Page 1 2006-2010 Turf/Carryall 272/472, XRT1200/SE Maintenance and Service Manual Turf 272, Carryall 272, Carryall 472, XRT 1200, and XRT1200 SE Gasoline Vehicles Manual Number 102907711 Edition Code 1007B0810A...
Page 3 Club Car distributor/dealer representative or by a Club Car factory- trained technician. It is the policy of Club Car, LLC to assist its distributors and dealers in continually updating their service 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, LLC, is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.
Page 5: Table Of Contents
CONTENTS SECTION 1 – SAFETY General Warning ..........................Disabling The Vehicle ........................Disconnecting The Battery ......................Connecting The Battery ........................ SECTION 2 – VEHICLE SPECIFICATIONS General Information .......................... SECTION 3 – GENERAL INFORMATION General Information .......................... Engine Identification ......................... Serial Number Identification ......................Storage .............................
Page 6 Front Seat Support ........................... Front Seat Support Removal ......................Front Seat Support Installation ..................... Rear Seat Support ........................... Rear Seat Support Removal (Carryall 472/XRT 1200 SE) ............Rear Seat Support Installation (Carryall 472/XRT 1200 SE) ............Cargo Bed ............................4-11 Cargo Bed Removal ........................
Page 7 Brake Drum Removal ........................Front Wheel Brake Drum Removal ....................Rear Wheel Brake Drum Removal ....................Brake Shoe Removal ........................Front Brake Shoe Removal ......................Rear Brake Shoe Removal ......................Brake Cluster Inspection and Cleaning .................... 6-10 Brake Shoe Installation ........................6-11 Front Brake Shoe Installation .......................
Page 8 Master Cylinder and Bell Crank Replacement ................. 6-28 Bell Crank Removal ........................6-28 Bell Crank Installation ........................6-28 Master Cylinder Removal ......................6-28 Master Cylinder Installation ......................6-29 Bleeding the Hydraulic Brake System ....................6-31 Purging the Hydraulic System ...................... 6-32 Filling the Hydraulic System ......................
Page 9 Front Wheel Bearings and Hubs ....................... 7-19 Front Wheel Free Play Inspection ....................7-19 Front Wheel Bearings and Hub Removal ..................7-19 Front Wheel Bearings and Hub Installation .................. 7-19 SECTION 8 – WHEELS AND TIRES General Information .......................... SECTION 9 – REAR SUSPENSION Shock Absorbers ..........................
Page 10 Test Procedures ..........................11-10 Index of Test Procedures ......................11-10 SECTION 12 – ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model G425419) ....................12-1 Starter/Generator (Model 114-01-4005) ................... 12-10 Voltage Regulator ..........................12-21 Diode ..............................12-22 Key Switch ............................12-24 Solenoid ............................12-25 Fuse ..............................
Page 11 Ignition Coil and Flywheel ......................... 13-6 Crankcase Cover Installation ......................13-7 Flywheel Installation ......................... 13-7 Engine Installation ..........................13-8 Torque Specifications ........................13-9 Adjustment and Settings ....................... 13-9 SECTION 14 – FUEL SYSTEM General Information .......................... 14-1 Carburetor ............................14-1 Main Jet Elevation/Size Chart .......................
Page 12 Fuel Tank ............................14-22 Fuel Tank Removal ........................14-22 Fuel Tank Storage Or Disposal ....................14-26 Fuel Tank Installation ........................14-26 Fuel Lines ............................14-27 Fuel Shut-Off Valve .......................... 14-28 Carbon Canister (If Equipped) ......................14-28 Carbon Canister Removal ......................14-28 Carbon Canister Installation ......................
Page 13 Drive Clutch ............................17-4 Drive Clutch Removal ........................17-4 Drive Clutch Cleaning and Inspection ................... 17-5 Drive Clutch Disassembly ......................17-6 Inspection of Drive Clutch Parts ....................17-7 Drive Clutch Assembly ........................17-10 Drive Clutch Installation ........................ 17-11 Driven Clutch ............................ 17-12 Driven Clutch Removal .........................
Page 15: Section 1 - Safety
SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements contained within headings labeled DANGER, WARNING, CAUTION, or NOTE.
Page 16 SAFETY General Warning ý WARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and CAUTION statements in this manual as well as those on the vehicle. • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair.
Page 17: Disabling The Vehicle
SAFETY General Warning DISABLING THE VEHICLE 1. Set the park brake. 2. Turn the key switch OFF and remove the key. 3. Place the Forward/Reverse control in the NEUTRAL position. 4. In addition, chock the wheels if servicing or repairing the vehicle. DISCONNECTING THE BATTERY 1.
Page 19: Section 2 - Vehicle Specifications
SECTION 2 – VEHICLE SPECIFICATIONS GENERAL INFORMATION SPECIFICATIONS TURF/CA 272 XRT 1200 CARRYALL 472 XRT 1200 SE POWER SOURCE Engine: 4-cycle OHV, 400 cc, 13 maximum hp @ 3600 RPM (per SAE J 1940/1349), single-cylinder, • • • • air-cooled with pressure lubrication system Fuel system: Side-draft carburetor with float bowl, fixed jets, fuel filters...
Page 20 VEHICLE SPECIFICATIONS General Information SPECIFICATIONS TURF/CA 272 XRT 1200 CARRYALL 472 XRT 1200 SE Overall height (at steering wheel) 51 in. (130 cm) Wheelbase 80 in. (203 cm) 101 in. (256 cm) Ground clearance: (under differential) 6.6 in (17 cm) (under foot platform) 11.4 in (29 cm) Front wheel tread...
Page 21: Section 3 - General Information
SECTION 3 – GENERAL INFORMATION GENERAL INFORMATION Refer to the owner’s manual provided with the vehicle for information on the following topics: • Vehicle Feature Identification • Controls and Indicators • Driving Instructions • Towing with the Vehicle • Transporting on a Trailer •...
Page 22: Storage
GENERAL INFORMATION Storage NOTE: Always have the vehicle serial number at hand when ordering parts or making inquiries (Figure 3-1, Page 3-2). SERIAL NUMBER PH0901-123456 BC54679 Figure 3-1 Serial Number Decal STORAGE ý DANGER • Read General Warning, Section 1, Page 1-1. ý...
Page 23: To Return Vehicle To Service
GENERAL INFORMATION Storage 11. Plug the fuel tank vent nipple so that it is air tight using a slip-on vinyl cap. 12. Wash tops and terminals of battery with a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water).
Page 24 GENERAL INFORMATION Storage Figure 3-4 Fuel Shut-off Valve – 49-State Fuel Tank Figure 3-5 Fuel Shut-off Valve – California Fuel Tank 1. Fuel Shut-off Valve 2. Closed (OFF) 3. Open (ON) NOTE: When 1. Fuel Shut-off Valve 2. Closed (OFF) 3. Open (ON) NOTE: When selecting valve position, ensure that it is fully opened or fully selecting valve position, ensure that it is fully opened or fully closed.
Page 25: Section 4 - Body And Trim
(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 26: Front Body Repair
BODY AND TRIM Front Body Repair FRONT BODY REPAIR Read General Warning, Section 1, Page 1-1. ABRASIONS AND HAZE The original gloss can be restored by hand buffing with “Novus Plastic Polish”, “Mirror Glaze Professional For- mula Number 17”, or similar polishing compounds. A buffing wheel with a small amount of automotive type paste wax applied to the pad may also be used.
Page 27: Front Body Components
BODY AND TRIM Front Body Components FRONT BODY COMPONENTS Read General Warning, Section 1, Page 1-1. DASHBOARD REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Remove the key. Chock the wheels. 2.
Page 28 BODY AND TRIM Front Body Components Figure 4-1 Dash Panel Removal Page 4-4 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 29: Front Body Removal
BODY AND TRIM Seat FRONT BODY REMOVAL 1. Remove five caps (1) from top of dashboard (2) (Figure 4-2, Page 4-6). 2. Use a Torx #T-30 driver to remove the Torx-head screws (3) and washers (4) from top of front body (6). 3.
Page 30 BODY AND TRIM Seat TYPICAL 5 PLACES TYPICAL 6 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES FENDER SUPPORT TYPICAL 5 PLACES TYPICAL 4 PLACES TUBE BUMPER SHOWN. (SOME VEHICLES ARE EQUIPPED WITH A BRUSH GUARD) Figure 4-2 Front Body Assembly Page 4-6 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 31: Seat Adjustment
BODY AND TRIM Front Seat Support Light Soiling – A solution of 10% liquid dish soap and warm water applied with a soft, damp cloth is recommended. A soft bristle brush may be used if necessary. Wipe off any residue with a water damp- ened cloth.
