Club Car 2007 Carryall 295 Maintenance And Service Manual
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Club Car 2007 Carryall 295 Maintenance And Service Manual

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2007 Carryall 295/295SE
and XRT 1550/1550SE

Maintenance and Service

Manual
Gasoline, Diesel and IntelliTach, and Homologated Vehicles
Manual Number 103209114
Edition Code 1006F1208E

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Summary of Contents for Club Car 2007 Carryall 295

  • Page 1: Maintenance And Service

    2007 Carryall 295/295SE and XRT 1550/1550SE Maintenance and Service Manual Gasoline, Diesel and IntelliTach, and Homologated Vehicles Manual Number 103209114 Edition Code 1006F1208E...
  • 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

    Cleaning the Vehicle ......................... Seat Cleaning ..........................Front Body Repair ..........................Light Scratches ..........................Abrasions and Haze ........................Large Scratches and Abrasions ....................2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page iii...
  • Page 6 Rear Fender Removal ........................4-15 Rear Fender Installation ....................... 4-15 Floor Mat ............................4-15 Floor Mat Removal ........................4-15 Floor Mat Installation ........................4-15 Page iv 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 7 Bleeding the Hydraulic Brake System ....................6-22 Bleeding Brakes on a DOT 5 Fluid Filled System ................. 6-22 Purging the Hydraulic System ...................... 6-24 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page v...
  • Page 8 Steering Upright Installation ......................7-19 SECTION 8 – WHEELS AND TIRES General Information ......................... Wheels ............................. Wheel Removal ..........................Wheel Installation ......................... Page vi 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 9 Periodic Lubrication Schedule ......................10b-4 Lubricating The Attachment Arm And Interface ................10b-6 Brake Fluid Reservoir ........................10b-7 Brake Fluid ............................ 10b-7 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page vii...
  • Page 10 SECTION 11C – TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHI- CLES Troubleshooting Guide ........................11c-1 Wiring Diagram ..........................11c-6 Test Procedures ..........................11c-12 Index of Test Procedures ......................11c-12 Page viii 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 11 Fuel Gauge/Hour Meter ........................12b-5 Key Switch ............................12b-6 12-Volt Accessory Receptacle ......................12b-7 Bed Lift Switch ..........................12b-8 Bed Lift Circuit Breaker ........................12b-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page ix...
  • Page 12 Headlights ............................12c-16 Thermostat Switch ........................... 12c-17 Fan ..............................12c-19 Wire Harness Diodes ........................12c-20 Battery .............................. 12c-21 General Information ........................12c-21 Page x 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 13 Clutches ............................13a-27 Clutch Troubleshooting ......................... 13a-27 Drive Belt ............................13a-28 Drive Clutch ..........................13a-29 Driven Clutch ..........................13a-34 Clutch Cover ..........................13a-37 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page xi...
  • Page 14 Air Filter Intake Hose Removal ..................... 13b-27 Air Filter Intake Hose Installation ....................13b-28 Air Filter Outlet Hose Removal ..................... 13b-28 Air Filter Outlet Hose Installation ....................13b-29 Page xii 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 15 Air Filter Intake Hose Removal ..................... 13c-24 Air Filter Intake Hose Installation ....................13c-25 Air Filter Outlet Hose Removal ..................... 13c-26 Air Filter Outlet Hose Installation ....................13c-26 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page xiii...
  • Page 16 SECTION 15 – RADIATOR AND COOLANT SYSTEM (DIESEL) General Information ......................... 15-1 Engine Coolant Level Check ......................15-1 Engine Coolant Change ....................... 15-1 Page xiv 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 17 Hose Installation ........................... 16-24 Quick Connect Fittings (Auxiliary Hydraulic Circuit only) ..............16-25 Quick Connect Removal ....................... 16-25 Quick Connect Installation ......................16-25 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page xv...
  • Page 18 Pump Assembly ........................... 16-44 Reservoir ............................16-47 Motor ............................16-48 Pump ............................16-49 Priming the Pump ......................... 16-49 SECTION i – INDEX Page xvi 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 19: Section 1 - Safety

    • Do not operate engine in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 1-1...
  • Page 20 Forward/Reverse handle in either the FORWARD or REVERSE position. The all-wheel drive system will engage any wheel(s) with traction. See Figure 1-1, Page 1-3. Page 1-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 21 • Do not leave children unattended on vehicle. TO FUSE BLOCK DIESEL VEHICLE SHOWN Remove negative (–) cable first. TO GROUND Figure 1-2 Battery 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 1-3...

  • Page 23: Section 2A - Vehicle Specifications: Honda Gas & Kubota Diesel Powered

    *Overall height (with ROPS): with mud tires 82.3 in. (209 cm) with all-terrain tires 80.3 in. (203.8 cm) Specifications continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 2a-1...
  • Page 24 Fuel tank: diesel grade no.2 with cetane rating of 45 or higher (24.6 L) (24.6 L) TIRE PRESSURE All-terrain tread and mud tires 20 - 22 psi (1.38 - 1.52 Bars) Page 2a-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 25: Intellitach Specifications

    3825 Turning radius (per SAE J 695) 23 ft-10 in. Load bed height 32.5 in. (83 cm) continued on next page... DIMENSIONS/WEIGHT 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 2a-3...
  • Page 26 Hydraulic fluid: ExxonMobil DTE15M (is compatible with Bobcat Hydraulic Fluid) 1.3 gallons (5.0 L) TIRE PRESSURE 20-22 psi All-terrain tread and mud tires (1.38 - 1.52 Bars) Page 2a-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 27: Section 2B - Vehicle Specifications: Kawasaki Gas & Kubota Diesel Powered

    *Overall height (with ROPS): with mud tires 82.3 in. (209 cm) with all-terrain tires 80.3 in. (203.8 cm) Specifications continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 2b-1...
  • Page 28 Fuel tank: diesel grade no.2 with cetane rating of 45 or higher (24.6 L) (24.6 L) TIRE PRESSURE All-terrain tread and mud tires 20 - 22 psi (1.38 - 1.52 Bars) Page 2b-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 29: 295 Homologated Specifications

    NOISE AND VIBRATION SPECIFICATIONS Drive-by noise level to operator 84.4 dBA Drive-by noise level to environment 79.9 dBA Specifications continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 2b-3...
  • Page 30 2220 lb. (1007 kg) Gross vehicle weight limit (GVWR Max): 2756 lb. (1250 kg) 3016 lb. (1368 kg) fully loaded vehicle, accessories included Page 2b-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 31: Intellitach Specifications

    3825 Turning radius (per SAE J 695) 23 ft-10 in. Load bed height 32.5 in. (83 cm) continued on next page... DIMENSIONS/WEIGHT 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 2b-5...
  • Page 32 Hydraulic fluid: ExxonMobil DTE15M (is compatible with Bobcat Hydraulic Fluid) 1.3 gallons (5.0 L) TIRE PRESSURE 20-22 psi All-terrain tread and mud tires (1.38 - 1.52 Bars) Page 2b-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 33: Section 3 - General Information

    The decal is viewable by tilting the pas- senger seat forward. See following NOTE. NOTE: Have the vehicle serial number available when ordering parts or making inquiries. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 3-1...

  • Page 34: Storage

    • Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery. Frozen batteries can explode. ý CAUT ION • Batteries in a low state of charge will freeze at low temperatures. Page 3-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 35: Preparing The Vehicle For Extended Storage

    12. Thoroughly clean the front body, rear body, seats, cargo bed, engine compartment, and underside of vehicle. 13. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 3-3...

  • Page 36: Returning The Stored Vehicle To Service

    6. Perform the Pre-Operation and Daily Safety Checklist. See the Pre-Operation and Daily Safety Checklist in the vehicle owner’s manual. Page 3-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 37: Using A Booster Battery (Jump Starting)

    1. Turn the key switch to the OFF position. Place the Forward/Reverse handle in the NEUTRAL position, engage the park brake, and chock the wheels. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 3-5...
  • Page 38 • Damage to the alternator can result if the following actions occur: - Engine is operated with battery cables disconnected. - Booster cables are connected incorrectly. Figure 3-7 Jump Starting Page 3-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 39: Section 4 - Body And Trim

    30 minutes. Rinse with a water dampened cloth to remove any remaining bleach concentration. See following CAUTION. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 4-1...

  • Page 40: Front Body Repair

    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 bodies. Page 4-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 41: Front Body Components

    Gain access to the rear nut and washer by raising hood and reaching up inside rear of instrument panel. Snap the black plastic cap in place over the exposed hex bolt head. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 4-3...

  • Page 42: Front Fascia Removal

    Tuflok plastic locking screws by using a size P2 Phillips head screwdriver. The outer portion of the Tuflok fastener may be left in the panel at this time. Page 4-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 43: Center Cowl Panel Installation

    4. Grip the front leading edge of the side cowl panel and twist it towards the center of the vehicle and guide the rear side tab of the side cowl panel into the slot in the front, side of the instrument panel. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 4-5...

  • Page 44: Front Fender Flare Removal

    • Do not operate the vehicle if the ROPS is damaged. If the ROPS is damaged, replace the structure. Do not attempt repair. Page 4-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 45: Rops Removal

    4. Remove the two hex-head bolts (24) and two flanged lock nuts (25) securing the top brace (23). Remove top brace from vehicle. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 4-7...

  • Page 46: Rops Installation

    NOTE: It may be necessary to tap the side support tubes (4) with a rubber mallet in order for them to align properly with the front and rear support tubes. Page 4-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 47: Seat

    2. Bucket seats 2.1. Push back and down on the seat back to secure the seat latch to the frame. See preceding WARN- 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 4-9...

  • Page 48: Seat Support Removal

    2. Remove the coiled safety belt assembly. 3. Remove the bolt from the safety belt buckle assembly (center location) (Figure 4-3, Page 4-11). Page 4-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 49: Safety Belt Installation

    5. Remove the locknut, bolt, sleeve, spacers and washers from the base of the bed lift motor and vehicle frame and remove the bed lift motor. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 4-11...

  • Page 50: Bed Lift Motor Installation

    4. Install a nylon locknut on each bolt, and tighten the hardware to 15 ft-lb (21 N·m). 5. Install the electric actuator. See Bed Lift Motor Installation on page 4-12. Page 4-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 51: Cargo Bed - Manual Lift

    6. Lift the bed from the bed latch and, with the prop rod in a slot notch, place the prop rod (17) in the bed mounting hole. Install a flat washer (4) and a new cotter pin (3) onto the prop rod. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 4-13...
  • Page 52 BODY AND TRIM Cargo Bed – Manual Lift TYPICAL 2 PLACES Figure 4-4 Cargo Bed Page 4-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 53: Rear Fender

    2. Roll out and tuck the front edge of the mat under the dash and behind the lower portion of the fenders. 3. Install the two hex screws securing the lower portion of each front fender. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 4-15...

  • Page 55: Section 5 - Accelerator And Brake Pedal Assemblies

    8. Inspect the pedal and return spring hub bushings for excessive side-to-side movement. Replace the pedal assembly if either or both show signs of excessive wear. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 5-1...

  • Page 56: Accelerator Pedal Installation

    7.1. Turn the ground speed set screw clockwise (tightening the spring) to decrease the RPM. 7.2. Turn the ground speed set screw counterclockwise (loosening the spring) to increase the RPM. See following NOTE. Page 5-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 57: Brake Pedal

    5. Connect the battery cables, positive (+) cable first, and tighten the hardware to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 5-3...

  • Page 58: Brake Pedal Adjustment

    2. Secure the pulley mounting plate and park brake pedal assembly with three bolts and locknuts. Tighten the hardware to 15 ft-lb (20 N·m). Page 5-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 59 Battery Terminal Protector Spray (CCI P/N 1014305). 5. Adjust the brake cable equalizer. See Park Brake Cable Adjustment on page 6-25. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 5-5...

  • Page 61: Section 6 - Hydraulic And Park Brake Systems

    See Bleeding the Hydraulic Brake System on page 6-22. • Check the brake fluid level. See Brake Fluid on page 10b-7. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-1...
  • Page 62 See Brake Pads and Caliper on page 6-5. Also See Hydraulic Line Replacement on page 6-17. Page 6-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 63: Brake System Troubleshooting

    Line Replacement on page 6-17. Improperly adjusted master cylinder push See Brake Pedal Adjustment, Section 5, Page 5-4. Troubleshooting Guide continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-3...
  • Page 64 Bent, damaged, or incorrect brake pads scraping sound upon brake application and Caliper on page 6-5. Troubleshooting Guide continued on next page... Page 6-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 65: Brake Pads And Caliper

    • Prior to servicing hydraulic brakes, thoroughly clean the vehicle, paying particular attention to areas immediately surrounding hydraulic connections, to prevent dirt or debris from entering system. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-5...
  • Page 66 (one per bolt). 4. Repeat steps 1 through 3 for the opposite front wheel if necessary. Page 6-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 67: Front Brake Pad And Caliper Installation

    2. Install the tire and wheel. Finger-tighten the lug nuts. 3. Lower the vehicle and use a crisscross pattern to tighten the lug nuts to 85 ft-lb 115 N·m). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-7...

