 1-1. Test cylinder compression using a standard compression tester. Low compression would normally indicate a problem in the cylinder assembly such as defective rings, gaskets, etc. FE400 model engines are equipped with an automatic compression release valve (ACR). This valve releases compression pressure at normal cranking RPM, resulting in lower compression.
  • Page 200 FE400 ENGINE Crankcase Engine Removal, Continued: 4. Remove muffler. See Muffler Removal, Section 15, Page 15-1. 5. Remove engine mounting hardware (items 1, 2, 5 and 6) (Figure 13-1, Page 13-4). 6. Lift engine from the mounting plate. 7. Remove crankcase oil drain plug and filler tube. Tip the engine slightly to allow all of the oil to drain from the crankcase.
  • Page 201 FE400 ENGINE Crankcase STARTER/ GENERATOR Figure 13-2 Oil Level Sensor Wire Figure 13-3 Crankcase Cover OIL LEVEL SENSOR Testing the Oil Level Sensor See Test Procedure 21, Section 11, Page 11-32. Oil Level Sensor Removal 1. If not already removed, remove crankcase cover. See Crankcase Cover Removal on page 13-4. 2.
  • Page 202 FE400 ENGINE Ignition Coil and Flywheel IGNITION COIL AND FLYWHEEL See General Warning, Section 1, Page 1-1. Ignition Coil and Flywheel Removal 1. Loosen three screws and remove the remaining four screws attaching the flywheel housing as shown, then remove the housing (Figure 13-5, Page 13-6). 2.
  • Page 203 FE400 ENGINE Flywheel Installation 0.012 INCH (0.304 MM) Figure 13-7 Flywheel Nut Removal Figure 13-8 Adjust Ignition Coil Air Gap CRANKCASE COVER INSTALLATION CAUT ION • Before assembly, make sure parts are clean. • Do not reuse the gasket. Install a new one. •...
  • Page 204 FE400 ENGINE Engine Installation Flywheel Installation, Continued: CAUT ION • The flywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to loosen. • Be careful not to damage the fan blades. Use a strap wrench to hold flywheel. Do not place screwdriver or pry bar between fan blades.
  • Page 205 FE400 ENGINE Engine Installation 11. Connect the battery cables, positive (+) cable first, and tighten terminals to 12 ft-lb (16.3 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 12. Adjust the engine RPM setting. See Engine RPM Adjustment, Section 14, Page 14-10. 13.
  • Page 207 SECTION 14 – FUEL SYSTEM ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The FE400 engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The size of the jets are determined by the altitude where the engine will be operating.
  • Page 208 FUEL SYSTEM Carburetor MAIN JET ELEVATION/SIZE CHART FE400 ENGINE ALTITUDE MAIN JET SIZE 0-3280 ft. (0-1000 m) 3280-6562 ft. (1000-2000 m) 6562 ft. and over (2000 m and over) CHANGING THE MAIN JET See General Warning, Section 1, Page 1-1. 1.
  • Page 209 FUEL SYSTEM Carburetor NOTE: Note the orientation of the gasket (16), between the carburetor intake pipe (17) and the carburetor body (12) so that it can be replaced in the same orientation (Figure 14-2, Page 14-4). Disconnect the throttle return spring (11). Note the orientation so that it can be replaced the same. The carburetor must be kept upright during removal.
  • Page 210 FUEL SYSTEM Carburetor Changing the Main Jet, Continued: TYPICAL 2 PLACES Figure 14-2 Carburetor Installation Page 14-4 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 211 FUEL SYSTEM Carburetor STEPS 2 AND 3 Drain carburetor over a catch basin by turning bowl drain screw (11) counterclockwise 2 to 3 turns. STEP 4 Mark carburetor and corresponding position of fuel bowl. CAUTION: DO NOT REMOVE VALVE/SPRING FROM FLOAT. TO DO SO WILL DAMAGE SPRING. If spring looks like this...
  • Page 212 FUEL SYSTEM Engine Control Linkage Changing the Main Jet, Continued: 20. Install the intake hose (23) and secure with hose clamp (22) (Figure 14-2, Page 14-4). NOTE: Make sure the intake hose is not twisted during installation. 21. Turn fuel shut-off valve (on fuel tank) to the ON position (Figure 14-21, Page 14-28, and Figure 14-22, Page 14-29).
  • Page 213 FUEL SYSTEM Engine Control Linkage Figure 14-4 Accelerator Rod Accelerator Rod Installation and Adjustment 1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. 2. Adjust accelerator pedal position. See Accelerator Pedal Adjustment, Section 5, Page 5-6. 3.