Page 32 BODY AND TRIM Front Seat Support ý WARNING • Both armrests must be installed before operating the vehicle, unless the vehicle is fitted with a structural cab. 3. Connect differential lock cable to differential lock handle. See step 33 of Unitized Transaxle Installa- tion, Section 16, Page 16-21.
Page 33: Rear Seat Support
BODY AND TRIM Rear Seat Support REAR SEAT SUPPORT Read General Warning, Section 1, Page 1-1. REAR SEAT SUPPORT REMOVAL (CARRYALL 472/XRT 1200 SE) 1. Lift rear seat cushion and remove from the vehicle. 2. Remove eight 1/4-20 flange nuts (21) and eight 1/4-20 x 3/4-inch carriage bolts (20) and remove arm rests (10 and 11) (Figure 4-4, Page 4-10).
Page 34 BODY AND TRIM Rear Seat Support TYPICAL 4 PLACES TYPICAL 10 PLACES TYPICAL 4 PLACES Figure 4-4 Carryall 472/XRT 1200 SE Rear Seat Support Page 4-10 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 35: Cargo Bed
NOTE: Cargo bed removal and installation will be easier with the help of an additional person. 1. Turf 272/Carryall 272/XRT 1200: 1.1. Raise bed and ensure that the prop rod (25) is secured in the prop rod track (2). Hold bed securely in an upright position.
Page 36 BODY AND TRIM Cargo Bed TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 4-5 Turf/CA 272/XRT 1200 Cargo Bed Page 4-12 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 37: Bed Stop Bumper Adjustment
2.6. Proceed to Bed Stop Bumper Adjustment on page 4-13. BED STOP BUMPER ADJUSTMENT 1. Turf 272/Carryall 272/XRT 1200: 1.1. Adjust the two front bumpers (16) by loosening the 1/4-20 nylon locknuts (17) and position so that when the cargo bed is lowered, both bumpers are centered on the bed frame weldments (Figure 4-5, Page 4-12).
Page 38: Rear Fender
BODY AND TRIM Rear Fender 2. Carryall 472/XRT 1200 SE: 2.1. Adjust the two bed stop bumpers (5) by loosening the 1/4-20 nylon locknuts (7) and washers (6) and position so that when the cargo bed is lowered, both bumpers are centered on the bed frame weld- ments (Figure 4-6, Page 4-13).
Page 39: Trailer Hitch
Read General Warning, Section 1, Page 1-1. TRAILER HITCH REMOVAL 1. Turf 272/Carryall 272/XRT 1200: 1.1. Remove the tailskirt. See Tailskirt Removal on page 4-14. 1.2. Remove two 5/16-18 hex nuts (20), lockwashers (21), flat washers (22) and 5/16-18 x 1-inch bolts (23) from hitch brace (10) and hitch frame (8) (Figure 4-7, Page 4-16).
Page 40 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 4-7 Turf 272/Carryall 272/XRT 1200 Rear Fender, Tailskirt, and Trailer Hitch Page 4-16 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 41 BODY AND TRIM Receiver Hitch TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 4-8 Carryall 472/XRT 1200 SE Rear Fender, Tailskirt, and Receiver Hitch 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page 4-17...
Page 42: Floor Mat
FLOOR MAT Read General Warning, Section 1, Page 1-1. FLOOR MAT REMOVAL 1. Turf 272/Carryall 272/XRT 1200: 1.1. Remove the brake and accelerator pedals. See Accelerator Pedal Removal, Section 5, Page 5-5. Also see Brake Pedal Removal, Section 5, Page 5-1.
Page 43: Section 5 - Accelerator And Brake Pedal Assemblies
SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. BRAKE PEDAL See General Warning, Section 1, Page 1-1. BRAKE PEDAL REMOVAL 1.
Page 44 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES CA 294/XRT 1200SE PLUG Figure 5-1 Brake Pedal Assembly Page 5-2 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 45: Brake Pedal Adjustment
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal Adjustment BRAKE PEDAL ADJUSTMENT See General Warning, Section 1, Page 1-1. 1. Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Remove the key. Chock the wheels. 2.
Page 46 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal Adjustment Brake Pedal Adjustment, Continued: 6. Adjust the brake stop bumper (22) up to increase the distance between the pedal and the floorboard. or down to increase (Figure 5-4, Page 5-3). Proper brake pedal height is 6-5/8 inches ± 1/4 inch (16.8 cm ±...
Page 47: Accelerator Pedal
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal ACCELERATOR PEDAL See General Warning, Section 1, Page 1-1. ACCELERATOR PEDAL REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Remove the key. Chock the wheels. See following WARNING. ý...
Page 48: Accelerator Pedal Adjustment
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment Accelerator Pedal Installation, Continued: 3. Tighten bolts (22) to 75 in-lb (8.5 N·m). 4. Install spacer (24), aligning the splined parts, and tighten the nylon locknut (26) to 18 ft-lb (24.5 N·m). 5.
Page 49 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment 1/2 IN. SOCKET 1/2 IN. WRENCH Correct pedal position is 5-3/4 in. ±1/4 in. (14.6 cm ±6 mm) from floormat to back of accelerator pedal Figure 5-7 Accelerator Pedal Height Figure 5-8 Accelerator Pedal Adjustment ACCELERATOR PEDAL ADJUSTMENT TOOL (CCI P/N 101871001)
Page 50 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment Accelerator Pedal Adjustment Continued: RETAINING PARALLEL NUTS WITH TOP VIEW OF THE ELECTRICAL COMPONENT Figure 5-10 Accelerator Cable and Electrical Box 8. Connect the accelerator rod at the accelerator pedal (Figure 5-11, Page 5-9). 8.1.
Page 51 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment FLOORBOARD REMOVED FOR CLARITY Figure 5-11 Accelerator Pedal Assembly 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page 5-9...
Page 53: Section 6 - Mc012C-Bs00 Transaxle: Hydraulic And Park Brake Systems
SECTION 6 – MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. BRAKE SYSTEM INSPECTION See General Warning, Section 1, Page 1-1. The hydraulic brake system and park brake system should be inspected immediately after any service to either of the brake systems.
Page 54 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Inspection REFERENCE FRONT TYPICAL BRAKE HOSE 2 PLACES BLEEDER TYPICAL VALVE 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 6-1 Front Hydraulic Brake Cluster Assembly Brake Line and Hose Inspection •...
Page 55: Brake System Troubleshooting
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting Brake Drum and Shoe Inspection • Remove and inspect each brake drum. The drum should not be cracked, warped or have excessive scores or heat checks. • Inspect the brake shoes. Shoes should not be distorted, cracked or have broken welds. •...
Page 56 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Low pedal – Pedal may go to the floor, Replace the worn hose. See Hydraulic continued Weak (bulging) brake hose Line and Hose Replacement on page 6-23.
Page 57 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle pulls to one side, continued Replace hub, axle seal or wheel cylinder Grease or brake fluid on the brake shoe and replace the brake shoes. See Brake linings Shoe Removal on page 6-8.
Page 58: Brake Drum Removal
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Removal TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Rear brakes drag Binding park brake cables Adjust or replace cables and adjust. Adjust shoes and repair the brake shoe Improper brake adjustment adjusters if necessary.
Page 59 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Removal Figure 6-2 Front Spindle and Brake Drum Assembly 5. To remove tight brake drums: 5.1. On the back of each brake cluster assembly, locate the heads of the two brake shoe adjusters. 5.2.
Page 60: Rear Wheel Brake Drum Removal
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Removal REAR WHEEL BRAKE DRUM REMOVAL ý WARNING • Use only approved replacement brake drums designed for your vehicle. For MC012C-BS00 transaxles, use CC P/N 102264701. 1. Place chocks at the front wheels, release the park brake, loosen the rear wheel lug nuts and lift the rear of the vehicle with a chain hoist or floor jack.
Page 61 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Removal NOTE: It is recommended that the wheel bolt flange (22) be removed prior to brake shoe removal (Figure 6-5, Page 6-9). 2. Remove rubber boot (26), cotter pin (25), locking cap (27) and large flat washer (23) (Figure 6-5, Page 6-9).