  • Page 68: Rear Brake Pad And Caliper Removal

    3. Remove and discard the two hex-head bolts that secure the caliper assembly to the axle tube and remove the caliper (Figure 6-5, Page 6-9). 4. Repeat steps 1 through 3 for the opposite rear wheel if necessary. Page 6-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 69: Rear Brake Pad And Caliper Installation

    Tighten the hardware to 32 ft-lb (43 N·m). See following NOTE. NOTE: It may be necessary to loosen the park brake adjuster arm on the caliper. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-9...

  • Page 70: Brake Disc And Hub

    4. Remove the axle spindle nut and washer (Figure 6-7, Page 6-11). See following NOTE. NOTE: A new spindle nut will be required during assembly. Page 6-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 71 TION. NOTE: It may be necessary to use a ball joint removal tool to separate the ball joint stud from the upright. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-11...
  • Page 72 11.1. Position the upright (5) with the two ball joint arms down on one steel block (1) and the drag link arm down on a second steel block (1) (Figure 6-12, Page 6-13). Page 6-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 73 The bearing should be flush with the non-lip side of the upright. Figure 6-13 Position Upright for New Bearing Figure 6-14 Press Disc and Hub into Bearing 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-13...

  • Page 74: Front Wheel Disc And Hub Installation

    • Do not allow anti-seize compound to contact the brake disc or pads. 4. Apply anti-seize compound to the upper and lower ball joint studs. Page 6-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 75: Rear Wheel Disc Removal

    9. Slide the splined wheel disc and hub from the axle spindle (Figure 6-17, Page 6-16). See following NOTE. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-15...

  • Page 76: Rear Wheel Disc Installation

    NOTE: It may be necessary to loosen the park brake adjuster arm on the caliper. 8. Install the rubber dust cap. 9. Install the tire and wheel and loosely attach the lug nuts. Page 6-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 77: Hydraulic Line Replacement

    2. Carefully insert the flared end of the brake line end into the master cylinder and tighten the hardware to 132 in-lb (15 N·m). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-17...

  • Page 78: Rear Brake Line Removal

    2. Remove the top screw caps and screws from the dashboard and front body. 3. Open hood. 4. Use a flare-nut wrench to remove the rear brake line at the master cylinder. See following NOTE. Page 6-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 79: Rear Brake Line Installation

    5. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Bleeding the Hydraulic Brake System on page 6-22. 6. Perform all of the brake system inspections. See Brake System Inspection on page 6-1. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-19...

  • Page 80: Master Cylinder And Reservoir

    4. Fill the reservoir with brake fluid specified for this vehicle and bleed the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6-22. 5. Inspect the brake system. See Brake System Inspection on page 6-1. Page 6-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 81: Master Cylinder Removal

    1. Secure the master cylinder to the master cylinder bracket with two bolts and locknuts. Tighten the hard- ware to 16 ft-lb (22 N·m). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-21...

  • Page 82: Bleeding The Hydraulic Brake System

    3. Remove the cap from the master cylinder reservoir and top off the master cylinder with fresh DOT 5 sil- icone brake fluid. NEVER mix DOT 3, DOT 4, or DOT 5.1 with DOT 5 as it IS NOT compatible. Page 6-22 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 83 See following WARNING. Once vehicle is level, place jack stands under the rear axle tubes and lower onto stands. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-23...

  • Page 84: Purging The Hydraulic System

    2. Draw 1 qt. (0.9464 L) of the brake fluid into the vacuum-type brake bleeder tool. 3. With the vacuum running, tighten the two top bleeder valves. Page 6-24 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 85: Park Brake System

    7. Inspect the brake system to ensure that both the hydraulic brake system and the park brake system are adjusted and operating correctly before the vehicle is returned to service. See Brake System Inspec- tion on page 6-1. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-25...

  • Page 86: Park Brake Wheel Cables

    4. Route the cable up and across the air filter box and secure the P-clamp and cable to the top bolt on the filter mounting bracket (Figure 6-23, Page 6-27). Page 6-26 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 87: Front Park Brake Cable Removal

    7. Reach under the driver side wheel well area behind the front wheel and remove the outboard hex-head bolt securing the plastic splash panel. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-27...

  • Page 88: Front Park Brake Cable Installation

    4. Remove the rear park brake cables from the equalizer and remove the equalizer. PARK BRAKE EQUALIZER INSTALLATION 1. Secure the equalizer to the ends of the rear park brake cables (Figure 6-24, Page 6-28). Page 6-28 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 89 5. Secure the extension spring to the end of the threaded end of the cable and the vehicle frame. 6. Adjust the brake cable equalizer. See Park Brake Cable Adjustment on page 6-25. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 6-29...

  • Page 91: Section 7 - Steering And Front Suspension

    7.4. Use a 1/2-inch drive air impact wrench to tighten the anvil screw (6) until the steering wheel releases from the steering shaft. 7.5. Remove the steering wheel from the steering column. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-1...

  • Page 92: Steering Wheel Installation

    NOTE: Bolts are pressed into the steering column mount bracket. 9. Remove the steering column, and pull the shaft up through the hole in the splash guard. Page 7-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 93: Steering Column Installation

    2. Place jack stands under the outer front frame beams, and lower the vehicle onto the stands. See Figure 6-2, Section 6, Page 6-6. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-3...

  • Page 94: Rack And Pinion Installation

    10. Adjust the inner drag link jam nuts, and tighten the hardware to 21 ft-lb (28.4 N·m). 11. Remove the vehicle jack stands, and lower the vehicle to the ground. Page 7-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 95: Rack And Pinion Disassembly

    (5) (Figure 7-16, Page 7-8). 7. Remove the dust seal (Figure 7-10, Page 7-6). 8. Remove the snap ring (4) (Figure 7-11, Page 7-6). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-5...
  • Page 96 13. Inspect the inner ball joints for wear (Figure 7-16, Page 7-8). If either is excessively worn, replace both ball joints. 13.1. Secure the rack and housing assembly in a vise (Figure 7-14, Page 7-7). See following CAU- TION. Page 7-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 97 14. Remove the rack (2) from the housing (1) (Figure 7-16, Page 7-8). Figure 7-14 Secure Racks Figure 7-15 Remove Inner Ball Joints 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-7...
  • Page 98 STEERING AND FRONT SUSPENSION Rack and Pinion TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-16 Steering Gear Assembly Page 7-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 99: Rack And Pinion Assembly

    8. Tap a flange into the notch on the rack. 9. Place a few drops of Loctite 222 on the threads of the screw (7) (Figure 7-18, Page 7-9). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-9...
  • Page 100 (Figure 7-7, Page 7-5). Nuts will be tightened during the toe-in adjustment procedure. See Toe-in Measurement on page 7-11. 20. Install the rack and pinion assembly. See Rack and Pinion Installation on page 7-4. Page 7-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 101: Front Suspension

    (Figure 7-23, Page 7-12). 3. Tighten the jam nuts to 21 ft-lb (28 N·m). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-11...
  • Page 102 1. Locate the bolts that secure the flat camber adjustment bar in position at the underside of the lower A- arm. Loosen the bolts just enough to allow the bar to move with some resistance (Figure 7-25, Page 7-13). Page 7-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 103: Front Suspension Components

    • Strain on the brake hose or the brake hose fittings can result in damage to the line or fittings and cause a leak in the hydraulic system, diminished brake performance, or brake failure. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-13...

  • Page 104: Upper A-Arm Removal

    1. Chock the rear wheels, set the park brake, loosen the front wheel lug nuts, and lift the front of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2. Page 7-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 105 2. Install the C-clip. Verify that the C-clip is seated in the groove of the ball joint. 3. Allow the Loctite to set up for at least 20 minutes before assembling the front suspension. See following NOTE. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-15...

  • Page 106: Upper A-Arm Installation

    5. Remove the bolt, washer, and flanged locknut from the lower A-arm and frame. 6. Remove the A-arm from the frame and the bushings. Page 7-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 107: Lower A-Arm Installation

    3. Slide the A-arm over the frame bushings, and locate the bolt alignment. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-17...

  • Page 108: Front Coil-Over Shock Absorber Removal

    6. Remove the bolt and flanged locknut from the top of the shock mount. Remove the shock absorber. 7. Repeat steps 3 through 6 for the remaining shock absorber. Figure 7-34 Jack Stand Placement Page 7-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 109: Front Coil-Over Shock Absorber Installation

    9. Secure the bottom end of the shock absorber to the A-arm with new flanged bolt. Tighten the hardware to 85 ft-lb (115 N·m). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-19...
  • Page 110 14. Tighten the spindle nut and washer to 150 ft-lb (203 N·m). 15. Align the front wheels, and adjust the toe-in and the camber. See Wheel Alignment on page 7-11. Page 7-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 111: Section 8 - Wheels And Tires

    • Keep the front end properly aligned and adjusted. • Inspect the brake hoses at all four wheels. The hoses should not come in contact with any component. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 8-1...

  • Page 112: Wheels

    2. Remove the valve cap and valve core and allow air to escape from the tire. 3. Use a tire machine to remove the tire from the wheel. Page 8-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 113: Tire Installation

    See General Information on page 8-1. 5. Install the valve cap. 6. Install the wheel. See Wheel Installation on page 8-2. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 8-3...

  • Page 115: Section 9 - Rear Suspension

    Use the adjustment position of the existing shock absorbers as a reference. 9. Repeat steps 5 through 8 for the remaining shock absorber. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 9-1...

  • Page 116: Swing Arms

    3. Remove the swing arm bolt and grease fitting (Figure 9-4, Page 9-3). See following NOTE. NOTE: Do not hammer against the threaded end of the swing arm bolt. 4. Remove the swing arm. Page 9-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 117: Swing Arm Installation

    6. Attach a new rue pin to the pivot bolt. 7. Install the rear axle. See Rear Axle Installation, Section 14, Page 14-10. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 9-3...

  • Page 119: Section 10A - Periodic Maintenance: Honda Gasoline & Kubota Diesel Powered Vehicles

    See Performance Inspection in the vehicle owner’s manual. Hydraulic System (IntelliTach vehicle only) Check hydraulic fluid; add if necessary. Periodic Service Schedule continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10a-1...
  • Page 120 Checklist in the Owner’s Manual. See also Section 6 – Hydraulic and Park Brake Systems Periodic Service Schedule continued on next page... Page 10a-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 121 • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10a-3...

  • Page 122: Periodic Lubrication Schedule

    20 oz. (600 mL) Mobil 424, Exxon whichever comes first Change transmission lubricant Hydraul 560, or Esso Hydraul 56 lubricant Page 10a-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 123 Periodic Lubrication Schedule FLOORBOARD Figure 10a-1 Lubrication Points – Gasoline Vehicles FLOORBOARD * IntelliTach Vehicle Only Figure 10a-2 Lubrication Points – Diesel Vehicles 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10a-5...

  • Page 124: Lubricating The Attachment Arm And Interface

    4. Attachment Arm Pivot - interface side (both sides). Figure 10a-3 Lubricate Grease Zerks located on Cylin- der and Attachment Arm Ends Page 10a-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 125: Brake Fluid Reservoir

    The gasoline engine has an oil filter that is mounted on a bracket next to the back side of the front panel. Inlet and outlet oil-carrying hoses enable oil circulation to and from the engine. See following NOTE. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10a-7...

  • Page 126: Engine Oil Level Check

    1. Turn the key switch to the OFF position and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the front wheels. Page 10a-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 127 (40 N·m) for gasoline vehicles, 31 ft-lb (42 N·m) for diesel vehicles. Figure 10a-8 Engine Oil Drain Plug and Pan – Figure 10a-9 Replace Engine Oil Filter – Gasoline Vehicles Gasoline Vehicles 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10a-9...
  • Page 128 Dispose of used oil according to the environmental laws and regulations for your area. Page 10a-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 129 6. Tighten the oil filter by hand 2/3 turn after gasket contact. Do not use a band wrench or channel lock pli- ers. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10a-11...

  • Page 130: Oil Viscosity

    SAE 10W SAE 10W-30 SAE 10W-30/SAE 10W-40 SAE 5W-30 Figure 10a-15 Oil Viscosity Chart – Gasoline Figure 10a-16 Oil Viscosity Chart – Diesel Page 10a-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 131: Gearcase Lubrication

    Check the level of lubricant at the level indicator plug (1). Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft-lb (28 N·m). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10a-13...
  • Page 132 Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft-lb (28 N·m). Figure 10a-19 Rear Differential Lubrication Level Page 10a-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 133: Hydraulic System - Intellitach Vehicle

    9. If hydraulic oil must be added, thoroughly clean the area around the fill cap. Remove the fill cap and add hydraulic fluid until it is between the Maximum Fluid Level and the Minimum Fluid Level lines. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10a-15...