  • Page 214 FUEL SYSTEM Engine Control Linkage Accelerator Rod Installation and Adjustment, Continued: 9. Tighten the jam nuts against the ball joints at each end of the accelerator rod, accelerator ball joint first, while holding the ball joints with pliers. 10. Check rod adjustment for proper switch activation. 11.
  • Page 215 FUEL SYSTEM Engine Control Linkage PARALLEL RETAINING WITH NUTS PULL SPRING RELEASE TO INSTALL ACCELERATOR ROD BOTTOM VIEW Figure 14-5 Cam Position Figure 14-6 Accelerator Rod 6. Remove the accelerator cable (7) from the engine bracket (17) and lift the Z-shaped cable end from the bracket (Figure 14-8, Page 14-11).
  • Page 216 FUEL SYSTEM Engine Control Linkage CLOSED THROTTLE OR IDLE ADJUSTMENT 1. With the engine running and the Forward/Reverse handle in the NEUTRAL position, attach a tachometer (CCI P/N 1016112) to the spark plug wire and adjust the low idle screw on the carburetor until the tachometer reads 1200 to 1250 RPM (Figure 14-7, Page 14-10).
  • Page 217 FUEL SYSTEM Engine Control Linkage TYPICAL 2 PLACES Figure 14-8 Governor and Accelerator Cables 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-11...
  • Page 218 FUEL SYSTEM Choke and Air Intake System CHOKE AND AIR INTAKE SYSTEM See General Warning, Section 1, Page 1-1. CHOKE CABLE REMOVAL 1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position.
  • Page 219 FUEL SYSTEM Choke and Air Intake System 2.2. Place hose (16) onto air box top (4) and secure with wire clamp (15). 2.3. Attach choke cable (18) to the air box top (4). See Choke Cable Installation on page 14-12. 3.
  • Page 220 FUEL SYSTEM Choke and Air Intake System Intake Duct Removal, Continued: 2.5. Remove the front wheels. 2.6. Remove the bolt (1) that connects the steering joint to the steering column shaft (Figure 14-9, Page 14-13). See following NOTE. NOTE: The bolt must be removed completely before the splined coupling can be separated. Make an alignment mark on the steering column shaft and the steering joint for use during replace- ment.
  • Page 221 FUEL SYSTEM Choke and Air Intake System 1. Slide the intake duct between the round crossmember and the floorboard, moving it to the rear along the underside of the floorboard. See following NOTE. NOTE: It is best to have a second person guide the air box end of the duct into position as it is pushed from the front of the vehicle.
  • Page 222 • If air box is extremely dirty, remove air box from vehicle and clean thoroughly. • Use only Club Car replacement air filters (CCI P/N 1015426). The use of other air filters could result in engine damage. If the air filter is too thin, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.
  • Page 223 FUEL SYSTEM Fuel Pump FUEL FILTER INSTALLATION CAUT ION • Fuel filters are marked with flow direction arrows. Make sure that filters are installed with arrows pointing in the direction of fuel flow from tank to carburetor. 1. Install the primary fuel filter (17) in reverse of removal. Use new clamps (16) (Figure 14-16, Page 14-25 or Figure 14-17, Page 14-26).
  • Page 224 FUEL PUMP DISASSEMBLY NOTE: A fuel pump rebuild kit is available from Club Car (CCI P/N 1014524). 1. Remove four screws (24) and lockwashers (25) from front of the fuel pump (Figure 14-10, Page 14-18).
  • Page 225 FUEL SYSTEM Fuel Pump TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 14-12 Turf 272/Carryall 272/XRT 1200 Air Intake and Choke Assemblies 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-19...
  • Page 226 FUEL SYSTEM Fuel Pump TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 14-13 Carryall 472/XRT 1200SE Air Intake and Choke Assemblies Page 14-20 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 227 FUEL SYSTEM Fuel Pump FUEL PUMP CLEANING AND INSPECTION 1. Use a nonflammable solvent to clean the front cover, pumping chamber and back cover. Be sure the vent on the front cover is clean both inside and out. 2. Inspect the valve assemblies (31, 32, and 33), gaskets and diaphragms for damage (Figure 14-10, Page 14-18).
  • Page 228 FUEL SYSTEM Fuel Tank FUEL TANK See General Warning, Section 1, Page 1-1. ý WARNING • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure. CAUT ION •...
