Light Scratches; Large Scratches And Abrasions; Tube Bumper/Brush Guard; Tube Bumper/Brush Guard Removal - Club Car TURF 272 2005 Maintenance Service Manual

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BODY AND TRIM

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. Start with wet silicone carbide abrasive paper (320 grit or finer). Use progressively finer grits (i.e.
400, 600, 800) to reduce sanding marks. Use Ajax cleanser (or equivalent) for final smoothing. A "Micro
Mesh" acrylic polishing kit with abrasive papers from 1800 to 8000 grit will provide the best final finish.
Restore gloss with soft polishing compound. It is not the intent of any of these processes to fill-in material
removed due to light scratches but rather to blend the finish of the surrounding area and the scratch together.

LARGE SCRATCHES AND ABRASIONS

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

TUBE BUMPER/BRUSH GUARD

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

TUBE BUMPER/BRUSH GUARD REMOVAL

1. Remove the truss-head screws (14) and nuts (15) that secure the tube bumper or brush guard to the
vehicle frame (Figure 4-2, Page 4-5).

TUBE BUMPER/BRUSH GUARD INSTALLATION

1. Installation is the reverse of removal. Tighten the nuts (15) to 15 ft-lb (20.3 N·m) (Figure 4-2,
Page 4-5).

FRONT BODY COMPONENTS

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

DASHBOARD 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.
2. Disconnect the battery as instructed. See WARNING "To avoid unintentionally starting..." in General
Warning, Section 1, Page 1-2
3. Remove the dash panel:
3.1. Loosen the seven Tuflok
3.2. Remove Tuflok screws from dash panel shown in Detail B.
3.3. Pull forward on top of dash panel to access back of panel.
4. Disconnect the wiring from components mounted in the dash panel.
5. Remove five caps (1) from top of dashboard (2) (Figure 4-2, Page 4-5).
6. Remove screws (3) and special plastic washers (4) from top of dashboard (2) using a Torx #T-30 driver.
7. Remove five screws (5) from underside of dashboard and pull dashboard away from front body (6).
8. Remove the steering wheel. See Steering Wheel Removal, Section 7, Page 7-1.
9. Remove dashboard from vehicle.
Page 4-2 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
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screws shown in Detail A (Figure 4-1, Page 4-3).
Tube Bumper/Brush Guard