  • Page 134: Engine Coolant - Diesel Vehicles

    Biodiesel is an excellent medium for microbial growth and contamination. Microbial contamination can cause corrosion of the fuel system and prematurely plugged fuel filters. See following NOTE. Page 10a-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 135: Draining Water From Fuel Filter

    3. Locate the valve (1) on the underside of the filter. Turn the valve clockwise until water begins to stream from the filter. 4. Drain the water until it changes color (to fuel). See following WARNING. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10a-17...

  • Page 136: Battery

    Drain Valve Figure 10a-22 Fuel Filter BATTERY For periodic battery maintenance, see Battery on page 12b-15 (gasoline vehicles) or page 12c-21 (diesel vehicles). Page 10a-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 137: Section 10B - Periodic Maintenance: Kawasaki Gasoline & Kubota Die

    Lubrication Schedule. Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep the vehicle in optimum operating condition. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10b-1...
  • Page 138 Checklist in the Owner’s Manual. See also Section 6 – Hydraulic and Park Brake Systems Periodic Service Schedule continued on next page... Page 10b-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 139 • If any problems are found during scheduled inspection or service, do not operate vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10b-3...

  • Page 140: Periodic Lubrication Schedule

    20 oz. (600 mL) Mobil 424, Exxon whichever comes first Change transmission lubricant Hydraul 560, or Esso Hydraul 56 lubricant Page 10b-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 141 Periodic Lubrication Schedule FLOORBOARD Figure 10b-1 Lubrication Points – Gasoline Vehicles FLOORBOARD * IntelliTach Vehicle Only Figure 10b-2 Lubrication Points – Diesel Vehicles 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10b-5...

  • Page 142: Lubricating The Attachment Arm And Interface

    4. Attachment Arm Pivot - interface side (both sides). Figure 10b-3 Lubricate Grease Zerks located on Cylin- der and Attachment Arm Ends Page 10b-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 143: Brake Fluid Reservoir

    The Kawasaki gasoline engine has an oil filter that is mounted on a bracket between and in front of the engine and transmission. Inlet and outlet oil-carrying hoses enable oil circulation to and from the engine. See follow- ing NOTE. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10b-7...

  • Page 144: Engine Oil Level Check

    • Kubota diesel engine after the first 50 hours of operation. After that, the oil should be changed every 100 hours of operation or annually, whichever comes first. Page 10b-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 145 Figure 10b-8 Engine Oil Drain Plug and Pan – Figure 10b-9 Replace Engine Oil Filter – Gasoline Vehicles Kawasaki Powered Gasoline Vehicles 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10b-9...
  • Page 146 Gasoline Vehicles 4. Use a clean, lint-free rag to wipe the oil filter port flange surface clean where the oil filter gasket seats. Page 10b-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 147: Oil Viscosity

    Using multi-grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. If multi-grade oil is used, check the oil level more frequently. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10b-11...

  • Page 148: Spark Plugs

    2. If the gap is incorrect, carefully bend the side electrode with a suitable tool to obtain the correct gap. • Spark Plug Gap: 0.030 in. (0.75 mm) Page 10b-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 149: Gearcase Lubrication

    See Periodic Lubrication Schedule on page 10b-4. Apply Loctite 567 to the threads of the fill plug and tighten to 21 ft-lb (28 N·m). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10b-13...
  • Page 150 Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft-lb (28 N·m). Figure 10b-18 Rear Differential Lubrication Level Page 10b-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 151: Hydraulic System - Intellitach Vehicle

    9. If hydraulic oil must be added, thoroughly clean the area around the fill cap. Remove the fill cap and add hydraulic fluid until it is between the Maximum Fluid Level and the Minimum Fluid Level lines. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10b-15...

  • Page 152: Engine Coolant - Diesel Vehicles

    Biodiesel is an excellent medium for microbial growth and contamination. Microbial contamination can cause corrosion of the fuel system and prematurely plugged fuel filters. See following NOTE. Page 10b-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 153: Draining Water From Fuel Filter

    3. Locate the valve (1) on the underside of the filter. Turn the valve clockwise until water begins to stream from the filter. 4. Drain the water until it changes color (to fuel). See following WARNING. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 10b-17...

  • Page 154: Battery

    Figure 10b-21 Fuel Filter BATTERY For periodic battery maintenance, see Battery on page 12a-17 (gasoline vehicles) or page 12c-21 (die- sel vehicles). Page 10b-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 155: Section 11A - Troubleshooting And Electrical System: Kawasaki Powered Gasoline Vehicles

    Test Procedure 8E – Diode 5 on wire 131 Diode 5 failed open and 129 on page 11a-22 Troubleshooting Guide continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-1...
  • Page 156 Spark plug heat range is incorrect Spark Plugs on page 10b-12 Unsuitable or contaminated fuel Fuel System on page 13a-9 Troubleshooting Guide continued on next page... Page 11a-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 157 Test Procedure 1 – Battery on page 11a-9 Test Procedure 13 – Charge Coil on Charge coil failed page 11a-25 Troubleshooting Guide continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-3...
  • Page 158 13a-30 Section 13a – Kawasaki Gasoline Engine, Governor is sticking Muffler, Fuel System, and Clutches Troubleshooting Guide continued on next page... Page 11a-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 159 Bed lift switch failed page 11a-40 Test Procedure 31 – Bed Lift Circuit Bed lift circuit breaker failed Breaker on page 11a-41 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-5...

  • Page 160: Wiring Diagram

    (Style A) 18_ORG(W23) 18_BLU(W41) 18_BLK(W16) DETAIL 000662-001 Figure 11a-1 Wiring Diagram – Kawasaki Powered Gasoline Carryall 295 and XRT 1550 Vehicles (Front) Page 11a-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 161 Wiring Diagram DIODE 4 DIODE 5 000662-001 Figure 11a-2 Wiring Diagram – Kawasaki Powered Gasoline Carryall 295 and XRT 1550 Vehicles (Rear) 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-7...

  • Page 162: Test Procedures

    26. Hour Meter 27. Light Switch 28. Voltage at Headlight Socket 29. Bed Lift Motor 30. Bed Lift Switch 31. Bed Lift Circuit Breaker Page 11a-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 163 Remove the hydrometer from the cell and release pres- sure from the bulb. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-9...
  • Page 164 When the variations between cells reach 0.050 or more, the battery should be replaced. Page 11a-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 165 8. If the reading is less than 9.6 volts at 70 °F (21 °C) (electrolyte temperature), check the battery electrolyte in each cell. See Test Procedure 1A – Hydrometer Test on page 11a-9. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-11...

  • Page 166: Test Procedures

    General Warning, Section 1, Page 1-1. 3. Check the frame ground for corrosion, loose connections, and/or damaged terminals (Figure 11a-6, Page 11a-13). Repair or replace as required. Page 11a-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 167 (L) terminal of the key switch. The reading should indicate continuity. If the reading does not indicate continuity, replace the key switch (Figure 11a-8, Page 11a-14). See Key Switch Removal, Section 12a, Page 12a-7. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-13...
  • Page 168 5. Monitor the multimeter. The reading should indicate 0 volts with the key in the OFF and ON positions. The reading should indicate approximately 12 VDC when the key is in the START position. Page 11a-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 169 NOTE: The carburetor heater and accessory relays (if equipped with accessory relay) may be removed to isolate the sound of the start relay click. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-15...
  • Page 170 1. Turn the key switch OFF. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Set the multimeter to 20 VDC. Page 11a-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 171 (Transmission) on page 11a-22. • Check for continuity of the wire harness on wires w139, w135, and w47. See Wiring Diagram on page 11a-6. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-17...
  • Page 172 The wire harness is equipped with several in-line diodes. The following table describes each diode’s function in the electrical system, the location in the wire harness, and the symptom(s) of a diode failure. Page 11a-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 173 See Wire Harness Diode Removal, Section 12a, Page 12a-16. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-19...
  • Page 174 10. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12a, Page 12a-16. Figure 11a-16 Carburetor Solenoid Bullet Connector Page 11a-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 175 See Wire Harness Diode Removal, Section 12a, Page 12a-16. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-21...
  • Page 176 4. Check for continuity on the switch contacts with the Forward/Reverse handle in the FORWARD position (Figure 11a-18, Page 11a-23). The multimeter should indicate no continuity. Page 11a-22 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 177 (Figure 11a-20, Page 11a-23). The multimeter should indicate no continuity. 7. If any of the continuity readings are incorrect, replace the neutral switch. See Neutral Switch Removal on page 12a-2. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-23...
  • Page 178 4. Place the red (+) probe of the multimeter on one terminal and the black (–) probe on the other terminal of the switch. With the accelerator pedal fully released, the reading should be no continuity. Page 11a-24 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 179 5. If the resistance is high, or the multimeter indicates an over limit (no continuity), the coil has failed. See the Kawasaki FH680D engine manual (CCI P/N 103351201). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-25...
  • Page 180 2. Remove the spark plug wire from one of the spark plugs. 3. Use an ignition spark gap test tool (Thexton 404 or equivalent) to check for correct spark. Page 11a-26 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 181 Test Procedure 18 – Key Switch (Engine Kill Circuit) on page 11a-28. Figure 11a-23 Engine Harness Connector Figure 11a-24 Engine Kill Wire 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-27...
  • Page 182 6. Reconnect the key switch to the wire harness. Ensure that the connector is connected correctly and is tight. If it is not, repair or replace as necessary. Page 11a-28 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 183 3. Move the Forward/Reverse handle to REVERSE and listen for an audible click from the limit switch. If there is no click, check the switch for proper alignment and switch arm movement. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-29...
  • Page 184 • Diode 4. See Test Procedure 8D – Diode 4 on wire 130 and 122 on page 11a-21. 2. Check the carburetor solenoid coil. Page 11a-30 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 185 7. Touch the frame (ground) with the remaining end of the jumper wire. 8. Turn the key switch to the ON position. The low oil warning light should illuminate. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-31...
  • Page 186 4. With a multimeter set to 2k ohms, place the red (+) probe on the center post of the sending unit. Place the black (–) probe on the ground connection of the sending unit (Figure 11a-28, Page 11a-33). Page 11a-32 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 187 8. If the readings are correct according to the position of the float, but the reading on the fuel gauge/hour meter is incorrect, test the fuel gauge/hour meter. See Test Procedure 25 – Fuel Gauge on page 11a-34. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-33...
  • Page 188 (Figure 11a-32, Page 11a-35). The voltage reading should be approximately 1.81 volts. If the reading is incorrect, replace the fuel gauge/hour meter. Page 11a-34 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 189 20 VDC BLACK SETTING Figure 11a-33 Fuel Gauge Voltage Test - Terminal 2 Figure 11a-34 Fuel Gauge Voltage Test - Terminal 4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-35...
  • Page 190 NOTE: The hour meter is designed to record actual engine running time and will not start adding incre- ments until the engine is running and the oil pressure switch has opened. Page 11a-36 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 191 Check the fuse. See Test Procedure 2 – Fuse on page 11a-12. If the wires and fuse show continuity and the readings are still incorrect, replace the switch. See Light Switch Removal, Section 12a, Page 12a-10. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-37...
  • Page 192 8. Check the continuity of the headlight jumper harness wires. 9. If the readings are correct in all of the previous steps, replace the headlight bulb. Page 11a-38 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 193 • A reading of approximately + (positive) 12 VDC indicates that the bed lift harness and switch are wired correctly. Proceed to step 6. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-39...
  • Page 194 • A reading of approximately – (negative) 12 VDC indicates that the bed lift harness or switch are wired incorrectly. Check the wiring of the bed lift harness and bed lift switch. See Wiring Diagram on page 11a-6. • A reading of approximately 0 VDC indicates a failed bed lift switch, failed bed lift circuit breaker, a poor connection in the bed lift wire harness, or a broken wire.
  • Page 195 2. Place the red probe of the multimeter on the circuit breaker terminals. If the multimeter does not indicate continuity, replace the circuit breaker. See Bed Lift Circuit Breaker Installation, Section 12a, Page 12a-9. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-41...
  • Page 197 Test Procedure 9C – Diode 3 on wire 45 Diode 3 failed open on page 11b-21 Troubleshooting Guide continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-1...
  • Page 198 Spark plug heat range is incorrect (CCI P/N 102615401). Unsuitable or contaminated fuel Fuel System on page 13b-7 Troubleshooting Guide continued on next page... Page 11b-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 199 Test Procedure 1 – Battery on page 11b-9 Test Procedure 13 – Charge Coil on Charge coil failed page 11b-26 Troubleshooting Guide continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-3...
  • Page 200 Drive Belt Removal on page 13b-31 smoothly. frayed Drive Clutch Cleaning and Inspection on Drive clutch malfunction page 13b-32 Troubleshooting Guide continued on next page... Page 11b-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 201 Bed lift switch failed page 11b-39 Test Procedure 31 – Bed Lift Circuit Bed lift circuit breaker failed Breaker on page 11b-40 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-5...
  • Page 202 DIODE 3 DIODE 2 DIODE 1 000535-001 Figure 11b-1 Wiring Diagram – Honda Powered Gasoline Carryall 295 and XRT 1550 Vehicles (Front) Page 11b-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 203 TROUBLESHOOTING AND ELECTRICAL SYSTEM: HONDA POWERED GASOLINE VEHICLES Wiring Diagram DIODE 7 000535-001 Figure 11b-2 Wiring Diagram – Honda Powered Gasoline Carryall 295 and XRT 1550 Vehicles (Rear) 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-7...