Page 62: Brake Cluster Inspection And Cleaning
NOTE: Factory installed brake shoes have non-asbestos linings (CC P/N 102050201). When replacing brake shoes, Club Car, LLC, recommends non-asbestos replacement parts. 1. Remove the brake drum. See Front Wheel Brake Drum Removal on page 6-6, and Rear Wheel Brake Drum Removal on page 6-8.
Page 63: Brake Shoe Installation
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation 9.3. Disassemble the lever and strut by removing the C-clip and pin (Figure 6-8, Page 6-10). 9.4. Use a wire brush to remove corrosion and contaminants from the contact areas of the strut and lever.
Page 64: Front Brake Shoe Installation
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation FRONT BRAKE SHOE INSTALLATION 1. Install one shoe onto the back plate, positioning the bottom tip of the shoe into the brake shoe mounting block, and the top tip of the shoe into the wheel cylinder piston. 2.
Page 65 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation Lever is present on rear brake clusters only. TOP SLOTS BOTTOM SLOTS Figure 6-12 Brake Shoe Installation Figure 6-13 Slide Brake Shoes 4. Position the bottom tip of the remaining shoe into the mounting block and the top tip into the slot in the wheel cylinder piston.
Page 66: Brake Drum Installation
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation Rear Brake Shoe Installation, Continued: NOTE: Push the rubber boot onto the washer so that the washer edge fits into the boot-lip groove. 9. Install rear wheel brake drum. See Rear Wheel Brake Drum Installation on page 6-16. 10.
Page 67 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation 9. If the brake drum is difficult to push over the brake shoes, use the following procedure: 9.1. Locate the bolt heads of the two brake shoe adjusters on the back of the brake cluster plates. 9.2.
Page 68: Rear Wheel Brake Drum Installation
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation Rotate adjuster bolts Rotate adjuster bolts to loosen brake shoes. to tighten brake shoes. Hex-Head Bolt Wrench Torx-Head Bolt Wrench Torx Torx Figure 6-14 Loosen or Tighten Brake Adjusters REAR WHEEL BRAKE DRUM INSTALLATION NOTE: Prior to installing the brake drum, inspect the brake lines, hoses, drums and brake cluster assem- blies.
Page 69: Brake Cluster Assembly Replacement
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement 5. Install the wheel and finger-tighten the lug nuts (21) (Figure 6-19, Page 6-21). 6. Repeat steps 1 through 5 for the opposite rear wheel as required. 7. Lower the vehicle and finish tightening the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m) for steel wheels or 65 ft-lb (88 N·m) for alloy mag wheels.
Page 70: Rear Brake Cluster Assembly Removal
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement Front Brake Cluster Assembly Installation, Continued: ý CAUTION • Do not substitute hex-head bolts for Torx-head bolts. Hex-head bolts can interfere with the proper operation of the brake shoe adjusters. 2.
Page 71: Rear Brake Cluster Assembly Installation
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement PLASTIC WIRE TIE FLEX BRAKE HOSE Figure 6-18 Rear Brake Hose With Plastic Bag REAR BRAKE CLUSTER ASSEMBLY INSTALLATION 1. Install the back plate to the axle tube flange with four new Torx-head bolts (16), washers (17) and lock- nuts (18).
Page 72: Front Wheel Cylinder Installation
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement Front Wheel Cylinder Removal, Continued: 3. Remove the banjo bolt (16) and two copper washers (17) (Figure 6-1, Page 6-2). 4. Lift the hose above the brake cluster assembly and place a plastic bag over the hose fitting to keep dirt and debris from entering the hydraulic brake system (Figure 6-15, Page 6-17).
Page 73: Brake Shoe Adjuster Replacement
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Adjuster Replacement REFERENCE BRAKE HOSE BLEEDER VALVE TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL TYPICAL 4 PLACES 2 PLACES Figure 6-19 Rear Hydraulic Brake Cluster Assembly BRAKE SHOE ADJUSTER REPLACEMENT See General Warning, Section 1, Page 1-1.
Page 74: Front Brake Shoe Adjuster Removal
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Adjuster Replacement FRONT BRAKE SHOE ADJUSTER REMOVAL 1. Remove front wheel brake drum. See Front Wheel Brake Drum Removal on page 6-6. 2. Remove front brake shoes. See Front Brake Shoe Removal on page 6-8. 3.
Page 75: Hydraulic Line And Hose Replacement
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement 2. Apply a light coat of grease to the Bellville washer (5) and install the washer onto the bolt (4) and against the inside surface of the back plate (1). 3.
Page 76: Front Brake Hose Assembly Removal
6. Perform all of the brake system inspections. See Brake System Inspection on page 6-1. REAR BRAKE LINE REMOVAL 1. Turf 272/Carryall 272/XRT 1200: 1.1. Chock the front wheels, release the park brake, and lift the rear of the vehicle with a chain hoist or floor jack.
Page 77: Rear Brake Line Installation
2.9. Remove the bolt (18) from the brake tee (17) and remove the tee from the vehicle frame. REAR BRAKE LINE INSTALLATION 1. Turf 272/Carryall 272/XRT 1200: 1.1. Install brake line (10 or 11) to rear brake hose at the I-beam of the vehicle frame and tighten to 11 ft-lb (14.9 N·m) (Figure 6-20, Page 6-26).
Page 78 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement Rear Brake Hose Removal, Continued: 4. Use a 3/8-inch flare nut wrench to remove the brake hose from the wheel cylinder (Figure 6-17, Page 6-18). 5. Use a 3/8-inch flare nut wrench to remove the rear brake line (10 or 11) from the rear brake hose at the I-beam of the vehicle frame (Figure 6-20, Page 6-26 or Figure 6-21, Page 6-27).
Page 79 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement TYPICAL BOTH SIDES TYPICAL 2 PLACES REFERENCE REFERENCE FRONT SUSPENSION MASTER CYLINDER REFERENCE FRONT BRAKE ASSEMBLY TYPICAL BOTH SIDES REFERENCE REAR BRAKE ASSEMBLY Figure 6-21 Carryall 472/XRT 1200 SE Four-Wheel Hydraulic Brake System 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page 6-27...
Page 80: Rear Brake Hose Installation
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement REAR BRAKE HOSE INSTALLATION 1. Install brake hose (9) through the oval-shaped hole in the vehicle I-beam, and install the horseshoe clip (12) that secures the brake hose to the I-beam frame (Figure 6-20, Page 6-26 or Figure 6-21, Page 6-27).
Page 81: Master Cylinder Installation
4. Use a 7/16-inch flare nut wrench to remove the brake line (4) from the master cylinder (Figure 6-20, Page 6-26 or Figure 6-21, Page 6-27). 5. Turf 272/Carryall 272/XRT 1200: 5.1. Use a 3/8-inch flare nut wrench to remove the brake lines (10 and 11) from the master cylinder (Figure 6-20, Page 6-26).
Page 82 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement Turf-Carryall PLUG TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 6-22 Master Cylinder Page 6-30 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 83: Bleeding The Hydraulic Brake System
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System BLEEDING THE HYDRAULIC BRAKE SYSTEM See General Warning, Section 1, Page 1-1. The hydraulic system must be free of air. Air enters the hydraulic system whenever the system is opened and will result in a “spongy”...
Page 84: Purging The Hydraulic System
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System PURGING THE HYDRAULIC SYSTEM In some cases it may be necessary to completely drain the front, rear or entire hydraulic brake system of brake fluid. To completely purge the hydraulic system, perform the following procedure. 1.
Page 85: Park Brake System
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Full Level Safe Level Level Figure 6-24 Master Cylinder Reservoir PARK BRAKE SYSTEM See General Warning, Section 1, Page 1-1. PARK BRAKE CABLE REMOVAL Equalizer Cable Removal 1. Chock the wheels and release the park brake. 2.
Page 86: Park Brake Cable Installation
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System PARK BRAKE CABLE INSTALLATION Park Brake Pulley Installation 1. Align the equalizer cable pulley assembly (13) with the mounting holes in the frame (Figure 6-27, Page 6-37). 2. Install the four 10-24 x 3/4-inch socket-head screws (14), flat washers (17) and locknuts (18) and tighten to 54 in-lb (6.1 N·m).
Page 87: Park Brake Handle Removal
MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System 5. Pull the end of the brake cable (8) up and into a keyhole opening in the park brake equalizer bracket (10). 6. Adjust the park brake. See Park Brake Adjustment on page 6-35. 7.
Page 88 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Park Brake Adjustment, Continued: 5. With the park brake released (down), tighten the conical nut (23) until significant resistance is observed in the equalizer cable in order to fully lock the brakes (Figure 6-27, Page 6-37). 6.