  • Page 229 FUEL SYSTEM Fuel Tank ý DANGER • Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. ý WARNING • Never attempt to siphon fuel using a hose that does not have a built-in suction device. •...
  • Page 230 FUEL SYSTEM Fuel Tank Fuel Tank Installation, Continued: 2. Carryall 474/XRT 1200SE: 2.1. Position the retaining strap (13) and install the fuel tank (Figure 14-17, Page 14-26). 2.2. Install the nut (12) onto the J-bolt (8) and tighten to 25 in-lb (2.8 N·m). 2.3.
  • Page 231 FUEL SYSTEM Fuel Tank SEE ABOVE GAS TANK FUEL PICKUP TUBE TYPICAL 2 PLACES FUEL LINE FUEL LINE ROUTING ROUTING LENGTH LENGTH Solid Color Solid Color Clear Clear Fuel tank to primary fuel filter Fuel tank to primary fuel filter 14.0 in.
  • Page 232 FUEL SYSTEM Fuel Tank SEE ABOVE GAS TANK FUEL PICKUP TUBE TYPICAL 2 PLACES ROUTING LENGTH FUEL LINE Solid Color Clear Fuel tank to primary fuel filter 2.5 in. (6.4 cm) Primary fuel filter to fuel pump 46.5 in. (118.1 cm) Fuel pump to secondary fuel filter 10.15 in.
  • Page 233 FUEL SYSTEM Fuel Lines Fuel Tank Installation, Continued: 11. Start the engine and allow it to idle. 11.1. Use the key to start the engine, and idle. See following DANGER. ý DANGER • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation.
  • Page 234 FUEL SYSTEM Fuel Shut-Off Valve Fuel Lines, Continued: Fuel line no. 3 runs directly from the fuel outlet of the fuel pump (18) to the secondary fuel filter (22). Arrow indicates flow. Fuel line no. 4 runs from the outlet of the secondary fuel filter (22) to the carburetor. Arrow indicates flow. A screw band clamp should be used at the carburetor.
  • Page 235 FUEL SYSTEM Fuel Shut-Off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 14-22 Incorrect Fuel Shut-off Valve 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-29...
  • Page 237 SECTION 15 – EXHAUST SYSTEM ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. MUFFLER MUFFLER REMOVAL 1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position.
  • Page 238 EXHAUST SYSTEM Muffler Muffler Installation, Continued: 8. Connect the spark plug wire. 9. Connect the battery cables, positive (+) cable first, and tighten terminals to 12 ft-lb (16.3 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 10.
  • Page 239 SECTION 16 – MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The Turf 272/Carryall 272/XRT 1200 and Carryall 472/XRT 1200SE vehicles are equipped with a heavy-duty, fully-synchronized unitized transaxle with differential lock.
  • Page 240 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK General Information Shifter Lever A shifter lever, connected to a shifter arm, is used to change the gears to one of three shift positions: FOR- WARD (F), NEUTRAL (N), or REVERSE (R) (Figure 16-2, Page 16-2). Bring the vehicle to a complete stop before changing FORWARD or REVERSE direction.
  • Page 241 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Neutral Lockout The neutral lockout feature is not a serviceable component on key-start vehicles. The neutral lockout should remain in the correct position at all times. See Lockout Cam, Section 11, Page 11-5. Governor System The governor system regulates vehicle ground speed.
  • Page 242 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Axle Shaft, Bearing, and Oil Seal Removal, Continued: 5. To remove the wheel bolt flange on the MC012C transaxle (Figure 16-5, Page 16-4): 5.1. Remove rubber boot (26) from large flat washer (23). 5.2.
  • Page 243 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft AXLE SHAFT, BEARING, AND OIL SEAL INSTALLATION 1. Replace the old oil seal with a new seal (89). Make sure the axle tube hub is free of debris. 2. Replace the old bearing with a new bearing (88). Slip the new bearing onto the machined journal, adja- cent to the machined seal hub on the end of the axle (Figure 16-8, Page 16-6).
  • Page 244 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal TYPICAL 8 PLACES Figure 16-8 Differential Axle and Wheel Hub Assembly UNITIZED TRANSAXLE REMOVAL See General Warning, Section 1, Page 1-1. ý WARNING • To perform this procedure, the hydraulic system must be opened. As a result, the brakes must be bled after the correct installation of the brake components.
  • Page 245 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal CLAMP Figure 16-9 Carburetor Vent Tube 4.2. Disconnect the air intake hose from the carburetor (Figure 16-10, Page 16-7). 4.3. Disconnect impulse line from fuel pump (Figure 16-11, Page 16-7). CLAMP IMPULSE LINE Figure 16-10 Air Intake Hose Figure 16-11 Impulse Line...