  • Page 204: Index Of Test Procedures

    26. Hour Meter 27. Light Switch 28. Voltage at Headlight Socket 29. Bed Lift Motor 30. Bed Lift Switch 31. Bed Lift Circuit Breaker Page 11b-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 205 Remove the hydrometer from the cell and release pres- sure from the bulb. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-9...
  • Page 206 When the variations between cells reach 0.050 or more, the battery should be replaced. Page 11b-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 207 8. If the reading is less than 9.6 volts at 70 °F (21 °C) (electrolyte temperature), check the battery electrolyte in each cell. See Test Procedure 1A – Hydrometer Test on page 11b-9. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-11...
  • Page 208 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. Page 11b-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 209 3. Ensure that the key switch connector is connected correctly and is tight. If it is not, repair or replace as necessary. 4. Remove the key switch. See Key Switch Removal, Section 12b, Page 12b-6. 5. Set the multimeter to 200 ohms. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-13...
  • Page 210 Page 11b-14). The reading should indicate continuity. If the reading does not indicate continuity, replace the key switch. See Key Switch Removal, Section 12b, Page 12b-6. Page 11b-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 211 7. If none of the previous steps resolves the problem, the starter solenoid and/or starter motor has failed. See the Honda GX620 engine manual (CCI P/N 102615401). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-15...
  • Page 212 7.4. If the multimeter does not indicate continuity while the key is in the START position and the relay clicks, the contacts have failed. Replace the relay. Figure 11b-12 Start Relay Coil Circuit Test Figure 11b-13 Start Relay Contact Test Page 11b-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 213 4. Place the probes to measure the voltage between the 18-gauge purple differential relay wire (w135) ter- minal and the frame ground. Figure 11b-14 Differential Relay Coil Circuit Test Figure 11b-15 Differential Relay Contact Test 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-17...
  • Page 214 The wire harness is equipped with several in-line diodes. The following table describes each diode’s function in the electrical system, the location in the wire harness, and the symptom(s) of a diode failure. Page 11b-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 215 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-19...
  • Page 216 7. Connect the red (+) probe of the multimeter to the 18-gauge yellow wire (w123) at the bullet connector (wire harness side). Page 11b-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 217 General Warning, Section 1, Page 1-1. 3. Remove the start relay, differential relay, and accessory relay from the multi-pin connector located on the electrical component mounting plate. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-21...
  • Page 218 4. Disconnect the two-pin connector between the neutral switch and the wire harness (Figure 11b-17, Page 11b-22). ç 5. Set the multimeter to the diode test function ( Page 11b-22 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 219 4. Disconnect the multi-pin connector between the voltage regulator and the wire harness. 5. Disconnect the 16-gauge green wire (w127) from the starter solenoid coil (Figure 11b-10, Page 11b-15). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-23...
  • Page 220 (Figure 11b-18, Page 11b-24). The multimeter should indicate no continuity. Figure 11b-18 Neutral Switch – Forward Position Figure 11b-19 Neutral Switch – Neutral Position Page 11b-24 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 221 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Disconnect the battery as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-25...
  • Page 222 Honda GX620 engine manual (CCI P/N 102615401). Figure 11b-21 Charge Coil Test (At Voltage Regulator Figure 11b-22 Charge Coil Test (At Bullet Connectors) Multi-Pin Connector) Page 11b-26 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 223 Install a new spark plug set to the proper gap setting and test the engine for proper operation. See the Honda GX620 engine manual (CCI P/N 102615401). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-27...
  • Page 224 (Figure 11b-23, Page 11b-28). See following NOTE. NOTE: Disconnecting the engine kill wire removes the engine ignition circuit from the vehicle start/stop cir- cuit. Page 11b-28 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 225 200nA 1000 --- FUSED 750V Reading with key switch in the OFF position Figure 11b-24 Key Switch Test – Engine Kill Circuit 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-29...
  • Page 226 Page 11b-6. If the buzzer does not function when properly wired, replace the buzzer. See Reverse Warning Buzzer Removal, Section 12b, Page 12b-10. Page 11b-30 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 227 (Figure 11b-26, Page 11b-32) The resistance should be approximately 37.5 ohms. 2.5. If the resistance reading is incorrect, replace the solenoid coil. See the Honda GX620 engine manual (CCI P/N 102615401). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-31...
  • Page 228 11. If the problem is not corrected by performing the previous steps, test the oil pressure switch. See the Honda GX620 engine manual (CCI P/N 102615401). Page 11b-32 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 229 (–) probe on the ground connection of the sending unit (Figure 11b-27, Page 11b-33). Figure 11b-27 Fuel Level Sending Unit Test 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-33...
  • Page 230 6. 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 11b-28, Page 11b-35). Page 11b-34 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 231 6. If the hour meter still does not function after the low oil warning light, oil pressure switch, and all of the appropriate wires have been checked for continuity, replace the fuel gauge/hour meter. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-35...
  • Page 232 2. Inspect the wires at the light bulb socket. Make sure the wires are securely fastened to the contacts inside the socket. Page 11b-36 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 233 12 volts, the black wire has continuity. 8. If the readings are correct in all of the previous steps, replace the headlight bulb. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-37...
  • Page 234 • A reading of approximately + (positive) 12 VDC indicates that the bed lift harness and switch are wired correctly. Proceed to step 6. Page 11b-38 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 235 Terminal 4 Terminal 8 #14 Red w7 #14 Black w2 Down Position REAR VIEW OF SWITCH Figure 11b-35 Bed Lift Switch Terminals 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11b-39...
  • Page 236 2. Place the red probe of the multimeter on the circuit breaker terminals. If the multimeter does not indicate continuity, replace the circuit breaker. See Bed Lift Circuit Breaker Installation, Section 12b, Page 12b-8. Page 11b-40 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 237 (CCI P/N 102615501). Improper valve timing Piston ring worn Cylinder compression leak Troubleshooting Guide continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-1...
  • Page 238 Throttle linkage out of adjustment Engine Control Linkages on page 13c-19 Restricted fuel flow Fuel System on page 13c-8 Troubleshooting Guide continued on next page... Page 11c-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 239 Coolant lines corroded Section 15 – Radiator and Coolant System (Diesel) Failed radiator cap Replace radiator cap. Troubleshooting Guide continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-3...
  • Page 240 See the Engines and Drivetrain Internal gears are damaged or worn Components manual (CCI P/N 102396501). Troubleshooting Guide continued on next page... Page 11c-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 241 Bed lift switch failed page 11c-52 Test Procedure 36 – Bed Lift Circuit Bed lift circuit breaker failed Breaker on page 11c-53 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-5...
  • Page 242 Wiring Diagram WIRING DIAGRAM DIODE 3 000535-002 Figure 11c-1 Wiring Diagram (2 Piece Harness) for Diesel Carryall 295 and XRT 1550 Vehicles (Front) Page 11c-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 243 Wiring Diagram DIODE 5 DIODE 4 000535-002 Figure 11c-2 Wiring Diagram (2 Piece Harness) for Diesel Carryall 295 and XRT 1550 Vehicles (Rear) 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-7...
  • Page 244 Wiring Diagram FRONT DIFFERENTIAL LIMIT SWITCH Figure 11c-3 Wiring Diagram (1 Piece Harness) for Diesel Carryall 295 and XRT 1550 Vehicles (Front) Page 11c-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 245 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Wiring Diagram DIODE 5 Figure 11c-4 Wiring Diagram (1 Piece Harness) for Diesel Carryall 295 and XRT 1550 Vehicles (Rear) 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-9...
  • Page 246 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Wiring Diagram Figure 11c-5 Main Light Wiring Diagram – Carryall 295 Homologated Vehicle Page 11c-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 247 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Wiring Diagram Figure 11c-6 High Beam Wiring Diagram – Carryall 295 Homologated Vehicle 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-11...
  • Page 248 31. Hour Meter 32. Light Switch 33. Voltage at Headlight Socket 34. Bed Lift Motor 35. Bed Lift Switch 36. Bed Lift Circuit Breaker Page 11c-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 249 Remove the hydrometer from the cell and release pres- sure from the bulb. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-13...
  • Page 250 When the variations between cells reach 0.050 or more, the battery should be replaced. Page 11c-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 251 8. If the reading is less than 9.6 volts at 70 °F (21 °C) (electrolyte temperature), check the battery electrolyte in each cell. See Test Procedure 1A – Hydrometer Test on page 11c-13. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-15...
  • Page 252 Use the appropriately rated fuse; if a fuse with a higher amp rating is used, damage to the vehicle electrical system may occur. Figure 11c-9 Electrical Component Mounting Plate Page 11c-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 253 If the connections are good and the reading is incorrect, repair or replace the wire. Figure 11c-10 Frame Ground Figure 11c-11 Engine Ground (Under Starter) 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-17...
  • Page 254 8. Check the BATT and ACC key switch terminals. 8.1. Use alligator clips to connect the multimeter probes between the BATT and ACC terminals. With the Page 11c-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 255 6.2. If the multimeter indicates continuity between the BATT and ACC terminals with the key in any posi- tion other than PREHEAT, the key switch has failed and should be replaced. See Key Switch Removal, Section 12c, Page 12c-7. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-19...
  • Page 256 7. If none of the previous steps resolves the problem, the starter solenoid and/or starter motor has failed. See the Kubota D722 diesel engine manual (CCI P/N 102615501). Page 11c-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 257 The multimeter should indicate continuity when the key is in the START position. 7.4. If the multimeter does not indicate continuity while the key is in the START position and the relay 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-21...
  • Page 258 (Figure 11c-17, Page 11c-22). Figure 11c-17 Differential Relay Coil Circuit Test Figure 11c-18 Differential Relay Contact Test Page 11c-22 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 259 3.2. Monitor the multimeter. The reading should indicate 0 volts with the key in the OFF position. If not, check for a short or incorrect wiring between the yellow fan relay wire (w146) terminal and the key 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-23...
  • Page 260 5. If the fan runs constantly, even with the key switch OFF, remove the relay. If fan stops, the relay contacts have failed closed and the relay must be replaced. Page 11c-24 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 261 4.6. The multimeter should indicate an over limit (no continuity) at room temperature. If the multimeter indicates continuity at room temperature, replace the thermostat switch. See Thermostat Switch Removal, Section 12c, Page 12c-17. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-25...
  • Page 262 See Thermostat Switch Installation, Section 12c, Page 12c-18. 6.9. Turn off the stove. See following WARNING. ý WARNING • Allow surfaces to cool adequately before touching them. Page 11c-26 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 263 6. Set a multimeter to measure 20 VDC. 7. Place the multimeter probes into each terminal of the two-pin connector disconnected from the fan motor (wire harness side). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-27...
  • Page 264 NOTE: If a diode conducts current in both directions, the diode has failed closed. If a diode will not conduct current in either direction, the diode has failed open (Figure 11c-25, Page 11c-29). Page 11c-28 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 265 May allow the vehicle to be started Closed when Forward/Reverse handle is in FORWARD or REVERSE positions. Troubleshooting Guide continued on next page... 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-29...
  • Page 266 9. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12c, Page 12c-20. Page 11c-30 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 267 7. Connect the red (+) probe of the multimeter to the 18-gauge black wire (w139) on the multi-pin differential relay connector located on the electrical component mounting plate. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-31...
  • Page 268 See Wire Harness Diode Removal, Section 12c, Page 12c-20. Page 11c-32 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 269 7. Disconnect the bullet connector, on the gray wire (w140), between the fuel pump and the wire harness (Figure 11c-30, Page 11c-34). ç 8. Set the multimeter to the diode test function ( 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-33...
  • Page 270 9. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12c, Page 12c-20. Page 11c-34 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 271 7. If any of the continuity readings are incorrect, replace the neutral switch. See Neutral Switch Removal, Section 12c, Page 12c-2. Figure 11c-31 Neutral Switch – Forward Position 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-35...
  • Page 272 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Check for proper wiring and tight connections at the front differential limit switch (Figure 11c-34, Page 11c-37). Page 11c-36 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 273 2. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-37...
  • Page 274 7. Place the red (+) probe on the fusible link ring terminal atttached to the alternator stud. The reading should indicate approximately 12 VDC (or full battery voltage). Page 11c-38 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 275 0 (zero) VDC with the key in the OFF position and approximately 12 VDC with the key switch in the ON position. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-39...
  • Page 276 6. Monitor the multimeter and turn the key to the PREHEAT position. Hold it for 5 seconds. The multimeter should indicate 11 to 12 VDC. Figure 11c-37 Glow Plug Circuit Test Page 11c-40 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 277 If either reading is incorrect, replace the limit switch (Figure 11c-38, Page 11c-41). Figure 11c-38 Reverse Warning Buzzer and Limit Switch 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-41...
  • Page 278 2. Disconnect the three-pin connector between the fuel solenoid and the wire harness (Figure 11c-29, Page 11c-34). 3. Set a multimeter to 20 VDC. Page 11c-42 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 279 • Wire continuity of wires w140, w121, w48, w37, w24, w125, w126, and w201. See Test Procedure 15 – Wire Continuity on page 11c-36. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-43...
  • Page 280 See Test Procedure 2 – Fuse on page 11c-16. 5. If the fuse is good, check the continuity of the wires connected to the accessory receptacle. Page 11c-44 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 281 240 ± 20 ohms Empty Center position (tank half full) 120 ± 20 ohms Half full Upper position (tank full) 60 ± 20 ohms Full 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-45...
  • Page 282 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Raise the hood. 3. Disconnect the orange wire (w104) from the fuel gauge/hour meter. Page 11c-46 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 283 (Figure 11c-45, Page 11c-48). The voltage reading should be approximately 4.94 volts. If the reading is incorrect, replace the fuel gauge/hour meter. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-47...
  • Page 284 Test Procedure 31B – Hour Meter (Late 2007) 1. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. Page 11c-48 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 285 Check the fuse. See Test Procedure 2 – Fuse on page 11c-16. If the wires and fuse show continuity and the readings are still incorrect, replace the switch. See Light Switch Removal, Section 12c, Page 12c-9. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-49...
  • Page 286 12 volts, the black wire has continuity. 8. If the readings are correct in all of the previous steps, replace the headlight bulb. Page 11c-50 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 287 • A reading of approximately + (positive) 12 VDC indicates that the bed lift harness and switch are wired correctly. Proceed to step 6. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-51...
  • Page 288 Terminal 4 Terminal 8 #14 Red w7 #14 Black w2 Down Position REAR VIEW OF SWITCH Figure 11c-51 Bed Lift Switch Terminals Page 11c-52 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 289 2. Place the red probe of the multimeter on the circuit breaker terminals. If the multimeter does not indicate continuity, replace the circuit breaker. See Bed Lift Circuit Breaker Installation, Section 12c, Page 12c-9. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11c-53...

