Club Car XRT 1500 2005 Owner's Manual
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Club Car XRT 1500 2005 Owner's Manual

Club Car XRT 1500 2005 Owner's Manual

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2005
XRT 1500
Vehicles
Gasoline and Diesel
Owner's Manual

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  • Page 1 2005 XRT 1500 Vehicles Gasoline and Diesel Owner’s Manual...
  • Page 3 Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
  • Page 4 We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehi- cle, please include the manual so that the next owner will have the important operating, safety, and mainte- nance information it contains.

  • Page 5: Table Of Contents

    Vehicle Specifications ..............® Club Car Limited Two Year Warranty for 2005 Transportation and Utility Vehicles ....

  • Page 6: Safety Decal Identification - Gasoline Vehicles

    Vehicle Feature Identification GASOLINE VEHICLES CCI 102459401 UNDERAGE WARNING DECAL Club Car, Inc WARNING Augusta, Georgia. USA Roll-over Protective Structure (ROPS) • Do not modify or remove Roll-over Protective Structure (ROPS). ROPS per ISO 3471, SAE J1040, • Replace ROPS if damaged. Do not attempt repair.
  • Page 7 Vehicle Feature Identification GASOLINE VEHICLES OPERATING INSTRUCTIONS • Read owner's manual and vehicle safety warnings. Study and understand controls. TO STAR T ENGINE • Place shift lever in Neutral ( ) position and press brake pedal. • Turn key to “START” position and hold until engine starts. TO OPERA T E VE HICL E GASOLINE WARNING DECAL •...

  • Page 8: Safety Decal Identification - Diesel Vehicles

    Vehicle Feature Identification DIESEL VEHICLES CCI 102459401 UNDERAGE WARNING DECAL Club Car, Inc WARNING Augusta, Georgia. USA Roll-over Protective Structure (ROPS) • Do not modify or remove Roll-over Protective Structure (ROPS). ROPS per ISO 3471, SAE J1040, • Replace ROPS if damaged. Do not attempt repair.
  • Page 9 Vehicle Feature Identification DIESEL VEHICLES DIESEL WARNING DECAL OPERATING INSTRUCTIONS WARNING • Read owner's manual and vehicle safety warnings. Study and understand controls. TO STAR T ENGINE • Place shift lever in Neutral ( ) position and press brake pedal. DIESEL FUEL EXPLOSION / FIRE.
  • Page 10 Safety signs like you see above may at first seem shocking, but their impact is mild compared with the reality of severe personal injury. Your safety and satisfaction are of the utmost importance to Club Car. That is why before operating the vehicle, we urge you to review the information in this manual.

  • Page 11: Safety Details

    If any of the operation or warning decals on the vehicle become damaged, have been removed, or cannot be easily read, they should be replaced immediately to avoid possible property damage, personal injury, or death. Contact your Club Car dealer. ý...

  • Page 12: General Warnings

    • A Club Car vehicle will not provide protection from lightning, flying objects, or other storm- related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.
  • Page 13 General Warnings ý WARNING • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation.

  • Page 14: General Information

    The fuel tank must be removed to view this decal. See following NOTE. NOTE: Have the vehicle serial number available when ordering parts or making inquiries. Club Car SERIAL NUMBER GC0501-123456...
  • Page 15 Forward/Reverse handle. See WARNING and CAUTION beginning on page 13. Club Car vehicles operate at a reduced speed in reverse. The reverse buzzer will sound as a warning when the Forward/Reverse handle is in the REVERSE position.
  • Page 16 Controls and Indicators WARNING WARNING START Figure 4 Instrument Panel – Gasoline Vehicles WARNING WARNING PREHEAT START Figure 5 Instrument Panel – Diesel Vehicles Page 14 2005 XRT 1500 Gasoline and Diesel Vehicle Owner’s Manual...
  • Page 17 Controls and Indicators ACCELERATOR PEDAL The accelerator pedal (1) is the pedal on the right (Figure 6). With the engine running and the Forward/Reverse handle in the FORWARD or REVERSE position, vehicle speed will increase as the accelerator pedal is pressed. When the accelerator pedal is released, it will return to the original position and the engine will idle.
  • Page 18 If the warning light comes on, stop the vehicle and allow it to idle for approxi- mately five minutes before stopping the engine. Contact a Club Car dealer/distributor or a trained technician. See following WARNING.

  • Page 19: Roll-Over Protective Structure (Rops) And Safety Belts

    WARNING • The ROPS must be properly installed before operating the vehicle. Club Car strongly urges that the vehicle’s occupants be properly restrained at all times with the safety belts provided. Pregnant woman: Consult your doctor for specific recommendations. The safety belt should be worn securely and as low as possible over the hips and not on the waist.

  • Page 20: Seat Latch And Adjustment

    • The Club Car vehicle is not designed to meet child seat compatibility requirements. Children requiring a child safety seat must not ride on the vehicle. Comply with state and local laws pertaining to child safety.

  • Page 21: Pre-Operation And Daily Safety Checklist

    5. Install seat in the vehicle. See preceding WARNING “Make sure seat hinges and latch...”. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.