  • Page 246 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: Rotate the cable connector toward the driver side of the vehicle to disconnect the cable from the differential lock lever. Figure 16-12 Differential Lock Cable Bracket 1. Apply pressure to locking tabs of the cable.
  • Page 247 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal TOP VIEW Loosen retaining nuts to remove Remove fuel line. accelerator cable from electric box. Figure 16-14 Fuel Line Figure 16-15 Accelerator Cable ENGINE GROUND TOP VIEW RETAINING NUT SPRING RELEASE NUTS Figure 16-16 Engine Ground Wire Figure 16-17 Shifter Cable...
  • Page 248 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: STARTER/ GENERATOR YELLOW YELLOW WHITE OIL LEVEL SENSOR JUMPER WIRE GROUND Figure 16-18 Generator Wires Figure 16-19 Oil Level Sensor Jumper Wire WHITE/BLACK WIRE BLACK WIRE Figure 16-20 Engine Kill Switch Wire 5.15.
  • Page 249 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal PLASTIC WIRE TIE FLEX BRAKE HOSE Figure 16-21 Cover Brake Hose Fitting CABLE SUPPORT BRACKET Figure 16-22 Park Brake Cable Figure 16-23 Brake Hose 8. Use a hydraulic jack under the transaxle (Figure 16-25, Page 16-12) and raise the vehicle. Place jack stands, set at approximately 17-1/2 inches (44.5 cm) in height, under the frame (Figure 16-26, Page 16-12).
  • Page 250 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: Figure 16-24 Shock Absorbers PROPER POSITIONING PROPER POSITIONING OF FLOOR JACK OF JACK STANDS APPROX. 17-1/2" (44.5 cm) Figure 16-25 Raise Vehicle Figure 16-26 Position Jack Stands Page 16-12 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 251 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal REMOVE BOLTS, THEN ROTATE SHACKLES UP AND AWAY FROM SPRINGS. Figure 16-27 Spring Retainer Bolts Figure 16-28 Rear Shackles 13. Carefully lift the snubber out of the snubber bracket in the vehicle frame and lower it to the floor (Figure 16-29, Page 16-13).
  • Page 252 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: 17. Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle (Figure 16-33, Page 16-14). 18. Loosen, but do not remove, the governor arm retaining bolt. Remove the governor arm from the shaft (Figure 16-34, Page 16-14).
  • Page 253 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Figure 16-35 Forward/Reverse Shifter Bracket UNITIZED TRANSAXLE INSTALLATION See General Warning, Section 1, Page 1-1. 1. Install the wheels. See General Information, Section 8, Page 8-1. 2. Install the leaf springs. See Multi-Leaf Spring Installation, Section 9, Page 9-3. 3.
  • Page 254 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 6. Install the differential lock cable and bracket. 6.1. Connect the differential lock cable spring (1) to the differential lock arm on the housing (Figure 16-36, Page 16-16). 6.2.
  • Page 255 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation 11. Install the key onto the input shaft (Figure 16-44, Page 16-19). 12. Position the driven clutch on the transaxle input shaft and install the washer (yellow side facing out) and mounting bolt and tighten to 14 ft-lb (19.0 N·m) (Figure 16-44, Page 16-19).
  • Page 256 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: Figure 16-41 Shock Absorber Figure 16-42 Leaf Springs Figure 16-43 Leaf Springs and Shackles Page 16-18 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 257 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation SNUBBER SNUBBER BRACKET Figure 16-44 Driven Clutch Figure 16-45 Snubber 19. Connect the park brake cables. See Park Brake Cable Installation, Section 6, Page 6-34. 20. Use a 3/8-inch flare nut wrench to connect the brake hoses to the left and right rear brake clusters and bleed the air from the brake lines.
  • Page 258 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 25. Connect the 6-gauge white wire to the F2 post and the 6-gauge black ground wire to the A2 post of the starter generator and tighten to 48 in-lb (5.4 N·m). Connect the 16-gauge yellow wire to the DF post and tighten to 30 in-lb (3.4 N·m) (Figure 16-48, Page 16-20).
  • Page 259 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation TOP VIEW CLAMP ACCELERATOR CABLE Figure 16-51 Connect Cable to Cam Figure 16-52 Connect Fuel Line 28. Connect accelerator cable to actuator cam in the electrical box. Position the accelerator cable in mount- ing slot in the wall of the electrical box and tighten mounting nuts to 18 in-lb (2.0 N·m) (Figure 16-51, Page 16-21).