  • Page 291: Starter And Starter Solenoid

    See Test Procedure 6, Section 11a, Page 11a-15. See also Test Procedure 7 – Carburetor Heater Relay on page 11a-16. Figure 12a-1 Relays Figure 12a-2 Neutral Switch 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12a-1...

  • Page 292: Neutral Switch

    Carburetor Solenoid Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. Page 12a-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 293: Carburetor Heater

    3. Remove the top cover from the engine. 4. Disconnect the green wire from the carburetor heater (1) (Figure 12a-4, Page 12a-4). 5. Remove the heater from the carburetor. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12a-3...

  • Page 294: Voltage Regulator

    3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12a-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 295: Warning Lights

    4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12a-5...

  • Page 296: Fuel Gauge/Hour Meter

    2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 3. Raise the hood. Page 12a-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 297: Key Switch

    5. Reach under the instrument panel to hold the key switch and remove the key switch nut (7) (Figure 12a-6, Page 12a-6). Pull the key switch, with spacer (8), from the back side of the instrument panel. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12a-7...

  • Page 298: Volt Accessory Receptacle

    4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12a-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 299: Bed Lift Switch

    3. Pull the circuit breaker out of the in-line fuse holder to remove. Bed Lift Circuit Breaker Installation Install the circuit breaker in the reverse order of removal. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12a-9...

  • Page 300: Light Switch

    Use the appropriately rated fuse; if a fuse with a higher amp rating is used, damage to the vehicle electrical system may occur. Page 12a-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 301: Reverse Warning Buzzer (If Equipped)

    5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12a-11...

  • Page 302: Reverse Warning Buzzer Limit Switch (If Equipped)

    5. Hold the limit switch in position and tighten the mounting screws and nuts to 4 in-lb (0.5 N·m). See fol- lowing CAUTION. Page 12a-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 303: Front Differential Limit Switch

    5. Remove the nuts (2) and screws (3) that secure the switch (1) and remove the switch. Figure 12a-10 Front Differential Limit Switch Removal 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12a-13...

  • Page 304: Fuel Level Sending Unit

    Refer to the engine manual for additional testing, removal, disassembly, and installation procedures. See the Kawasaki FH680D engine manual (CCI P/N 103351201). Page 12a-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 305: Oil Pressure Sensor

    1. Attach the connector harness to the halogen bulb. The retaining tab should lock onto the halogen bulb (Figure 12a-11, Page 12a-15). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12a-15...

  • Page 306: Wire Harness Diodes

    7. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12a-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 307: Battery

    4. Check the battery periodically to ensure that it is in a full state of charge. See Charging the Battery on page 12a-19. 5. Keep the battery hold-down clamp tight. See Vibration Damage on page 12a-18. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12a-17...
  • Page 308 General Warning, Section 1, Page 1-2. 3. Remove the driver-side seat. 4. Remove the battery hold-down located on the bottom of the battery. Page 12a-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 309 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 3. Fully charge the battery prior to storage. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12a-19...
  • Page 310 See following WARNING. ý WARNING • Do not jump-start a dead battery with another battery and jumper cables. Page 12a-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 311: Starter And Starter Solenoid

    See Test Procedure 7, Section 11b, Page 11b-16. See also Test Procedure 8 – Differential Relay on page 11b-17. Figure 12b-1 Relays Figure 12b-2 Neutral Switch 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12b-1...

  • Page 312: Neutral Switch

    Carburetor Solenoid Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. Page 12b-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 313: Voltage Regulator

    1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally...” in General Warning, Section 1, Page 1-2. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12b-3...

  • Page 314: Warning Lights

    4. Disconnect the wires from the warning light (1) (Figure 12b-5, Page 12b-5). 5. Press the retaining tabs and remove the warning light from the instrument panel. Page 12b-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 315: Fuel Gauge/Hour Meter

    ON position and the engine is on. When recording, the hour- glass icon on the left blinks slowly. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12b-5...

  • Page 316: Key Switch

    5. Reach under the instrument panel to hold the key switch and remove the key switch nut (7) (Figure 12b-5, Page 12b-5). Pull the key switch, with spacer (8), from the back side of the instrument panel. Page 12b-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 317: Volt Accessory Receptacle

    4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12b-7...

  • Page 318: Bed Lift Switch

    3. Pull the circuit breaker out of the in-line fuse holder to remove. Bed Lift Circuit Breaker Installation Install the circuit breaker in the reverse order of removal. Page 12b-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 319: Light Switch

    Use the appropriately rated fuse; if a fuse with a higher amp rating is used, damage to the vehicle electrical system may occur. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12b-9...

  • Page 320: Reverse Warning Buzzer

    5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12b-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 321: Reverse Warning Buzzer Limit Switch

    5. Hold the limit switch in position and tighten the mounting screws and nuts to 4 in-lb (0.5 N·m). See fol- lowing CAUTION. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12b-11...

  • Page 322: Fuel Level Sending Unit

    Refer to the engine manual for additional testing, removal, disassembly, and installation procedures. See the Honda GX620 engine manual (CCI P/N 102615401). Page 12b-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 323: Charge Coil

    4. Remove the connector harness/halogen bulb assembly from the headlight lens. 5. Lift the retaining tabs on the connector and remove the halogen bulb. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12b-13...

  • Page 324: Wire Harness Diodes

    5. Cut the wires attached to each side of the diode and discard the diode. Page 12b-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 325: Battery

    D x 18.4 cm H). It is important to use the proper size to ensure that the battery clamp will fit correctly. Testing the Battery See Test Procedure 1, Section 11b, Page 11b-9. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12b-15...

  • Page 326: Preventive Maintenance

    NOTE: Contact your local water department for mineral content analysis. ALLOWABLE CONTENT IMPURITY (PARTS PER MILLION) Suspended matter Trace Total solids 100.0 Calcium and magnesium 40.0 oxides Iron Ammonia Page 12b-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 327 DC leads from the battery. Allow the battery to cool to room temperature and resume charging battery at a lower amp rate. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12b-17...
  • Page 328 See following WARNING. ý WARNING • Do not jump-start a dead battery with another battery and jumper cables. Page 12b-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 329: Starter And Starter Solenoid

    See Test Procedure 8, Section 11c, Page 11c-21. See also Test Procedure 9 – Differential Relay on page 11c-22 and Test Procedure 10 – Fan Relay on page 11c-23. Figure 12c-1 Relays Figure 12c-2 Neutral Switch 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-1...

  • Page 330: Neutral Switch

    Fuel Solenoid Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. Page 12c-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 331: Amp Fusible Link

    If the fusible link is blown, determine the cause of the open fusible link before replacing it. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-3...
  • Page 332 4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12c-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 333: Warning Lights

    1. Push a new warning light into the hole in the instrument panel until the plastic tabs are securely engaged (Figure 12c-6, Page 12c-5). 2. Reconnect the wires from the wire harness to the warning light. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-5...

  • Page 334: Fuel Gauge/Hour Meter

    2.2. Late 2007 vehicles: Force the mounting clip (14) onto the back of the fuel gauge/hour meter until fully seated. 3. Connect the wires to the fuel gauge/hour meter. See Wiring Diagram, Section 11c, Page 11c-6. Page 12c-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 335: Key Switch

    Chock the wheels. 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-7...

  • Page 336: Bed Lift Switch

    4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12c-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 337: Bed Lift Circuit Breaker

    4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-9...

  • Page 338: Fuse

    3. Raise the hood. 4. Remove the plastic rivets securing the reverse warning buzzer and remove the reverse warning buzzer (Figure 12c-7, Page 12c-11). Page 12c-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 339: Reverse Warning Buzzer Limit Switch (If Equipped)

    4. Disconnect the wires from the reverse warning buzzer limit switch (Figure 12c-7, Page 12c-11). 5. Remove the screws, nuts, washers, and lockwashers that secure the limit switch. 6. Remove the limit switch. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-11...
  • Page 340 Battery Terminal Protector Spray (CCI P/N 1014305). 10. Turn the key switch to the ON position. With the Forward/Reverse handle in REVERSE, the buzzer should sound. Page 12c-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 341: Front Differential Limit Switch

    5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-13...

  • Page 342: Electric Fuel Pump

    2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 3. Disconnect the 18-gauge purple wire from the alternator (Figure 12c-11, Page 12c-15). Page 12c-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 343 (Figure 12c-14, Page 12c-15). Tighten the bolt so that it is snug but will allow the alternator to pivot when the belt tension is adjusted. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-15...

  • Page 344: Oil Pressure Sensor

    3. From the front of the vehicle, reach under the cowl and turn the connector harness/halogen bulb assem- bly clockwise one-quarter turn (Figure 12c-15, Page 12c-17). 4. Remove the connector harness/halogen bulb assembly from the headlight lens. Page 12c-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 345: Thermostat Switch

    • Hot! Coolant system is pressurized. Do not remove thermostat switch while engine is hot. 3. Loosen the radiator cap to relieve pressure. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-17...
  • Page 346 5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12c-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 347 4. Connect the battery cables, positive (+) cable first, and tighten the hardware to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-19...

  • Page 348: Wire Harness Diodes

    7. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12c-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 349: Battery

    4. Check the battery periodically to ensure that it is in a full state of charge. See Charging the Battery on page 12c-23. 5. Keep the battery hold-down clamp tight. See Vibration Damage on page 12c-22. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-21...
  • Page 350 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 3. Remove the driver-side seat. Page 12c-22 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 351 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 3. Fully charge the battery prior to storage. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 12c-23...
  • Page 352 See following WARNING. ý WARNING • Do not jump-start a dead battery with another battery and jumper cables. Page 12c-24 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 353: Gasoline Engine

    10. Remove the fuel line from the fuel pump (3) on the engine. See following DANGER. ý DANGER • Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-1...
  • Page 354 KAWASAKI GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Gasoline Engine TYPICAL 4 PLACES Figure 13a-1 Engine Removal and Installation Components Page 13a-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 355: Engine Installation

    2. Lower the engine into the engine compartment and closely align the engine block mounting holes with the holes in the engine plate (10) (Figure 13a-1, Page 13a-2). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-3...
  • Page 356 17. Install the engine air inlet hose (4). See Air Filter Outlet Hose Installation on page 13a-26. 18. Secure the fuel line to the fuel pump (3) with a new clamp. See following DANGER. Page 13a-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 357: Oil Filter Hoses

    3. Loosen the clamps on the oil hoses at the engine ports and slide them from the engine port nozzles. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-5...

  • Page 358: Exhaust System

    Page 13a-7). See following NOTE. NOTE: Shift the end of the muffler inlet and intermediate pipe from side to side to relax and disconnect the springs. Page 13a-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 359: Intermediate Pipe Removal

    • Always wear eye protection when springs are removed or installed. NOTE: Shift the end of the muffler inlet and intermediate pipe from side to side to relax and connect the springs. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-7...