  • Page 22: Driving Instructions

    • For night use, the vehicle must be equipped with headlights, taillights, and reflectors. • The vehicle is not specially equipped for handicapped persons: - Be sure all passengers are capable of securing themselves in a moving Club Car vehicle before allowing them to ride in one.
  • Page 23 Driving Instructions ý WARNING • Stop the vehicle before shifting the Forward/Reverse handle. Engine must be at idle before shifting the Forward/Reverse handle. Failure to do so may result in injury to inattentive passengers and (or) damage to the vehicle. •...
  • Page 24 Driving Instructions 6. Make sure the Forward/Reverse handle is in the NEUTRAL position. 7. Press and hold the brake pedal. 8. To start the vehicle: 8.1. Gasoline vehicles: Turn the key all the way to the START position and hold, activating the choke as necessary, until the engine starts.

  • Page 25: Bed Latch And Prop Rod

    Bed Latch and Prop Rod ý WARNING • Reduced steering control can occur if the front differential becomes locked. To help prevent this condition, avoid extremely hard braking in reverse. STOPPING THE VEHICLE To stop the vehicle, release the accelerator pedal and press the brake pedal until the vehicle comes to a com- plete stop.

  • Page 26: Front Shock Absorbers

    Front Shock Absorbers Figure 10 Bed Latch Figure 11 Prop Rod ý WARNING • For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged. Do not close bed until all persons are clear of cargo bed area.

  • Page 27: Towing With The Vehicle

    Towing another Club Car vehicle or a trailer can have adverse effects on vehicle handling. Be especially cau- tious when towing other equipment with a Club Car vehicle. See the preceding chart for vehicle capacities.

  • Page 28: Transporting On A Trailer

    • For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. • Never tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer.
  • Page 29 Storage ý WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a fire hazard. • Gasoline vehicles only: Turn fuel shut-off valve to the closed (OFF) position (Figure 12, Page 27).
  • Page 30 4.3. Disconnect the fuel vent line from the fuel tank vent nipple (Figure 34, Page 43). 4.4. Plug the fuel tank vent nipple so that it is air tight. Club Car recommends using a slip-on vinyl cap. 5. Remove both spark plugs and pour 1/2 ounce (14.2 mL) of SAE 10 weight oil through each of the two spark plug holes.

  • Page 31: Maintenance

    Any vehicle not functioning correctly should not be used until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car dealer/distributor for repairs and semiannual and annual periodic service. ý...

  • Page 32: Periodic Service Schedule

    Periodic Service Schedule ý WARNING • To help avoid unintentionally starting the vehicle: - Disconnect battery cables, negative (–) cable first (Figure 1, Page 9). - Gasoline vehicles only: Disconnect the spark plug wires from the spark plugs. • If wires are removed or replaced make sure wiring and wire harness are properly routed and secured.
  • Page 33 Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily service by owner Check engine oil level; add if necessary. or trained technician See Engine Oil Level Check on page 35. Engine Diesel vehicles: Check engine coolant; add if necessary. See Engine Coolant Level Check on page 41.
  • Page 34 (or every 100 hours of operation, Gasoline vehicles: Inspect, clean, and whichever comes first) gap spark plug; replace if necessary. See authorized Club Car dealer or trained technician for service. Engine Diesel vehicles: Check the v-belt for proper tension or damage. Adjust or replace if necessary.

  • Page 35: Periodic Lubrication Schedule

    Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Gasoline vehicle: First change 20 hours – Diesel vehicle: Gasoline vehicles: 1 qt.-25 oz. (1.7 L) First change 50 hours – with filter Change engine oil and oil filter additional change for both Diesel vehicles: 3 qt.

  • Page 36: Brake Fluid Reservoir

    Brake Fluid Reservoir FLOORBOARD Figure 16 Lubrication Points – Diesel Vehicles BRAKE FLUID RESERVOIR Ful l Lev el Safe Le vel Lev el Figure 17 Brake Fluid and Coolant Access Door Figure 18 Brake Fluid Reservoir The brake fluid reservoir (1) is located under the dashboard (Figure 17). Raise the access panel located on top of the dashboard to check the brake fluid level.

  • Page 37: Engine Oil

    Engine Oil BRAKE FLUID Brake fluid level should be within 1/4-inch (6 mm) from the top of the reservoir (Figure 18). Also, brake fluid should be clean with no residue in the bottom of the reservoir or other evidence of contamination. ý...
  • Page 38 Engine Oil Full Level Safe Level Full Level Level Safe Level Level Figure 19 Engine Oil Level Check – Gasoline Vehicles Figure 20 Engine Oil Level Check – Diesel Vehicles ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 20 hours of operation (gasoline) or 50 hours of oper- ation (diesel).
  • Page 39 Engine Oil 7. Use a socket- or box-end (do not use an open-end) wrench to replace the oil drain plug. Turn the plug clockwise and tighten to 29 ft-lb (40 N·m) for gasoline vehicles, 31 ft-lb (42 N·m) for diesel vehicles. Figure 21 Engine Oil Drain Plug and Pan –...
  • Page 40 Engine Oil NOTE: An oil drip guard can be used to prevent excess oil from dripping onto the engine base plate. Use an empty quart (liter) container and cut the bottom off at an angle, then slide the open area of the container up and under the oil filter before removal.
  • Page 41 Engine Oil NOTE: Use only Club Car oil filters designed for your engine. 6. Tighten the oil filter by hand 2/3 turn after gasket contact. Do not use a band wrench or channel lock pliers. Engine Oil Filling 1. Add engine oil; use a funnel or pour spout to direct the oil into the opening (Figure 26 or Figure 27). With filter change, the engine requires 1 qt.-25 oz.