  • Page 260 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: CLAMP Figure 16-55 Carburetor Vent Tube 34. Install transaxle drain plug and tighten to 21 ft-lb (28.5 N·m). 35. Fill transaxle with 29 oz. (.85 liter) 80-90 WT. API Class GL-3 or 80-90 WT. AGMA Class 5 EP gear lubri- cant.
  • Page 261 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Forward/Reverse Shifter Cable Push cable into the bracket. Figure 16-57 Differential Cable Installation TOP VIEW SHIFTER SHIFTER F N R LEVER Figure 16-58 Forward/Reverse Positions FORWARD/REVERSE SHIFTER CABLE See General Warning, Section 1, Page 1-1. If the Forward/Reverse shifter cable is damaged in any way, it must be replaced.
  • Page 262 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Forward/Reverse Shifter Cable FORWARD/REVERSE SHIFTER CABLE INSTALLATION 1. Route the cable to the transaxle shifter lever, beginning at the Forward/Reverse shifter. 2. Secure the cable with retaining nut (5) on each side of the shifter cable support bracket at the transaxle (Figure 16-59, Page 16-24) and tighten nuts to 22 ft-lb (29.8 N·m).
  • Page 263 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System FORWARD/REVERSE SHIFTER CABLE ADJUSTMENT Place the shifter lever in the NEUTRAL position (straight up) (Figure 16-58, Page 16-23). For minor adjust- ments, the nut (1) may be loosened and the ball joint socket (2) rotated to get the proper adjustment (Figure 16-59, Page 16-24).
  • Page 264 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System DIFFERENTIAL LOCK CABLE REMOVAL 1. Place the differential lock handle in the disengaged position. 2. Remove wire tie (6) securing the cable to the vertical support (Figure 16-60, Page 16-27). 3. Use a pair of pliers and apply pressure to the locking tabs of the cable end (1) where it attaches to the differential lock handle mounting bracket (Figure 16-12, Page 16-8).
  • Page 265 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System 1. Rotate the cable connector toward the passenger side of the vehicle to connect the cable to the differential lock lever. 2. Push plastic cable retainer toward the front of the vehicle to secure the cable to the bracket.
  • Page 267 SECTION 17 – TORQUE CONVERTER ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. To provide optimum perfor- mance for the OHV engines and powertrain, the vehicle uses a pair of tuned clutches.
  • Page 268 TORQUE CONVERTER General Information TORQUE CONVERTER TOOL KIT (CCI P/N 1014510) DRIVEN CLUTCH CAM PRESS TOOL (CCI P/N 101809101) DRIVE CLUTCH HUB PULLER DRIVEN CLUTCH CAM PULLER (CCI P/N 1014497) (CCI P/N 1014508) DRIVEN CLUTCH PULLER PLUG (CCI P/N 1014507) DRIVE CLUTCH HOLDER TOOL (CCI P/N 1015524) DRIVE...
  • Page 269 Maintaining proper adjustment of each of these is critical to the overall performance of the vehicle. If the engine and governor adjustments are within Club Car specifications but, when climbing a steep hill, the engine begins to lose RPM before the drive belt reaches the top of the driven clutch, there is a torque con- verter problem.
  • Page 270 TORQUE CONVERTER Drive Clutch Drive Belt Removal, Continued: 4. Grasp the belt midway between the drive and driven clutches. Lift upward on the belt to force the sheaves of the driven clutch apart, then roll the belt off the driven clutch by rotating the clutch counterclockwise (Figure 17-2, Page 17-3).
  • Page 271 Drive Clutch CAUT ION • Do not hit or tap the clutch with a hammer. Do not pry the clutch. These actions will damage the clutch. Use Club Car clutch holder while tightening or loosening drive VEHICLE BODY clutch retaining bolt.
  • Page 272 TORQUE CONVERTER Drive Clutch DRIVE CLUTCH DISASSEMBLY CAUT ION • The drive clutch is balanced as an assembly. Before disassembly, make match marks on the clutch cover and on the moveable face assembly so they can be reassembled in the same positions (Figure 17-5, Page 17-6).
  • Page 273 TORQUE CONVERTER Drive Clutch 5. Remove the clutch weights. 5.1. Remove the screws and flat washers attaching the weights (Figure 17-9, Page 17-9). 5.2. Pull the weight assemblies, with pins, from the clutch. 5.3. Remove the plastic washers, weights and wave washer from the pins. Before removing, note the orientations of the wave washer and of the primary and secondary weights to one another (Figure 17-12, Page 17-10 and Figure 17-13, Page 17-10).