Page 89 MC012C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL EACH SIDE OF VEHICLE TYPICAL EACH SIDE OF VEHICLE Figure 6-27 Park Brake System 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page 6-37...
Page 91: Section 7 - Steering And Front Suspension
SECTION 7 – STEERING AND FRONT SUSPENSION ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. STEERING WHEEL See General Warning, Section 1, Page 1-1. STEERING WHEEL REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Chock the wheels.
Page 92 STEERING AND FRONT SUSPENSION Steering Wheel TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-3 Steering Column Page 7-2 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 93: Steering Wheel Installation
STEERING AND FRONT SUSPENSION Steering Column STEERING WHEEL INSTALLATION NOTE: To minimize corrosion, apply a small amount of oil or anti-seize compound to steering shaft splines and taper before installing the steering wheel. 1. Install the steering wheel (25) on the splines of the steering shaft (11) (Figure 7-3, Page 7-2). Align the match marks placed on the wheel and steering column shaft in step 4, Steering Wheel Removal on page 7-1.
Page 94: Steering Column Assembly
STEERING AND FRONT SUSPENSION Steering Column Figure 7-4 Steering Joint Assembly STEERING COLUMN ASSEMBLY 1. Insert bearing seat (10) into both ends of steering tube (14). Place a block of wood on bearing seat and tap lightly on block until bearing seat (10) is fully seated in steering tube (14) (Figure 7-5, Page 7-5 and Figure 7-6, Page 7-5).
Page 95: Steering Column Installation
STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN INSTALLATION 1. Install boot (14) (if previously removed) (Figure 7-3, Page 7-2). 2. To minimize corrosion, apply a light coat of anti-seize lubricant to both splined ends of the steering shaft. COLUMN RETAINING TOOL (CCI P/N 1014259) STEP 1...
Page 96: Rack And Pinion
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION See General Warning, Section 1, Page 1-1. CAUT ION • Front impacts that bend tie rods and/or drag links can possibly damage internal steering gear components. See Rack and Pinion Inspection on page 7-6. The manufacturer recommends inspecting the rack and pinion and replacing if damaged.
Page 97: Rack And Pinion Disassembly
STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-7 Rack and Pinion Bolts Figure 7-8 Remove Rack and Pinion RACK AND PINION DISASSEMBLY 1. Remove the two ball joints and inspect for excessive wear (Figure 7-9, Page 7-7). 2. Remove both drag links (Figure 7-10, Page 7-7). Figure 7-9 Ball Joint Figure 7-10 Drag Link 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 98 STEERING AND FRONT SUSPENSION Rack and Pinion 3. Remove both bellows clamps (metal clamps or plastic wire ties) (Figure 7-11, Page 7-8). NOTE: If the dust seal bellows are secured with a metal clamp, remove the clamp. Do reuse the clamp when the rack and pinion is reassembled.
Page 99 STEERING AND FRONT SUSPENSION Rack and Pinion of the vise to protect the rack from damage. 11.2. Tap the flange out of the notch in the rack (Figure 7-18, Page 7-9). 11.3. Remove the ball joint (9) from the rack (2) (Figure 7-19, Page 7-10). Figure 7-14 Pinion Snap Rings Figure 7-15 Remove Pinion Gear Assembly 12.
Page 100 STEERING AND FRONT SUSPENSION Rack and Pinion TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-19 Steering Gear Page 7-10 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 101: Rack And Pinion Assembly
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY 1. Apply a liberal amount of EP grease to the teeth of the rack (2), then slide the rack through the bushing (17) and housing (1) (Figure 7-19, Page 7-10). CAUT ION •...
Page 102: Rack And Pinion Installation
STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Assembly, Continued: 11. Insert a 3/8-inch, 1/4-drive, deep-well socket into the steering column end of the universal joint (2) and tighten the bolts (1) to 15 ft-lb (20.3 N·m) (Figure 7-22, Page 7-12). 12.
Page 103: Front Suspension
STEERING AND FRONT SUSPENSION Front Suspension 4. Install remaining bolt and lockwasher on the upper universal joint and tighten it to 15 ft-lb (20 N·m). 5. Check all universal joint bolts for proper torque of 15 ft-lb (20 N·m). 6. Adjust the toe-in. See Toe-in Adjustment on page 7-13. FRONT SUSPENSION See General Warning, Section 1, Page 1-1.
Page 104: Front Suspension Components
STEERING AND FRONT SUSPENSION Front Suspension Components Toe-in Adjustment, Continued: 4. Measure the distance between the marks on the forward-facing surfaces of the tires (Figure 7-24, Page 7-13). See following NOTE. NOTE: The front measurement must be less than the rear measurement. 5.
Page 105: Kingpin And Steering Spindle Installation
STEERING AND FRONT SUSPENSION Front Suspension Components 4. Rest the brake cluster on the A-arm as shown (Figure 7-27, Page 7-15). Ensure that there is no strain on the brake hose. See following WARNING. ý WARNING • Strain on the brake hose or the brake hose fittings can result in damage to the hose or fittings, causing a leak in the hydraulic system, diminished brake performance, or brake failure.
Page 106: A-Arm Removal
STEERING AND FRONT SUSPENSION Front Suspension Components Kingpin and Steering Spindle Installation, Continued: 9. Install a new cotter pin (18) and bend it to secure it to the ball joint. 10. Use a grease gun and apply grease to the grease fitting (17) in the A-arm (13) (Figure 7-28, Page 7-17). See Lubrication on page 7-13.
Page 107 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL TYPICAL 4 PLACES TYPICAL 2 PLACES 4 PLACES TYPICAL 4 PLACES TYPICAL...
Page 108: Shock Absorber Removal
STEERING AND FRONT SUSPENSION Front Suspension Components A-Arm Installation, Continued: 12. Install the brake cluster. See Front Brake Cluster Assembly Installation, Section 6, Page 6-17. 13. Install the wheel and tighten the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m) for steel wheels or 65 ft-lb (88 N·m) for alloy mag wheels.
Page 109: Front Wheel Bearings And Hubs
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS See General Warning, Section 1, Page 1-1. FRONT WHEEL FREE PLAY INSPECTION 1. Chock rear wheels, loosen the front wheel lug nuts and lift the front of the vehicle with a chain hoist or floor jack.
Page 111: Section 8 - Wheels And Tires
SECTION 8 – WHEELS AND TIRES ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION • Keep tires properly inflated as follows: Front: 7-11 psi (.48-.76 Bars) All Terrain Tread Rear: 14-18 psi (.97-1.24 Bars) Front: 12-16 psi (.83-1.10 Bars)
Page 113: Section 9 - Rear Suspension
SECTION 9 – REAR SUSPENSION ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. SHOCK ABSORBERS See General Warning, Section 1, Page 1-1. SHOCK ABSORBER REMOVAL AND INSPECTION 1. Check shock absorbers (1) for damage or fluid leakage around the housing and replace if necessary (Figure 9-1, Page 9-2).
Page 114 REAR SUSPENSION Multi-Leaf Springs TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE AXLE SADDLE Figure 9-1 Rear Suspension for MC012C-BS00 Transaxle Page 9-2 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 115: Multi-Leaf Spring Installation
REAR SUSPENSION Multi-Leaf Springs Multi-Leaf Spring Removal, Continued: 4. Position jack stands under the two side stringers as shown (Figure 9-3, Page 9-3). Lower the floor jack to let the jack stands support the vehicle. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2.
Page 116: Snubber
REAR SUSPENSION Snubber Multi-Leaf Spring Installation, Continued: 3. Align opposite end of leaf spring with spring shackles (19). Insert bolt (16) through shackles and leaf spring eye. Attach locknut (17) and tighten to 15 ft-lb (20.3 N·m). Lower transaxle onto leaf spring (18) (Figure 9-1, Page 9-2).
Page 117: Section 10 - Periodic Maintenance
SECTION 10 – PERIODIC MAINTENANCE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. PERIODIC SERVICE SCHEDULE ý WARNING • Service, repairs, and adjustments must be made per instructions in this maintenance and service manual.
Page 118 PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily service by owner See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist in the Owner’s Manual. See Performance Inspection in the Performance Inspection Owner’s Manual. Monthly service by owner Check engine oil level;...
Page 119: Periodic Lubrication Schedule
(1.12 liters) with filter. See Oil Viscosity operation or annually, on page 10-8. whichever comes first Figure 10-1 Turf 272/Carryall 272/XRT 1200 and Carryall 472/XRT 1200 SE Lubrication Points 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page 10-3...