  • Page 42: Gearcase Lubrication

    Gearcase Lubrication GEARCASE LUBRICATION NOTE: Dispose of used oil according to the environmental laws and regulations for your area. LUBRICATION LEVEL CHECK FOR FRONT DIFFERENTIAL, TRANSMISSION, AND REAR DIFFERENTIAL Each gearcase component is equipped with two oil port plugs (1 and 2) (Figure 30, Figure 31, and Figure 32).

  • Page 43: Engine Coolant - Diesel Vehicles

    Engine Coolant – Diesel Vehicles Rear differential: Clean and install the drain plug (2) and washer before filling the rear differential with new lubricant (Figure 32). Tighten the drain plug to 8 ft-lb (10.8 N·m). Use a funnel when filling the differential through the lubricant level indicator hole (1).

  • Page 44: Air Intake System

    3. Remove the air filter cartridge. See following NOTE. NOTE: The air filter cartridge is specifically designed for this engine. It only fits into the canister one way. Use only the Club Car part (CCI P/N 102498601) designed for this engine. Figure 33 Air Filter Cartridge Air Filter Installation 1.

  • Page 45: Fueling Instructions

    Fueling Instructions FUELING INSTRUCTIONS See General Warnings on page 10. ý DANGER • Turn key switch to the OFF position before fueling. • Never pour fuel into the fuel tank when the engine is hot or while it is running. •...
  • Page 46 Fueling Instructions DRAINING WATER FROM FUEL FILTER Diesel Vehicles Only Water should be drained from the fuel filter daily. The fuel filter is mounted on a plate by the lower seat support panel (Figure 36). 1. Position a pan under the fuel filter. 2.

  • Page 47: Battery

    ý WARNING • Do not jump-start a dead battery using another battery and jumper cables. The battery in a Club Car vehicle is a 12-volt, low-maintenance battery that requires infrequent checks (Figure 37). Electrolyte level should be checked semiannually. BATTERY...

  • Page 48: Cleaning The Vehicle

    (No. 00) steel wool. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.
  • Page 49 There is a complete line of accessory equipment available from Club Car and our dealers/distributors. You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www.clubcar.com and clicking the “Find a Dealer” link.

  • Page 50: Vehicle Specifications

    In the event a vehicle is bought as a used vehicle, we strongly urge the new owner to register the vehicle with Club Car. This will enable us to contact you if the need arises. Please send your name, address, and serial number of the vehicle to Club Car, Inc., P.O.
  • Page 51 Vehicle Specifications GASOLINE DIESEL SPECIFICATIONS VEHICLES VEHICLES BODY/CHASSIS Frame/Chassis: Twin I-Beam welded aluminum tube frame • • Side and rear body: All aluminum • • Cargo bed: Powder-coated steel • • Front body: ABS/DR acrylic cap • • Tires: All Terrain: 23 x 8.0 – 12 front, 23 x 10.5 – 12 rear; tubeless, 4-ply rated load range •...

  • Page 52: Club Car ® Limited Two Year Warranty For 2005 Transportation And Utility Vehicles

    Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period. If CLUB CAR elects to repair the vehicle, it may provide factory-reconditioned parts or components.
  • Page 53 This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state. 8. INFORMATION: For further information contact WARRANTY SERVICES, CLUB CAR, INC., P.O. Box 204658, Augusta, Georgia 30917- 4658, U.S.A., 706-863-3000.
  • Page 54 TECHNICAL & CONSUMER INFORMATION (GASOLINE ENGINES) Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.
  • Page 55 The emission control systems on your Honda engine were designed, built, and certified to conform with EPA and California emission regulations. We recommend replacement parts be purchased from Club Car, Inc.. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance.
  • Page 56 - As the vehicle engine owner, you should however be aware that CLUB CAR may deny you warranty coverage if vehicle engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 57 5. NO CONSEQUENTIAL DAMAGES: In no event shall Club Car be liable for any incidental or consequential damages including, but not limited to, loss related to property other than the vehicle, loss of use, loss of time, inconvenience, or any other economic loss. This warranty is applicable only where the California or U.S.
  • Page 58 2. Ease of Finding Information 3. Clarity of Illustrations 4. Periodic Service and Periodic Lubrication Schedules Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2005 XRT 1500 Gasoline and Diesel Vehicle Owner’s Manual...
  • Page 60 Publication Part Number 102680211 Edition Code 0704C1004B Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Intl’l +1 706.863.3000 1.706.863-5808...

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