  • Page 274 TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES Figure 17-7 Drive Clutch Assembly Page 17-8 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 275 TORQUE CONVERTER Drive Clutch Remove these items from ribs: 1/4-20 SCREW 10-24 SCREW FLAT WASHER FLAT WASHER WEIGHT DRIVE BUTTON DRIVE BUTTON TAKE UP SPRING RIBS WEIGHT SLOTS IN HUB CASTING Figure 17-8 Drive Button Mounting Figure 17-9 Weight Position PRESS RAM Use a scribe to remove spiral back-up rings from both...
  • Page 276 TORQUE CONVERTER Drive Clutch DRIVE CLUTCH ASSEMBLY 1. Press idler bearing (3) onto the shaft of the fixed face assembly (2). Press on the inner race of the bearing only. Make sure that the cup side of bearing is facing away from the fixed face (Figure 17-7, Page 17-8). 2.
  • Page 277 TORQUE CONVERTER Drive Clutch 11. Install the weight assemblies into the slots in the hub casting (Figure 17-9, Page 17-9). Make sure the mounting pin protrudes an equal amount on each side of the weights when the assemblies are in position (Figure 17-14, Page 17-11).
  • Page 278 TORQUE CONVERTER Driven Clutch Drive Clutch Installation, Continued: DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED Figure 17-15 Correct Orientation of Drive Button Take-up Spring 4. Install the drive belt as instructed. See Drive Belt Installation on page 17-4. 5. Connect the spark plug wire. 6.
  • Page 279 TORQUE CONVERTER Driven Clutch 3. Disconnect the spark plug wire. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 4. Remove the drive belt as instructed. See Drive Belt Removal on page 17-3. 5. Remove the bolt (11) and mounting washer (12) from the clutch shaft (Figure 17-16, Page 17-14). 6.
  • Page 280 TORQUE CONVERTER Driven Clutch TYPICAL 3 PLACES Figure 17-16 Driven Clutch Assembly Page 17-14 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 281 TORQUE CONVERTER Driven Clutch Place puller plug in bore of cam (A). Then clamp driven clutch cam puller onto three flat surfaces of the cam. Using external snap DRIVEN CLUTCH ring pliers, remove CAM PULLER retaining ring. PULLER PLUG Figure 17-17 Remove Retaining Ring Figure 17-18 Driven Clutch Disassembly 5.1.
  • Page 282 TORQUE CONVERTER Driven Clutch Driven Clutch Assembly, Continued: CAM PRESS TOOL Figure 17-19 Cam Press Tool Figure 17-20 Cam Installation Tool 5.2.1. With the clutch loosely assembled, set the edge of the clutch body (5) on a clean, flat sur- face.
  • Page 283 TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH INSTALLATION 1. To install the driven clutch, reverse the removal procedure. Make sure 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).
  • Page 285 INDEX bumper, tube installation ............4-2 accelerator removal ..............4-2 pedal adjustment .............5-6 removal ............5-5 cargo bed air filter ..............14-16 bumper adjustment ..........4-12 axle CAUTION bearing definition of ............1-1 installation ...........16-5 cleaning removal ............16-3 vehicle body ............4-1 column, steering assembly ............7-4 battery hydrometer test ..........11-11 installation ............12-32 DANGER...
  • Page 286 INDEX fuel level sending unit kill wire, engine testing ............11-33 testing ............11-31 hour meter circuit testing ............11-35 operation ............12-21 lockout cam fuel level sending unit limit switch ............. 11-17 testing ............11-33 testing ............11-32 fuel lines ............14-27 lockout cam circuit fuel pump function ............
  • Page 287 INDEX solenoid ignition coil .............11-24 testing ............11-17 ignition test .............11-23 spark plug key switch gap adjustment ..........13-2 specifications engine kill circuit ........11-30 vehicle ..............2-1 starter circuit ..........11-15 starter/generator lockout cam ............11-32 armature lockout cam limit switch .........11-17 ground test ..........12-7 assembly ..........
  • Page 289 3. Clarity of Illustrations 4. Index Usability 5. Troubleshooting Chart Usability Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 292 Club Car, Inc. www.clubcar.com Phone 1.706.863.3000 P.O. Box 204658 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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Carryall 272 2005Carryall 472 2005Xrt 1200 2005Xrt 1200se 2005

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