Page 120: Master Cylinder
PERIODIC MAINTENANCE Master Cylinder MASTER CYLINDER Figure 10-2 Brake Fluid Reservoir 1. Full Level 2. Safe Level 3. Low Level The master cylinder is located under the passenger seat toward the center of the vehicle (Figure 10-2). Raise or remove the seat to check the brake fluid level. When checking the brake fluid, also inspect the following: •...
Page 121: Engine Oil And Filter Change
Figure 10-3 Engine Oil Level Check – Figure 10-4 Engine Oil Level Check– Turf 272/Carryall 272/XRT 1200 Carryall 472/XRT 1200 SE 1. Full Level 2. Safe Level 3. Low Level 1. Full Level 2. Safe Level 3. Low Level ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 100 hours of operation.
Page 122 PERIODIC MAINTENANCE Engine Oil ý WARNING • Do not attempt to change engine oil when the engine is hot or even warm. Engine oil can cause skin burns. • Wear safety glasses or approved eye protection when servicing the vehicle. Wear rubber gloves when handling oil drain plug, oil filter, and oil drain pan.
Page 123 12. Coat new oil filter gasket with clean engine oil and install the oil filter onto the engine oil filter port (Figure 10-8). See following NOTE. NOTE: Use only Club Car oil filters (CC P/N 1016467) designed for this engine. Figure 10-6 Compress Snubber Downward Figure 10-7 Remove Engine Oil Filter 1.
Page 124: Oil Viscosity
16. Connect battery and spark plug wire(s). See Connecting The Battery on page 1-3. • Turf 272/Carryall 272/XRT 1200: 16.1. Lower the cargo bed. See WARNING “For vehicles with cargo beds...” on page 1-2. • Carryall 472/XRT 1200 SE: 16.2.
Page 125 ý WARNING • Make sure seat hinges and latch are securely engaged before operating vehicle. Figure 10-11 Fuel Tank – Turf 272/Carryall 272/XRT Figure 10-12 Fuel Tank – Carryall 472/XRT 1200 SE 1200 1. Vent Tube* 2. To Carburetor 3. Vent 4. Fuel Shut-off Valve 5.
Page 126: Battery
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 10-13). Electrolyte level should be checked semiannually. 1. Turn the key switch to the OFF position and remove the key. Place the Forward/Reverse handle in the NEUTRAL position.
Page 127 PERIODIC MAINTENANCE Battery CAUT ION • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in fire, property damage, or personal injury. Figure 10-13 Battery Figure 10-14 Battery Electrolyte Level 1.
Page 129: Section 11 - Troubleshooting And Electrical System: Fe400, Key-Start Engine
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difficulties should they occur. The guide includes the symptom, probable cause(s) and suggested checks.
Page 130 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine turns but fails to start. Fuel tank is empty Section 14 – Fuel System Fuel line or filters clogged Section 14 – Fuel System Fouled spark plug Section 13 –...
Page 131 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Spark plug fouls repeatedly, continued. Section 11 – Troubleshooting and Ignition coil failed Electrical System: FE400, Key-Start Engine, Test Procedures 14, 15, and 16 Rings are heavily worn, low cylinder See the Engines and Transaxles manual pressure...
Page 132 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Starter/Generator does not charge Starter/generator belt is loose or slipping Belt Tension Adjustment on page 12-9 battery, continued. Section 11 – Troubleshooting and Voltage regulator failed Electrical System: FE400, Key-Start Engine, Test Procedure 12 Section 11 –...
Page 133: Electrical System
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Electrical System ELECTRICAL SYSTEM The electrical system on the FE400 key-start vehicles is 12 volts DC with negative ground to frame. It consists of ten circuits that are easily identified: • Starter Circuit •...
Page 134: Wiring Diagrams
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagrams WIRING DIAGRAMS FUEL GUAGE/ HOUR METER (2006 to mid-2007) FUELTANK 18_ORG(W23) 18_BLU(W41) SENDING UNIT 18_ORG(W23) 18_BLK(W16) DETAIL CENTER DASH PANEL ASSEMBLY OIL SENDING FNR LIMIT OIL LIGHT HEAD LIGHT UNIT SWITCHES RIGHT FUEL GUAGE/ HOUR METER...
Page 135 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagrams BATTERY YELLOW BROWN OPTIONAL BLACK TALL LIGHT BARE 10_NON_INSUL(W27) ENGINE 6_RED(W28) 6_WHT(W1) STARTER GENERTOR 6_RED(W28) 18_BLK(W53) BLACK BROWN OPTIONAL WHITE TALL LIGHT 18_RED(W25) 18_YEL(W26) 18_RED(W36) 18_WHT(W20) UNDER 18_RED(W37) DASH ELECTRICAL COMPONENT BOX BRAKE LIGHT PRESSURE SWITCH...
Page 136 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagrams FUEL GUAGE/ HOUR METER FUEL TANK (2006 to mid-2007) SENDING UNIT 18_ORG(W23) ORANGE 18_BLU(W41) BLACK CENTER DASH PANEL ASM. 18_BLK(W16) DETAIL LIGHT SWITCH YELLOW YELLOW OIL LIGHT OIL SENDING UNIT BLUE HEADLIGHT RIGHT YELLOW...
Page 137 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagrams OPTIONAL TAILLIGHT YELLOW BROWN FNR LIMIT SWITCHES BLACK BLACK BLACK GREEN RED/WHT BATTERY BARE ENGINE ORANGE ORANGE RED/WHT RED/WHT POS (+) NEG (-) YELLOW WHITE REVERSE BUZZER STARTER/GENERATOR BLACK P/N 1014948 WHITE BLUE BLUE...
Page 138: Test Procedures
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURES INDEX OF TEST PROCEDURES 1. Battery 2. Fuse 3. Ground Cables 4. Key Switch (Starter Circuit) 5. Key Switch (Accessory Terminal) 6. Solenoid 7. Lockout Cam Limit Switch 8. Starter/Generator (Starter Function) 9.
Page 139 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 1 – BATTERY See General Warning, Section 1, Page 1-1. ý DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working around a battery.
Page 140 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 1 – Battery, Continued: 7. Record the reading. 8. Return the electrolyte to the cell from which it was taken. Replace vent cap. 9. Repeat steps 2 through 8 on all cells. BATTERY PLATES 1.250...
Page 141 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures NOTE: A fully charged battery that is in good condition should have a specific gravity of at least 1.225 in all cells, and the difference in the specific gravity of any two cells should be less than 50 points. Open circuit voltage should be at least 12.4 volts.
Page 142 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 3 – GROUND CABLES See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 143 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Place black (–) probe on frame. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Disconnect the 6 gauge black wire from the battery. Place red (+) probe on disconnected end of wire. Figure 11-10 Battery Ground Cable Test TEST PROCEDURE 4 –...
Page 144 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- 1000 --- FUSED FUSED 750V 750V Reading with key switch Reading with key switch in the ON position in the START position Figure 11-11 Key Switch Test –...
Page 145 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 6 – SOLENOID See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2.
Page 146 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 7 – Lockout Cam Limit Switch, Continued: SOLENOID SOLENOID WAVETEK WAVETEK 1000 1000 2000 2000 200k ELECTRICAL 200k COMPONENT 200nA 200nA ELECTRICAL 1000 --- FUSED 1000 --- 750V FUSED 750V COMPONENT BOX FRAME...
Page 147 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 8 – STARTER/GENERATOR (STARTER FUNCTION) See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 148 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 8 – Starter/Generator (Starter Function), Continued: 8. With the wires still disconnected, using a multimeter set to 200 ohms, place the red (+) probe on the DF terminal and the black (–) probe on the F1 terminal. The reading should be between 4.5 and 5.5 ohms. If the reading is incorrect, a possible grounded DF terminal and/or grounded field coil may be the cause.
Page 149 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures ý WARNING • Incorrect wiring could result in severe injury or death. • Diode and solenoid connections must have correct polarity. • Keep all persons clear of engine belts when making final connections. RED FROM VOLTAGE REGULATOR Some wires...
Page 150 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 11 – STARTER/GENERATOR (GENERATOR FUNCTION) See General Warning, Section 1, Page 1-1. NOTE: Perform Test Procedure 10 before proceeding with this test procedure. Keep the battery connected while performing this test procedure. 1.