  • Page 360: Muffler Installation

    • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation. Page 13a-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 361: Fuel System

    • Make sure fuel lines are the correct length and are properly routed. Failure to heed this warning could result in damage to the fuel lines and fire. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-9...

  • Page 362: Fuel Filter

    FH680D engine manual (CCI P/N 103351201). No adjustment of the pilot air screw is recommended. The following chart lists the elevation ratings for various jet sizes. Page 13a-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 363: Fuel Level Sending Unit

    Immediately place the fuel level sending unit in a pan to catch fuel. See following DANGER and NOTE. ý DANGER • Clean up any spilled fuel before operating the vehicle. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-11...
  • Page 364 Ensure the replacement gasket is rubber and that the mounting holes in the gasket are aligned properly with the mounting holes on the fuel tank. Page 13a-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 365 5. Use a crisscross pattern to tighten the hardware to 9 in-lb (1 N·m). If the hardware cannot be tightened to 9 in-lb (1 N·m), the fuel tank must be replaced. See following CAUTION. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-13...

  • Page 366: Fuel Tank

    See following DANGER and WARNING. ý DANGER • Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Page 13a-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 367 3. Feed the threaded tab end down into the bottom of the frame. Install a nylon locknut and tighten the nut to 40 in-lb (4.5 N·m). See following NOTE. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-15...
  • Page 368 17.1. Check all clamps at the carburetor, fuel filters, fuel pump, and fuel tank for leaks. 17.2. Inspect each fuel line to ensure that the lines are not cracked, cut, or worn. Page 13a-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 369: Fuel Shut-Off Valve

    Figure 13a-11 Closed Fuel Shut-Off Valve Figure 13a-12 Open Fuel Shut-Off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 13a-13 Incorrect Fuel Shut-Off Valve 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-17...

  • Page 370: Engine Control Linkages

    7. Disconnect the Z-shaped end (1) on the accelerator cable from the pedal (Figure 13a-14, Page 13a-18). Figure 13a-14 Z-Shaped Cable End Figure 13a-15 Accelerator Cable Pedal Bracket (Gasoline Vehicles) (Gasoline Vehicles) Page 13a-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 371 4.1. Secure the cable sheath strain relief (4) to the bracket (5). 4.2. Secure the cable ring end (7) with the E-clip (6). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-19...

  • Page 372: Choke Cable

    11. Compress the choke ferrule tines on the back side of the instrument panel. Pull the cable up from the engine compartment and remove the cable. See following NOTE. Page 13a-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 373: Engine Governor Arm

    12. Install the center seat plate (bucket seat vehicles only). 13. Install seat(s). 14. Lower and secure the hood. ENGINE GOVERNOR ARM See General Warning, Section 1, Page 1-1. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-21...

  • Page 374: Engine Rpm Adjustment

    3. Adjust the high-speed RPM screw (1) until the tachometer displays 3825 ± 25 RPM (Figure 13a-21, Page 13a-22). See following NOTE. Page 13a-22 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 375: Air Intake System

    1. Push the new filter cartridge onto the nozzle inside the canister. 2. Position the canister cap so the TOP mark is at the top center of the canister (Figure 13a-22, Page 13a-24). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-23...

  • Page 376: Air Canister Removal

    Figure 13a-23 Air Filter Canister AIR CANISTER INSTALLATION 1. Position the canister next to the frame bracket with the rubber valve down. Page 13a-24 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 377: Air Filter Intake Hose Removal

    1. Slide the air intake hose through the frame support bracket (Figure 13a-24, Page 13a-25). 2. Secure the air intake hose to the air port under the vehicle body (Figure 13a-25, Page 13a-26). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-25...

  • Page 378: Air Filter Outlet Hose Removal

    1. Connect the air filter outlet hose to the air filter outlet port and secure it with a clamp. 2. Connect the air filter outlet hose to the carburetor inlet port and secure it with a clamp. Page 13a-26 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 379: Clutches

    Check the engine RPM and governor adjustments. If these adjustments are within speci- fications, there is a clutch problem. See Engine RPM Adjustment on page 13a-22. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-27...

  • Page 380: Drive Belt

    6. Guide the belt over the driven clutch and roll the belt off the driven clutch by rotating the clutch clockwise. See following CAUTION. Page 13a-28 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 381: Drive Clutch

    • Hold the clutch assembly firmly when the clutch removal tool is advanced. Once loosened, the clutch will drop quickly. Do not allow the clutch to fall on a hard surface. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-29...
  • Page 382 Drive Clutch Disassembly The following service tools are required to disassemble the drive clutch and are available from a service parts representative: Page 13a-30 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 383 NOTE: Keep the cover as square to the post as possible to minimize wear between the post and cover. 6. Use a crisscross pattern to continue tightening the hardware. 7. Tighten the bolts to 120 in-lb (14 N·m). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-31...
  • Page 384 10. Connect the battery cables, positive (+) cable first, and tighten the hardware to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 11. Drive the vehicle and check for proper operation. Page 13a-32 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 385 KAWASAKI GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Figure 13a-30 Drive Clutch Assembly 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-33...

  • Page 386: Driven Clutch

    • Spring compression base (CCI P/N 102603501) • Spring compression collar (CCI P/N 102605201) • Spring compression nut (CCI P/N 102606101 Page 13a-34 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 387 NOTE: Both the moveable and fixed sheaves have spacers (6). Be sure to retain the spacers for reassem- bly of the driven clutch. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-35...
  • Page 388 4. Install the driven clutch assembly on the transmission splined shaft. 5. Install the mounting washer and retaining bolt and tighten to 39 ft-lb (53 N·m). Page 13a-36 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 389: Clutch Cover

    NEUTRAL. 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-37...
  • Page 390 10. Connect the battery cables, positive (+) cable first, and tighten the hardware to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Figure 13a-33 Clutch Inner Cover Page 13a-38 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 391: Gasoline Engine

    9. Close the shut-off valve on the fuel tank. 10. Remove the fuel line and in-line filter from the engine. See following DANGER. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-1...
  • Page 392 • Carburetor Spring • Engine Governor Arm • Engine Governor Cable Bracket • Governor Wire • Oil Filter Adapter • Exhaust Manifold Page 13b-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 393: Engine Installation

    6. Use new gaskets and install the exhaust manifold. Tighten the hardware to 21 ft-lb (28 N·m). 7. Install the clutch inner cover. See Clutch Inner Cover Installation on page 13b-40. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-3...
  • Page 394 28. Install the center seat plate. 29. Install both seats. 30. Test-drive the vehicle to ensure all systems are functional and adjusted correctly. Page 13b-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 395: Exhaust System

    2. Remove the springs from the intermediate pipe and muffler inlet. See following WARNING and NOTE. ý WARNING • Always wear eye protection when springs are removed or installed. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-5...

  • Page 396: Intermediate Pipe Installation

    • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation. Page 13b-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 397: Fuel System

    Fuel tank to fuel filter 24.3 inches (61.5 cm) Vent tube (fuel tank) 22 inches (55.8 cm) Figure 13b-3 Fuel System (Honda Powered Gasoline Vehicles) 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-7...

  • Page 398: Fuel Lines

    In the event that carburetor jetting needs to be changed, determine the proper jet size for the operating altitude. See the Main Page 13b-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 399: Fuel Level Sending Unit

    8. Carefully remove the sending unit and gasket (3). Feed the rheostat arm and float (4) through the fuel tank hole. Immediately place the fuel level sending unit in a pan to catch fuel. See following DANGER and NOTE. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-9...
  • Page 400 NOTE: The distance between the flange identification mounting holes (1) is larger than the distance between any of the other mounting holes in the sending unit flange (5). Page 13b-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 401 • Use only the existing screws or new plastic-thread screws made for plastics applications. Do not use sheet metal screws as replacement hardware. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-11...

  • Page 402: Fuel Tank

    12. Use a siphon with a built-in suction device to siphon all fuel from the tank and into an approved container. See following DANGER and WARNING. Page 13b-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 403 • Dispose of wastewater and fuel tank in accordance with federal, state, and local laws and ordinances. 4. Store the tank upside down with the cap installed in a well-ventilated area. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-13...
  • Page 404 • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation. Page 13b-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 405: Fuel Shut-Off Valve

    Figure 13b-9 Closed Fuel Shut-Off Valve Figure 13b-10 Open Fuel Shut-Off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 13b-11 Incorrect Fuel Shut-Off Valve 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-15...

  • Page 406: Oil Filter Hoses

    RPM Adjustment on page 13b-24. 1. Turn the key switch OFF and place the Forward/Reverse handle in NEUTRAL. Remove the key. Chock the rear wheels. Page 13b-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 407 7.3. Disconnect the accelerator cable spring (3) from the transmission governor arm (4). Figure 13b-12 Z-Shaped Cable End Figure 13b-13 Accelerator Cable Pedal Bracket (Gasoline Vehicles) (Gasoline Vehicles) Figure 13b-14 Governor Arm (Gasoline Vehicles) 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-17...
  • Page 408 Battery Terminal Protector Spray (CCI P/N 1014305). Gasoline Cable Diesel Cable Figure 13b-15 Z-Shaped Cable End in Hole at Pedal Page 13b-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 409: Governor Guard

    2. Remove the cable sheath strain relief from the cable bracket on the transmission (Figure 13b-18, Page 13b-20). 3. Remove the Z-shaped end of the governor cable from the governor arm on the transmission. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-19...

  • Page 410: Accelerator Cable Retention Clip Adjustment

    1. Release the cable sheath retention clip (Figure 13b-13, Page 13b-17). Page 13b-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 411: Ground Speed (Transmission) Governor Arm Adjustment

    7/16-inch socket to tighten the pinch bolt (7) to 35 in-lb (4 N·m). 6. Install the governor guard. See Governor Guard Installation on page 13b-19. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-21...
  • Page 412 HONDA GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages Figure 13b-21 Engine (Honda) and Transmission 1/4 INCH (6.4 MM) Figure 13b-22 Pin Measurement at (Transmission) Governor Arm Page 13b-22 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 413: Engine Governor Arm

    1125 ± 25 RPM. See following NOTE. NOTE: Turn the screw counterclockwise to raise the RPM and clockwise to lower the RPM. 3. Release the throttle. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-23...

  • Page 414: Choke And Air Intake System

    • Do not drill into the driver-side frame. Failure to heed this caution could damage the engine by allowing excessive contamination to enter the air intake system. Page 13b-24 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 415: Choke Cable Removal

    9. Compress the choke ferrule tines on the back side of the instrument panel. Pull the cable up from the engine compartment and remove the cable. See following NOTE. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-25...

  • Page 416: Choke Cable Installation

    4. Remove the bottom (inlet) hose from the canister (Figure 13b-29, Page 13b-28). 5. Remove the top (outlet) hose from the canister. Page 13b-26 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 417: Air Canister Installation

    4. Remove the hose from under the vehicle body on the frame. 5. Slide the hose through the frame support bracket and remove the hose from the vehicle (Figure 13b-27, Page 13b-28). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-27...

  • Page 418: Air Filter Intake Hose Installation

    AIR FILTER OUTLET HOSE REMOVAL 1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL. Page 13b-28 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 419: Air Filter Outlet Hose Installation

    To assemble and disassemble the drive and driven clutches properly, the following tools should be used: • Drive clutch service tools: - Spider removal tool CCI P/N 102607501 - Fixed sheave tool CCI P/N 102601501 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-29...

  • Page 420: Clutch Troubleshooting

    As the drive belt wears, the engine RPM will increase to compensate for the change in torque ratio. This RPM increase helps maintain the correct maximum ground speed of 25 mph (40 km/h). Figure 13b-31 Drive Belt Removal Page 13b-30 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 421: Drive Clutch

    Drive Clutch Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-31...
  • Page 422 2. Inspect the belt contact surfaces of the clutch sheaves for wear. If any area of a sheave contact surface has wear of 0.060 inch (1.52 mm) or more, the clutch should be replaced. Page 13b-32 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 423 1.1. Use a pin driver to drive out the pin (8), which will release a pin (9) and allow the rollers (7) to slide out of the spider (6). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-33...
  • Page 424 10. Connect the battery cables, positive (+) cable first, and tighten the hardware to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 11. Drive the vehicle and check for proper operation. Page 13b-34 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 425 HONDA GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Figure 13b-33 Drive Clutch Assembly 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-35...