Page 151 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-22 Test Voltage Regulator TEST PROCEDURE 13 – GROUNDED KILL WIRE See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1.
Page 152 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 14 – Ignition Spark, Continued: 2.1. Adjust the tester probes to approximately to 18,000 volts (18 Kv) setting (SE – Small Engine Setting on the Thexton 404 tool). Connect the tester to the spark plug wire, and connect the alligator clip to a solid engine ground.
Page 153 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK FEMALE BULLET KILL CIRCUIT WIRE TERMINAL BLACK WIRE Figure 11-25 RPM Limiter Ignition Coil – In Vehicle Test 1.
Page 154 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 16 – Ignition Coil, Continued: 4. Using a multimeter set to 20k ohms, measure the resistance of the secondary coil and spark plug cap together. 4.1. Place the red (+) probe of the meter into the end of the spark plug cap that normally connects to the spark plug and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 11-27, Page 11-26).
Page 155 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Figure 11-28 Ignition Coil and Cap Figure 11-29 Spark Plug Cap Removal WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-30 Spark Plug Cap Test 6. Test the secondary coil separately from the spark plug cap. 6.1.
Page 156 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Ignition Coil – Bench Test 1. Remove the coil from the engine. See Ignition Coil Removal, Section 12, Page 12-34. 2. Using a multimeter set to 200 ohms, measure the primary coil resistance. 2.1.
Page 157 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK SECONDARY COIL 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 1000 --- FUSED 750V 200nA 1000 --- FUSED 750V Figure 11-32 Primary Coil Resistance – Bench Test Figure 11-33 Secondary Coil and Cap Resistance – Bench Test WAVETEK 1000...
Page 158 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 16 – Ignition Coil, Continued: 4. If not previously tested, test the spark plug cap separately from the secondary coil. 4.1. Remove the rubber gasket (1) on the plug cap (2) by rolling back the gasket onto the spark plug wire (3) (Figure 11-28, Page 11-27).
Page 159 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 18 – ENGINE KILL WIRE See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 160 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 21 – OIL LEVEL SENSOR See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 161 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 24 – BATTERY TEST (UNDER LOAD) See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 162 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 25 – Fuel Level Sending Unit, Continued: 6. If the readings are within the specifications listed above, the fuel level sending unit is working properly. If the readings are incorrect, the fuel level sending unit has failed and the fuel tank must be replaced. See Fuel Tank Removal, Section 14, Page 14-22.
Page 163 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Figure 11-37 Fuel Gauge/Hour Meter – Through mid- Figure 11-38 Fuel Gauge/Hour Meter – From mid-2007 2007 1. Orange 2. Blue 3. Black 4. White 5. Not used 6. Not used 1.
Page 164 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures ORANGE ORANGE WAVETEK 1000 WAVETEK 2000 1000 200k BLUE 2000 200k 200nA 1000 --- FUSED 750V 200nA 1000 --- FUSED 750V WHITE BLACK Figure 11-39 Test Fuel Gauge Continuity Figure 11-40 Test Fuel Gauge Voltage Test Procedure 26B –...
Page 165 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK 1000 WAVETEK ORANGE 1000 2000 ORANGE 200k 2000 200k 200nA 1000 --- FUSED BLUE 750V 200nA 1000 --- FUSED 750V 20 VDC WHITE SETTING 20 VDC BLACK SETTING Figure 11-41 Fuel Gauge Voltage Test - Terminal 2 Figure 11-42 Fuel Gauge Voltage Test - Terminal 4 TEST PROCEDURE 27 –...
Page 166 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 2. With the key switch OFF, check the hour meter display. It is powered by an internal battery and should always be on, even with the engine off and the key removed. 3.
Page 167 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V LIGHT SWITCH Figure 11-43 Light Switch Test TEST PROCEDURE 29 – HEADLIGHT DIODE See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 168 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 30 – VOLTAGE AT HEADLIGHT SOCKET See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 169 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures BLACK WIRE WAVETEK BLUE WIRE 1000 WIRE HARNESS 2000 200k 200nA 1000 --- FUSED 750V LEFT HEADLIGHT Figure 11-45 Check Voltage to Headlight Socket 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page 11-41...
Page 171: Section 12 - Electrical Components: Fe400, Key-Start Engine
SECTION 12 – ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. STARTER/GENERATOR (MODEL G425419) See General Warning, Section 1, Page 1-1. Testing the Starter/Generator See Test Procedure 8, Section 11, Page 11-19.
Page 172 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model G425419) 3. Remove the mounting/adjustment nut (12), washer (9) and bolt (11). Lower the starter/generator and slip the belt (4) off the pulley (10). 4. Support the starter/generator so that when the pivot bolts are removed the starter/generator will not fall to the ground.
Page 173 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model G425419) Brush Spring Inspection and Replacement 1. Visually inspect springs. Replace all four springs if any spring is discolored from heat (straw or bluish in color). 2. Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 12-3, Page 12-2).
Page 174 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model G425419) cover. The springs will help prevent them from sliding back towards the center (Figure 12-6, Page 12-4). 2. Remove nut (41), lockwasher (40), pulley (39), shaft key (34), spacer (37) and bearing retainer screws (43) and separate armature (33) from output end cover (36) (Figure 12-7, Page 12-4).
Page 175 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model G425419) Figure 12-8 Bearing Play Inspection Bearing Removal 1. Place the wedge attachment tool (CC P/N 1012812) between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller (CC P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 176 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model G425419) POLE PIECE SCREW RETAINING NUT POLE PIECES INSULATOR HOUSING FIELD COIL FIELD COIL TERMINAL Figure 12-10 Field Coil Removal Visual Inspection of Armature and Commutator Some defects can be seen by examining the armature and commutator. Defects seen during the visual inspection can aid in diagnosing the original cause of the failure.
Page 177 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model G425419) Measure each position in 2 places, 90 apart. Figure 12-11 Inspect Commutator Armature Ground Test CAUT ION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.
Page 178 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model G425419) Starter/Generator Rework Any rework must be performed by a qualified technician. Starter/Generator service specifications are listed in the following table. ITEM SERVICE LIMIT Commutator diameter (minimum) 1.535 in. (39 mm) Concentric with armature shaft 0.002 in.
Page 179 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model G425419) 7. Slide the housing with field coils over the armature. Use the locating pin to align housing to the cover. NOTE: The terminal insulators should be on the commutator end of the housing. 8.
Page 180: Starter/Generator (Model 114-01-4005)
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) 5. Place a pry bar (13) between the top of the starter/generator mounting bracket (2) and the underside of the starter/generator, by passing the pry bar under the exhaust header. TYPICAL 2 PLACES END VIEW Figure 12-13 Starter/Generator Assembly Figure 12-14 Belt Tension Gauge...
Page 181 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) 3. Mark and disconnect the wires from the starter/generator (1). Loosen the two pivot nuts (7) and bolts (5) (Figure 12-15, Page 12-11). Figure 12-15 Starter/Generator Removal 4. Remove the mounting/adjustment nut (12), washer (9) and bolt (11). Lower the starter/generator and remove the belt (4) from the pulley (10).
Page 182 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) NOTE: Clean and inspect the armature/commutator and the bearings. See Disassembly of the Starter/ Generator to Service the Armature/Commutator on page 12-14. Figure 12-16 Commutator End Cover Figure 12-17 Brush Covers and Brushes Brush Inspection and Replacement 1.
Page 183 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) 2. Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 12-17, Page 12-12). Insert the brush wiring terminal studs through the commutator end cover (23) and assem- ble using the terminal hardware (31).
Page 184 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) Figure 12-20 Pull Brushes Away from Center of the Commutator End Cover Disassembly of the Starter/Generator to Service the Armature/Commutator 1. Remove the commutator end cover to prevent damage to the brushes and armature. See Disassembly of the Starter/Generator to Service the Brushes on page 12-11.
Page 185 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) Bearing Cleaning and Inspection 1. Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 12-22, Page 12-15). Figure 12-22 Bearing Play Inspection 2.
Page 186 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) Field Coil Assembly 1. Replace entire field coil housing assembly if coils, pole shoes or terminals are damaged. (Figure 12-24, Page 12-16). Visual Inspection of Armature Obvious defects can be seen by examining the armature. If an armature has frayed or charred insulation, bro- ken wires or thrown solder, it is obvious without testing that it should be replaced.
Page 187 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) ý CAUTION • Do not use emery cloth on the commutator. Particles of emery are conductive and may short- circuit the commutator bars. Do not use oil or lubricants on the commutator or brushes. 2.