  • Page 426: Driven Clutch

    • Spring compression base (CCI P/N 102603501) • Spring compression collar (CCI P/N 102605201) • Spring compression nut (CCI P/N 102606101 Page 13b-36 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 427 NOTE: Both the moveable and fixed sheaves have spacers (6). Be sure to retain the spacers for reassem- bly of the driven clutch. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-37...
  • Page 428 4. Install the driven clutch assembly on the transmission splined shaft. 5. Install the mounting washer and retaining bolt and tighten to 39 ft-lb (53 N·m). Page 13b-38 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 429: Clutch Cover

    NEUTRAL. 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13b-39...
  • Page 430 10. Connect the battery cables, positive (+) cable first, and tighten the hardware to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Figure 13b-36 Clutch Inner Cover Page 13b-40 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 431: Diesel Engine

    10. Remove the fuel supply line (3) at the engine fuel injection pump and securely plug the fuel supply line (Figure 13c-1, Page 13c-2). See following DANGER. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-1...
  • Page 432 20. Disconnect the air filter outlet hose from the intake manifold. See Air Filter Outlet Hose Removal on page 13c-26. 21. Loosen the hardware that secures the muffler. See Muffler Removal on page 13c-5. Page 13c-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 433: Engine Installation

    5. Install the clutches. See Drive Clutch Installation on page 13c-32. Also See Driven Clutch Installa- tion on page 13c-35. 6. Install the drive belt. See Drive Belt Installation on page 13c-29. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-3...
  • Page 434 29. Adjust the engine RPM setting if required. See Engine RPM Adjustment on page 13c-20. 30. Install both seats. 31. Test-drive the vehicle to ensure all systems are functional and adjusted correctly. Page 13c-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 435: Exhaust System

    2. Remove the springs from the intermediate pipe and muffler inlet. See following WARNING and NOTE. ý WARNING • Always wear eye protection when springs are removed or installed. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-5...

  • Page 436: Manifold Pipe Removal

    2. Secure the intermediate pipe to the muffler inlet with new springs. See previous NOTE and WARNING. 3. Align the muffler with the intermediate pipe and tighten the muffler spring suspension bracket bolts to 21 ft-lb (29 N·m). Page 13c-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 437: Muffler Installation

    • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-7...

  • Page 438: Fuel System

    Vent tube (fuel tank) 22.0 in. (55.8 cm) Total 82.9 in. (210 cm) 22.0 in. (55.8 cm) Figure 13c-8 Fuel System (Diesel Vehicles) Page 13c-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 439: Fuel Lines

    The fuel filter is mounted on a plate under the passenger-side seat (Figure 13c-9, Page 13c-9). Secondary Fuel Filter Water Separator Drain Valve Figure 13c-9 Water Separator Drain Valve 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-9...
  • Page 440 3. Secure the bottom (outlet) hose (2) to the filter port with a new clamp (Figure 13c-8, Page 13c-8). 4. Secure the top (inlet) hose (1) to the filter port with a new clamp. Page 13c-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 441: Electric Fuel Pump

    3. Disconnect the white/black wire connector from the wire harness. 4. Place a large pan under the fuel pump to catch fuel. See following DANGER and WARNING. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-11...

  • Page 442: Fuel Level Sending Unit

    ý DANGER • Diesel fuel! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Page 13c-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 443 NOTE: The rheostat arm and float should be positioned toward the outside surface of the fuel tank. FRONT OF VEHICLE Figure 13c-10 Fuel Level Sending Unit Removal 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-13...
  • Page 444 3. Align the flange identification mounting holes (1) directly over the corresponding mounting holes in the gasket and fuel tank (Figure 13c-11, Page 13c-14). See following CAUTION and NOTE. Page 13c-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 445 Battery Terminal Protector Spray (CCI P/N 1014305). Tank viewed from front of vehicle. Figure 13c-12 Fuel Level Sending Unit Position 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-15...

  • Page 446: Fuel Tank

    • Never attempt to siphon fuel with a hose that does not have a built-in suction device. • Never attempt to siphon fuel with your mouth. Page 13c-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 447 4. Connect the clear vent tube to the fuel tank vent and secure the tube with a new clamp. 5. Connect the fuel line to the primary fuel filter on the vehicle frame and secure it with a new clamp. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-17...
  • Page 448 18.1. Check all clamps at the fuel rail, fuel filters, fuel pump, and fuel tank for leaks. 18.2. Inspect each fuel line to ensure that the lines are not cracked, cut, or worn. Page 13c-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 449: Engine Control Linkages

    This cord can be used to route the cable during installation. Figure 13c-15 Z-Shaped Cable End Figure 13c-16 Accelerator Cable Pedal Bracket (Diesel Vehicles) 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-19...

  • Page 450: Engine Rpm Adjustment

    • Do not operate the engine in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. Page 13c-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 451 NOTE: It will be necessary to cut the wire attached to the adjustment screws. The manufacturer recom- mends that a new wire be secured to the screws after new RPM settings are established. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-21...
  • Page 452 Measure the RPM. Repeat steps 5 and 6 until the high-speed RPM is correct. NOTE: The high-speed RPM for this diesel engine is 3825 RPM ± 25. Page 13c-22 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 453: Air Intake System

    AIR CANISTER REMOVAL 1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-23...

  • Page 454: Air Canister Installation

    1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL. Page 13c-24 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 455: Air Filter Intake Hose Installation

    NOTE: Ensure the air intake hose is positioned against the port surfaces and the clamps are positioned between the port bead and port surface. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-25...

  • Page 456: Air Filter Outlet Hose Removal

    3. Connect the battery cables, positive (+) cable first, and tighten the hardware to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 13c-26 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 457: Clutches

    Check the engine RPM. If engine speed is within manufacturer specifications, there is a clutch problem. See Engine RPM Adjustment on page 13c-20. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-27...

  • Page 458: Drive Belt

    (Figure 13c-30, Page 13c-28). See following CAUTION. ý CAUTION • Make sure your fingers are not underneath the belt when rolling the belt off the driven clutch. Page 13c-28 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 459: Drive Clutch

    • Do not lubricate the drive clutch. Lubricants attract dirt and dust, which interfere with proper clutch operation. • Use only a dry cloth and lightly wipe the shaft of the fixed face assembly (15) (Figure 13c-32, 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-29...
  • Page 460 (Figure 13c-31, Page 13c-30). 5. Place the fixed sheave of the drive clutch onto the service tool so that the drive clutch is stationary. Page 13c-30 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 461 7. Use a 1/2-inch drive ratchet to disengage the moveable sheave (14) and spider (6), which will come off as an assembly, from the fixed sheave (15) (Figure 13c-32, Page 13c-31). Figure 13c-32 Drive Clutch Assembly 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-31...
  • Page 462 8. Connect the battery cables, positive (+) cable first, and tighten the hardware to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 9. Drive the vehicle and check for proper operation. Page 13c-32 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 463: Driven Clutch

    NUT (CCI P/N 102606101) SPRING COMPRESSION COLLAR (CCI P/N 102605201) DRIVEN CLUTCH SPRING COMPRESSION BASE (CCI P/N 102603501) Figure 13c-33 Driven Clutch Service Tools 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-33...

  • Page 464: Driven Clutch Disassembly

    NOTE: Both the moveable and fixed sheaves have spacers (6). Be sure to retain the spacers for reassem- bly of the driven clutch. "X" "X" Figure 13c-34 Driven Clutch Assembly Page 13c-34 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 465: Clutch Cover

    Battery Terminal Protector Spray (CCI P/N 1014305). See following NOTE. NOTE: Ensure the hose clamp is tightly installed and positioned between the filter canister and canister port bead. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-35...
  • Page 466 4. Finger-tighten the bolts and washers. See following NOTE. NOTE: Use bolts with lengths appropriate for the hole depths on the engine block. Page 13c-36 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 467 11. Connect the battery cables, positive (+) cable first, and tighten the hardware to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13c-37...

  • Page 469: Half Shafts

    6. Place jack stands under each end of the floor crossmember and lower vehicle onto stands (Figure 14-1, Page 14-1). Figure 14-1 Place Jack Stands Under Crossmember Figure 14-2 Axle Spindle Nut And Washer 7. Remove both front wheels. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-1...
  • Page 470 (Figure 14-6, Page 14-3). 16. Repeat steps 9 through 15 for the remaining half shaft. Page 14-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 471: Half Shaft Installation

    (Figure 14-4, Page 14-2). 5. Install a large washer and new nut on the half shaft spindle and wheel hub. Finger-tighten the hardware. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-3...

  • Page 472: Front Differential

    NOTE: Use a 1/4-inch roll pin punch to drive-out the roll pin. 8. Remove the vent tube from the differential housing (Figure 14-9, Page 14-5). Page 14-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 473 NOTE: It is not necessary to remove the differential from its mounting plate to repair or service the unit. Remove These Bolts Figure 14-10 Differential Clutch Connector Figure 14-11 Front Differential Plate 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-5...

  • Page 474: Front Differential Installation

    3. Remove the roll pin from the differential pinion shaft and front driveshaft (Figure 14-8, Page 14-5). See following NOTE. NOTE: Use a 1/4-inch roll pin punch to drive-out the roll pin. Page 14-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 475: Front Driveshaft Installation

    82 ft-lb (111 N·m). 3. Secure the hydraulic brake line T-fitting and tighten the hardware to 48 in-lb (7 N·m) (Figure 14-13, Page 14-9). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-7...

  • Page 476: Rear Axle

    7. Remove the hydraulic brake line T-fitting and bracket from the passenger-side receiver frame (Figure 14-13, Page 14-9). 8. Remove the hydraulic brake line P-clamp from the rear differential (Figure 14-14, Page 14-9). Page 14-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 477 Support the longest end of the axle assembly while lowering it to the floor. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-9...

  • Page 478: Rear Axle Installation

    8. Secure shock absorbers to axle (Figure 14-17, Page 14-11). See following NOTE. NOTE: Hydraulic brake line brackets fit to the right side of both lower shock mounts. Page 14-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 479: Rear Driveshaft

    2. Push the car to a position that enables easy access to the roll pin securing the rear driveshaft to the dif- ferential pinion shaft (Figure 14-8, Page 14-5). Chock the front wheels. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-11...

  • Page 480: Rear Driveshaft Installation

    6. Remove the drive clutch. See Drive Clutch Removal on page 13b-31 (gasoline vehicles) or Drive Clutch Removal on page 13c-29 (diesel vehicles). Page 14-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 481 15. Lift the transmission body slightly to clear the opening in the engine mounting plate and remove the trans- mission from the rear of the vehicle sliding the splined shaft out of the front driveshaft. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-13...

  • Page 482: Transmission Installation

    8.1. Secure the governor cable from the engine to the governor arm. See Governor Cable Installation, Section 13b, Page 13b-20. 8.2. Secure the accelerator cable to the governor arm. See Accelerator Cable Installation, Page 14-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 483: Forward/Reverse Shifter Cable

    When installed, the cable must be routed and secured as it was originally. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-15...
  • Page 484 Secure a heavy nylon cord to the transmission end of the cable. Pull the cord and cable at the dash frame from the transmission and allow the cord to travel under the body. 11. Remove the shifter cable. Page 14-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 485 FNR shifter bracket and tighten the front nut to 25 ft-lb (34 N·m). 7. Move the shifter handle to the FORWARD, NEUTRAL, and REVERSE positions. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-17...

  • Page 486: Forward/Reverse Shifter Handle

    If only a tube or shaft is to be replaced, it can be done one side at a time without removing the entire rear axle. Page 14-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 487 9. If replacing shaft, transfer washer (1) and retaining ring (2) from old shaft to new (Figure 14-26, Page 14-19). FRONT OF VEHICLE Figure 14-25 Axle Shaft and Brake Rotor Figure 14-26 Axle Shaft Retaining Ring and Washer 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-19...

  • Page 488: Rear Differential And Axle Shaft Installation

    2. Remove the retaining ring (2) that is in front of the bearing (3) (Figure 14-27, Page 14-21). 3. Drive bearing from axle tube by applying force to the outer race. Page 14-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 489 4. Clean axle shaft and carefully install axle tube to avoid damaging new seals. See Rear Differential and Axle Shaft Installation on page 14-20. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 14-21...

  • Page 491: General Information

    6. Turn the drain valve on the engine counterclockwise to drain coolant (Figure 15-1, Page 15-2). 7. Remove the engine block coolant plug from the top rear of engine (Figure 15-2, Page 15-2). See fol- lowing NOTE. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 15-1...
  • Page 492 17. If necessary, remove reservoir cap and fill to the FULL mark. Replace cap. See preceding WARNING. 18. Lower and secure the hood. Figure 15-1 Engine Block Coolant Drain Valve Figure 15-2 Engine Block Coolant Plug Page 15-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 493: Coolant Reservoir

    9. Lift up rear of reservoir to clear mounting tab of chassis and pull reservoir forward and up to remove. Clamps Mounting Points 5/8” Hose and Clamp Figure 15-3 Reservoir Hoses And Mounting Points 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 15-3...

  • Page 494: Coolant Reservoir Installation

    5. Release the clamp securing the hose to the radiator fill spout and remove hose. 6. Release the clamps securing the upper and lower radiator hoses to the radiator and remove hoses. Page 15-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 495: Radiator Installation

    6. Attach the hose to the radiator fill spout and secure with clamp. 7. Refill the cooling system. See Engine Coolant Change on page 15-1. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 15-5...

  • Page 496: Coolant Pipe Weldment

    Finger-tighten a flanged locknut onto the bolt to sus- pend pipe weldment. Repeat at passenger side hole. Page 15-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 497: Fan Removal

    See General Warning, Section 1, Page 1-1. FAN REMOVAL See Fan Removal, Section 12c, Page 12c-19. FAN INSTALLATION See Fan Installation, Section 12c, Page 12c-19. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 15-7...

  • Page 499: Model Identification

    3. Turn the key switch to the OFF position to shut off vehicle. Turn the key switch back to the ON position, but DO NOT start the utility vehicle engine. Keep the joystick ON/OFF switch set to ON. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-1...

  • Page 500: Attachment Interface

    3. Inspect the linkages and pins for excessive wear or damage (Figure 16-3, Page 16-3). Replace any parts that are damaged, bent or missing. Keep all fasteners tight. Page 16-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 501: Removing And Installing The Attachment Arm Mechanism

    NOTE: When removing the cylinders from the attachment arm or the interface, the cylinders may need to be retracted slightly. Do not have hands in the area of the cylinders when extending or retracting the cylinders. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-3...
  • Page 502 15. To store, install pins (1) into the attachment arm holes (both sides) and secure with the retaining pins (2) (Figure 16-11, Page 16-5). Page 16-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 503 5. Install the pins (2) and retaining rings (1) (both sides). ý WARNING • Do not have hands in the area of the cylinders when extending or retracting the cylinders. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-5...
  • Page 504 12. Raise the attachment arm (1) and align it with the cylinder (2). Install the pin (3) and retaining ring (4) (Figure 16-16, Page 16-6). Page 16-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 505 13. Raise the attachment interface and align it with the cylinder. Install the pin (2) and the retaining ring (1) (Figure 16-17, Page 16-7). Figure 16-17 Raise Interface, Install Pin and Retainer Ring 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-7...

  • Page 506: Electrical

    HYDRAULIC ATTACHMENT SYSTEM Electrical ELECTRICAL Diode 2 Diode 3 Figure 16-18 Wiring Diagram for Hydraulic Attachment System Vehicles (Front) Page 16-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 507 HYDRAULIC ATTACHMENT SYSTEM Electrical Diode 4 Figure 16-19 Wiring Diagram for Hydraulic Attachment System Vehicles (Rear) 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-9...

  • Page 508: Joystick

    3.1. Does not work as stated in previous step, replace switch. 3.2. Does work as stated in previous step and the joystick still does not work: Page 16-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 509 3. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 4. Cut the wire tie securing joystick harness to chassis (Figure 16-22, Page 16-11). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-11...

  • Page 510: Joystick On/Off Switch

    3. If switch does not work as stated in previous step, replace switch. 4. If switch does work as stated in previous step and the joystick still does not have power: Page 16-12 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 511 5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-13...

  • Page 512: Attachment Arm Float Switch

    • Float and accessory relays. • Joystick switches. • Control valves. See Control Valves on page 16-21. • Continuity of the wires involved. Page 16-14 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 513: Auxiliary Hydraulic Switch

    See Test Procedure 2 – Fuse on page 11c-16. 1. Remove the auxiliary hydraulic switch. See Auxiliary Switch Removal on page 16-16. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-15...
  • Page 514 5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 16-16 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 515: Relays

    See Joystick Removal on page 16-11. 5. Ensure the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-17...
  • Page 516 5. Ensure the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. 6. Locate and pull or pry the accessory relay out of the multi-pin connector to remove (Figure 16-28, Page 16-18). Page 16-18 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 517: Solenoid

    General Warning, Section 1, Page 1-1. 5. Note wiring and disconnect wires and copper strap from solenoid. 6. Remove screws securing solenoid to motor and remove solenoid. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-19...

  • Page 518: Circuit Breaker

    3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 4. Lower the cargo bed. Page 16-20 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 519: Control Valves

    - If the valve does not shift, remove the cartridge from the valve body. - Blow compressed air through the cartridge in both directions while holding the plunger off its seat. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-21...
  • Page 520 • The valve “hot” wire and ground wire (Figure 16-19, Page 16-9). • The switch controlling the valves. See Electrical on page 16-8. Page 16-22 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 521: Hoses

    Green Pink No Color Blue Blue Color Green Pink HOSES AT CYLINDERS HOSES AT PUMP Figure 16-34 Lift And Tilt Circuit Hoses 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-23...

  • Page 522: Hose Removal

    1.1. Make sure to match factory color marking to correct fitting (Figure 16-34, Page 16-23). 1.2. Secure with wire ties at all factory established locations. 1.3. Tighten hose fittings to 22 ft-lb (30 N·m). Page 16-24 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 523: Quick Connect Fittings (Auxiliary Hydraulic Circuit Only)

    1. Reverse the removal procedure to install quick connect fittings. Tighten jam nuts to 30 ft-lb (41 N·m). 2. Match hose to fitting and connect hoses (Figure 16-35, Page 16-24). Tighten fittings to 22 ft-lb (30 N·m). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-25...

  • Page 524: Cylinders

    6. Mark hoses to ease reassembly and disconnect hoses from cylinders. Cover hoses and fittings to keep out debris. 7. Remove retaining pin(s) and pivot pin(s) securing cylinder to chassis and remove cylinder (Figure 16-37, Page 16-26). Page 16-26 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 525: Auxiliary Cylinder (Optional)

    2. Remove retaining pin (1) and pivot pin (2) from rod end of hydraulic cylinder (Figure 16-39, Page 16-27). Figure 16-38 Hoses Figure 16-39 Remove Rod End Pins 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-27...
  • Page 526 2. Install the retaining pin (1) as shown (Figure 16-39, Page 16-27). See following NOTE. NOTE: If installed wrong, this retaining pin will restrict attachment travel. Page 16-28 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 527: Cylinder Disassembly

    - Fluids are under pressure. - Flying debris or loose material is present. - Engine is running. - Tools are being used 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-29...
  • Page 528 9. Pull the piston (1) off the rod. If the cylinder has a cushion sleeve (2), pull it off the rod. Pull the head (3) off the rod (Figure 16-46, Page 16-31). Figure 16-43 Loosen the Head Figure 16-44 Remove Rod Assembly Page 16-30 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 529 13. Remove the oil seal from the head (Figure 16-50, Page 16-31). Figure 16-49 Remove Wiper Seal Figure 16-50 Remove Oil Seal 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-31...

  • Page 530: Cylinder Assembly

    4. Use the ring compressor to compress the seal to the correct size (Figure 16-56, Page 16-33). NOTE: Leave the piston in the ring compressor for three minutes. Page 16-32 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 531 NOTE: The O-ring side of the oil seal goes toward the inside of the cylinder. 6. Install the oil seal in the head (Figure 16-58, Page 16-34). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-33...
  • Page 532 11. Install the guide with a pilot and an adapter, if they are required, on the head (Figure 16-62, Page 16-35). 12. Install the seal on the head using the guide (Figure 16-62, Page 16-35). See following CAUTION. Page 16-34 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 533 15.2. For all other cylinders, install the cushion sleeve (if so equipped) and piston on the rod (Figure 16-66, Page 16-36). Figure 16-63 Compress Seal Figure 16-64 Install Head on Rod 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-35...
  • Page 534 23. Use the adjustable gland nut wrench to tighten the head until the head is flush with the case (Figure 16-72, Page 16-37). Page 16-36 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 535: Cylinder Bushings (If Equipped)

    2. Apply LOCTITE 271 (Red) to the bushings (2) before installing them into the cylinder (Figure 16-74, Page 16-38). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-37...
  • Page 536 4. Apply LOCTITE 271 (Red) to the bushings (2) before installing them into the cylinder (Figure 16-76, Page 16-38). Figure 16-75 Remove Bushings from Rod End Figure 16-76 Apply LOCTITE and Install Bushings Into Rod End Page 16-38 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 537: Angle Frame Bushings

    5. Apply LOCTITE 271 (Red) to the bushings before installing them into the angle frame (Figure 16-80, Page 16-40). 6. Install the four bushings (2) on both ends of the angle frame. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-39...

  • Page 538: Whisk Broom Angle Frame

    2. Apply LOCTITE 271 (Red) to the bushing before installing them into the angle frame. 3. Install the two bushings (1) (Figure 16-82, Page 16-40) on both sides of the angle frame. Page 16-40 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 539: Front Mount

    Contain and dispose of any leaking oil in an environmentally safe manner. 1. Remove attachment if installed. See Attachment Interface on page 16-2. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-41...

  • Page 540: Front Mount Installation

    4. Tighten the two nuts (5), washers (6) and bolts (7), securing top of mount to vehicle, to 37 ft-lb (50 N·m). 5. Match hoses to fittings and connect hoses (Figure 16-34, Page 16-23). Tighten fittings to 22 ft-lb (30 N·m). Page 16-42 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 541: Hydraulic Pump Assembly

    11. Inspect filler cap and replace if necessary. 12. Add fresh hydraulic fluid to reservoir until level is between the Maximum and Minimum Fluid Level lines. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-43...

  • Page 542: Pump Assembly

    7. Thoroughly clean the filler cap, reservoir, pump assembly, hose connections and the area around the pump assembly. 8. Loosen two bolts, located under pump assembly, securing pump assembly to cradle (Figure 16-90, Page 16-46). Page 16-44 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 543 (Figure 16-87, Page 16-45). 11. Cover edge of heat shield to protect hoses and wires while lifting pump assembly from chassis (Figure 16-88, Page 16-45). 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-45...
  • Page 544 6. Tighten the park brake cable clamp bolt to 60 in-lb (6.4 N·m). 7. Tighten the small terminals of solenoid to 10 in-lb (1.1 N·m) and 21 in-lb (2.4 N·m) on the large terminals. Page 16-46 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 545: Reservoir

    5. Lubricate o-ring with new fluid and install reservoir being careful not to pinch or deform the o-ring. Tighten clamp to 57 in-lb (6.3 N·m). 6. Install pump assembly. See Pump Assembly Installation on page 16-46. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-47...

  • Page 546: Motor

    3. Attach solenoid to motor and connect wires. See Solenoid Installation on page 16-20. 4. Assemble pump assembly to cradle and place unit in chassis. See Pump Assembly Installation on page 16-46. Page 16-48 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...

  • Page 547: Pump

    2. Cycle pump and cylinders, refilling reservoir as necessary, until the trapped air is forced into the reservoir and the cylinders function properly. 3. Once primed, check fluid level again and add as necessary. 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 16-49...
  • Page 549 (gasoline vehicles) removal ............7-17 installation .......... 12a-9, 12b-8 ball joint, upper removal ..........12a-9, 12b-8 installation ............7-15 testing ..........11a-40, 11b-39 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page i-1...
  • Page 550 .......11a-25, 11b-26 installation ........... 6-20 choke cable (gasoline vehicles) removal ............6-20 installation ........13a-21, 13b-26 brake system inspection ........6-1 removal ...........13a-20, 13b-25 Page i-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 551 (gasoline vehicles) ..13a-27, 13b-29 bushings ............16-37 assembly ........13a-31, 13b-34 disassembly ...........16-29 cleaning .......... 13a-30, 13b-32 parts identification ..........16-29 disassembly ........13a-30, 13b-33 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page i-3...
  • Page 552 ....11a-36, 11b-35 testing ............11c-27 installation ...........12a-7, 12b-6 fan relay (diesel vehicles) testing ............11c-23 operation ........12a-6, 12b-5, 12c-6 Page i-4 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 553 ............14-7 gearcase hoses, hydraulic lubrication ........10a-13, 10b-13 quick connect fitting ........16-25 gearcase coil see front drive gearcase coil routing ............16-23 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page i-5...
  • Page 554 ..........11a-28, 11b-29 oil warning light, low (diesel vehicles) kill wire, engine (gasoline vehicles) installation ............12c-5 testing ..........11a-27, 11b-28 removal ............12c-5 Page i-6 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 555 .......... 12a-2, 12b-2 removal ............16-44 removal ..........12a-2, 12b-2 pump, fuel (diesel vehicles) relay, float installation ........13c-12, 13c-13 installation ............16-18 removal ............13c-11 removal ............16-17 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page i-7...
  • Page 556 .............. 4-9 seat belt installation ............7-19 see safety belt removal ............7-13 steering wheel seat frame installation ............4-10 installation ............7-2 Page i-8 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 557 12-volt accessory receptacle (gasoline vehicles) 5 – key switch (accessory terminal) .....11b-14 testing ..........11a-32, 11b-33 6 – starter control circuit ....11a-14, 11b-15 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page i-9...
  • Page 558 (diesel vehicles) ..... 11c-6 see governor arm, transmission wiring diagram (gasoline vehicles) ..11a-6, 11b-6 troubleshooting brake system ............. 6-3 wiring diagram (hydraulic attachment) .... 16-8 Page i-10 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 559 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 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual...
  • Page 560 Club Car NOTES...
  • Page 561 Club Car NOTES...
  • Page 562 Club Car NOTES...
  • Page 564 Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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