Page 188 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 12-26 Armature Ground Test 1. 200 Ohms Setting 2. Commutator 3. Armature Shaft Visual Inspection of Field Coils If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings.
Page 189 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) 2. Press a new ball bearing (35) onto the output end of the armature (Figure 12-21, Page 12-14). Press a new ball bearing onto the commutator end of the armature shaft. See following CAUTION. ý...
Page 190 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005) 7. Connect battery and spark plug wire(s). See Connecting The Battery on page 1-3. Figure 12-27 Starter/Generator Installation Figure 12-28 Belt Tension Gauge 1. Belt Tension Gauge 2. End View Belt Tension Adjustment Belt tension should be checked periodically.
Page 191: Voltage Regulator
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Voltage Regulator VOLTAGE REGULATOR See General Warning, Section 1, Page 1-1. Testing the Voltage Regulator See Test Procedure 12, Section 11, Page 11-22. Voltage Regulator Removal 1. Disconnect battery and spark plug wire(s). See Disconnecting The Battery on page 1-3. 2.
Page 192: Diode
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Diode DIODE See General Warning, Section 1, Page 1-1. Testing the Diode See Test Procedure 10, Section 11, Page 11-20. Diode Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 193 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Diode RIGHT ANGLED Some wires SUPPORT omitted CARRYALL 472 for clarity. AND XRT 1200SE RED FROM VOLTAGE REGULATOR RED FROM DIODE RED FROM WHITE FROM FUSE BLOCK DIODE WHITE FROM STARTER/ RED FROM GENERATOR BATTERY ANGLED I-BEAM OUTER...
Page 194: Key Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Key Switch 5. Replace the electrical component box cover (6) and screw (5) and tighten the screw to 18 in-lb (2.0 N·m). 6. Connect the intake hose to the carburetor and secure the hose with the hose clamp. 7.
Page 195: Solenoid
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Solenoid Figure 12-33 Center Dash Panel Removal SOLENOID See General Warning, Section 1, Page 1-1. Testing the Solenoid See Test Procedure 6, Section 11, Page 11-17. Solenoid Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 196: Fuse
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuse ý WARNING • Incorrect wiring could result in severe injury or death. • Diode and solenoid connections must have correct polarity. • Keep all persons clear of engine belts when making final connections. 2. Connect all wires as indicated. 2.1.
Page 197: Lockout Cam Limit Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Lockout Cam Limit Switch 2. Install the snap-on electrical box cover by firmly pressing down on all corners and install the screw and tighten to 18 in-lb (2 N·m). 3. Install the air intake hose onto the carburetor. 4.
Page 198: Lockout Cam
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Lockout Cam LOCKOUT CAM See General Warning, Section 1, Page 1-1. If the cam lobes have worn to the point where they will no longer actuate the lockout cam limit switch, the cam must be replaced. Testing the Lockout Cam See Test Procedure 23, Section 11, Page 11-32.
Page 199: Reverse Warning Buzzer
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Reverse Warning Buzzer REVERSE WARNING BUZZER See General Warning, Section 1, Page 1-1. Testing the Reverse Warning Buzzer See Test Procedure 20, Section 11, Page 11-31. Reverse Warning Buzzer Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 200: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Reverse Buzzer Limit Switch REVERSE BUZZER LIMIT SWITCH See General Warning, Section 1, Page 1-1. Testing the Reverse Buzzer Limit Switch See Test Procedure 19, Section 11, Page 11-31. Reverse Buzzer Limit Switch Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 201: Fuel Gauge/Hour Meter
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuel Gauge/Hour Meter 3. Remove the dash panel. See Key Switch Removal on page 12-24. 4. Disconnect the wires from the oil warning light (1) (Figure 12-37, Page 12-31). Do not allow wires to touch. 5.
Page 202: Fuel Level Sending Unit
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuel Level Sending Unit The hour meter displays the number of hours of use in increments of 0.1 (one tenth) hour, but does not record additional time unless the key switch is in the ON position and the engine is on. When recording, the hour- glass icon on the left blinks (slowly on Early 2007 vehicles).
Page 203: Rpm Limiter
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE RPM Limiter RPM LIMITER See General Warning, Section 1, Page 1-1. Testing the RPM Limiter See Test Procedure 15, Section 11, Page 11-24. RPM Limiter Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 204: Ignition Coil
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ignition Coil IGNITION COIL See General Warning, Section 1, Page 1-1. The ignition coil is located under the flywheel shroud of the engine. To replace it requires the removal and installation of the engine and transaxle. It is recommended that the ignition coil be thoroughly tested prior to replacement.
Page 205 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ignition Coil Remove Figure 12-39 Remove Fan Housing Figure 12-40 Black Wire and Ignition Coil Ignition Coil Installation NOTE: If a new ignition coil is being installed, the spark plug cap, gasket, protector tube and grommet must be removed from the old coil and installed on the new coil.
Page 206 13. When installing fan housing, make sure the top front corner of the housing is above the upper cylinder shroud. The front edge of the fan housing should be behind the lower cylinder shroud. Align the slots in the housing with the flanged bolts (6) loosened earlier (Figure 12-39, Page 12-35). 14.
Page 207: Oil Level Sensor
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Oil Level Sensor OIL LEVEL SENSOR See General Warning, Section 1, Page 1-1. Testing the Oil Level Sensor See Test Procedure 21, Section 11, Page 11-32. Oil Level Sensor Removal See Oil Level Sensor Installation, Section 13, Page 13-5. Oil Level Sensor Installation See Oil Level Sensor Installation, Section 13, Page 13-5.
Page 208: Headlight Diode
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Headlight Diode 1. Connect wire harness (4) to the halogen bulb assembly (6). The retaining tab should lock onto the halo- gen bulb assembly (Figure 12-43, Page 12-37). 2. From the front of vehicle, reach under cowl and insert wire harness/halogen bulb assembly (4 and 6) into the headlight lens (7).
Page 209: Light Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Light Switch LIGHT SWITCH See General Warning, Section 1, Page 1-1. Testing the Light Switch See Test Procedure 28, Section 11, Page 11-38. Light Switch Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 210 Club Car recommends a group 70, side-post battery (CC P/N 1012328), with a 650 cranking amp rating at 32 °F (0 °C) (500 CCA at 0 °F (-17.8 °C)) and a reserve capacity of at least 105 minutes. The group 70 classifi- cation indicates battery size: 8-1/4 inches W x 6-1/2 inches D x 7-1/4 inches H (21.0 cm W x 16.5 cm D x 18.4...
Page 211 Chock the wheels. 2. Disconnect battery and spark plug wire(s). See Disconnecting The Battery on page 1-3. 3. Turf 272/Carryall 272/XRT 1200: 3.1. Remove the four bolts (8), eight washers (9) and four locknuts (10) from the armrests. See Figure 4-3, Section 4, Page 4-8.
Page 212 Figure 12-46 Turf 272/Carryall 272/XRT 1200 Battery Removal Charging the Battery See General Warning, Section 1, Page 1-1 and DANGER on page 12-39.
Page 213 (16.3 N·m). 3. Connect battery and spark plug wire(s). See Connecting The Battery on page 1-3. 4. Turf 272/Carryall 272/XRT 1200: 4.1. Return the seat support to its original position by rotating it 90° clockwise. Install the armrests using four bolts, eight washers and four locknuts.
Page 214: Ground Cables
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ground Cables 6. The frequency of recharging required depends on the temperature of the storage area, but it is recom- mended that the battery be monitored for state of charge every month. Also, if the storage area is unheated in a cold climate and recharging is required, it is recommended that the area be heated to at least 60 °F (16 °C) prior to charging.
Page 215: Section 13 - Fe400 Engine
GENERAL INFORMATION See General Warning, Section 1, Page 1-1. The Turf 272, Carryall 272, Carryall 472, XRT 1200 and XRT 1200 SE model vehicles are powered by an FE400 engine and key-start with neutral "rev". NOTE: Engine rotation on the engine is clockwise as viewed from the clutch side of the engine.
Page 216: Spark Plug
FE400 ENGINE General Information SPARK PLUG Spark plugs are selected to suit specific engine design and vehicle operating conditions. The spark plug (CC P/N AM1232301) is designed for FE400 engines, providing maximum life and efficient combustion of fuel. The spark gap should be set to 0.027 - 0.031 inches (0.69 - 0.79 mm). Spark Plug Removal See General Warning, Section 1, Page 1-1.
Page 217: Cylinder
FE400 ENGINE Cylinder CYLINDER See General Warning, Section 1, Page 1-1. Test cylinder compression using a standard compression tester. Low compression would normally indicate a problem in the cylinder assembly such as defective rings, gaskets, etc. FE400 model engines are equipped with an automatic compression release valve (ACR). This valve releases compression pressure at normal cranking RPM, resulting in lower compression.
Page 218: Crankcase Cover Removal
FE400 ENGINE Crankcase Engine Removal, Continued: 4. Remove muffler. See Muffler Removal, Section 15, Page 15-1. 5. Remove engine mounting hardware (items 1, 2, 5 and 6) (Figure 13-1, Page 13-4). 6. Lift engine from the mounting plate. 7. Remove crankcase oil drain plug and filler tube. Tip the engine slightly to allow all of the oil to drain from the crankcase.
Page 219: Oil Level Sensor
FE400 ENGINE Crankcase STARTER/ GENERATOR Figure 13-2 Oil Level Sensor Wire Figure 13-3 Crankcase Cover OIL LEVEL SENSOR Testing the Oil Level Sensor See Test Procedure 21, Section 11, Page 11-32. Oil Level Sensor Removal 1. If not already removed, remove crankcase cover. See Crankcase Cover Removal on page 13-4. 2.
Page 220: Ignition Coil And Flywheel
FE400 ENGINE Ignition Coil and Flywheel IGNITION COIL AND FLYWHEEL See General Warning, Section 1, Page 1-1. Ignition Coil and Flywheel Removal 1. Loosen three screws and remove the remaining four screws attaching the flywheel housing as shown, then remove the housing (Figure 13-5, Page 13-6). 2.
Page 221: Crankcase Cover Installation
FE400 ENGINE Flywheel Installation 0.012 INCH (0.304 MM) Figure 13-7 Flywheel Nut Removal Figure 13-8 Adjust Ignition Coil Air Gap CRANKCASE COVER INSTALLATION CAUT ION • Before assembly, make sure parts are clean. • Do not reuse the gasket. Install a new one. •...
Page 222: Engine Installation
FE400 ENGINE Engine Installation Flywheel Installation, Continued: CAUT ION • The flywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to loosen. • Be careful not to damage the fan blades. Use a strap wrench to hold flywheel. Do not place screwdriver or pry bar between fan blades.
Page 223: Torque Specifications
FE400 ENGINE Engine Installation 12. Adjust the engine RPM setting. See Engine RPM Adjustment, Section 14, Page 14-10. 13. Test-drive vehicle to ensure all systems are functional and correctly adjusted. Full Level Safe Level Level Figure 13-11 Check Engine Oil Level Figure 13-12 Add Engine Oil TORQUE SPECIFICATIONS ITEM...
Page 225: Section 14 - Fuel System
SECTION 14 – FUEL SYSTEM ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The FE400 engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The size of the jets are determined by the altitude where the engine will be operating.
Page 226: Main Jet Elevation/Size Chart
FUEL SYSTEM Carburetor MAIN JET ELEVATION/SIZE CHART FE400 ENGINE ALTITUDE MAIN JET SIZE 0-3280 ft. (0-1000 m) 3280-6562 ft. (1000-2000 m) 6562 ft. and over (2000 m and over) CHANGING THE MAIN JET See General Warning, Section 1, Page 1-1. 1.
Page 227 FUEL SYSTEM Carburetor 2. Position the carburetor with the drain screw (11) over a catch basin (Figure 14-3, Page 14-5). 3. Drain all the fuel from the bowl into the catch basin. Tighten the drain screw to 10 in-lb (1.1 N·m) and return fuel to the fuel tank or dispose of properly.
Page 228 FUEL SYSTEM Carburetor TYPICAL 2 PLACES Figure 14-2 Carburetor Installation Page 14-4 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 229 FUEL SYSTEM Carburetor STEPS 2 AND 3 Drain carburetor over a catch basin by turning bowl drain screw (11) counterclockwise 2 to 3 turns. STEP 4 Mark carburetor and corresponding position of fuel bowl. CAUTION: DO NOT REMOVE VALVE/SPRING FROM FLOAT. TO DO SO WILL DAMAGE SPRING. If spring looks like this...
Page 230: Engine Control Linkage
FUEL SYSTEM Engine Control Linkage ENGINE CONTROL LINKAGE See General Warning, Section 1, Page 1-1. GENERAL INFORMATION It is important that the accelerator pedal, governor linkage, and throttle adjustments are done correctly and in the proper sequence. See following CAUTION. CAUT ION •...
Page 231: Governor Cable
FUEL SYSTEM Engine Control Linkage Accelerator Rod Installation and Adjustment 1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. 2. Adjust accelerator pedal position. See Accelerator Pedal Adjustment, Section 5, Page 5-6. 3.
Page 232: Accelerator Cable
FUEL SYSTEM Engine Control Linkage 2. Install the Z-shaped end into carburetor throttle and push cable down into bracket (19) slot to secure. Be sure the bellows dust shield is attached. 3. Use a 1/8-inch punch or scratch awl to turn the governor arm shaft counterclockwise until it stops. Then pull the governor lever arm rearward until the carburetor throttle is in the “wide open throttle”...
Page 233: Closed Throttle Or Idle Adjustment
FUEL SYSTEM Engine Control Linkage Accelerator Cable Installation 1. Connect the accelerator cable (7) to the cam in the electrical box (Figure 14-8, Page 14-11). 2. Insert the cable housing into the mounting slot in the wall of the electrical box, with approximately the same number of threads visible between the jam nuts as are visible from the nut inside the box to the end of the cable housing (Figure 14-5, Page 14-8).
Page 234: Engine Rpm Adjustment
FUEL SYSTEM Engine Control Linkage ENGINE RPM ADJUSTMENT ý DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 1. Adjust the governor, then proceed to step 2. See Governor Cable Installation and Adjustment on page 14-7.
Page 235 FUEL SYSTEM Engine Control Linkage TYPICAL 2 PLACES Figure 14-8 Governor and Accelerator Cables 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page 14-11...
Page 236: Choke And Air Intake System
2. Remove choke cable bracket screw (17) and cable (18) from air box top (4) (Figure 14-10, Page 14-15 or Figure 14-11, Page 14-16). 3. Turf 272/Carryall 272/XRT 1200: 3.1. Remove air intake box (12) from the vehicle by removing hose clamp (15), intake hose (16), three screws (23) and washers (22) (Figure 14-10, Page 14-15).
Page 237: Intake Duct Repair
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2. Turf 272/Carryall 272/XRT 1200: 2.1. Remove the front body. See Front Body Removal, Section 4, Page 4-5.
Page 238 FUEL SYSTEM Choke and Air Intake System NOTE: The bolt must be removed completely before the splined coupling can be separated. Make an alignment mark on the steering column shaft and the steering joint for use during replace- ment. 2.7. Remove the four bolts and locknuts (2) from the rack and pinion assembly mount and gently dis- connect the steering joint from steering column shaft at the bolt (1) location (Figure 14-9, Page 14-13).
Page 239 Choke and Air Intake System TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 14-10 Turf 272/Carryall 272/XRT 1200 Air Intake and Choke Assemblies 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page 14-15...
Page 240 FUEL SYSTEM Choke and Air Intake System TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 14-11 Carryall 472/XRT 1200 SE Air Intake and Choke Assemblies Page 14-16 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 241: Intake Duct Installation
FUEL SYSTEM Choke and Air Intake System INTAKE DUCT INSTALLATION NOTE: The intake duct assembly is installed from the front of the vehicle, in reverse order of removal. This procedure is best accomplished using two people. See following NOTE. 1. Slide the intake duct between the round crossmember and the floorboard, moving it to the rear along the underside of the floorboard.
Page 242: Air Filter
• If air box is extremely dirty, remove air box from vehicle and clean thoroughly. • Use only Club Car replacement air filters (CC P/N 1015426). The use of other air filters could result in engine damage. If the air filter is too thin, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.
Page 243: Fuel Filter Installation
FUEL SYSTEM Fuel Pump 2. Disconnect battery and spark plug wire(s). See Disconnecting The Battery on page 1-3. 3. Turn the fuel shut-off valve (15) on the gas tank to the closed (OFF) position (Figure 14-20, Page 14-28 or Figure 14-21, Page 14-28). 4.
Page 244: Fuel Pump Disassembly (Metal Pump Only)
FUEL PUMP DISASSEMBLY (METAL PUMP ONLY) NOTE: A fuel pump rebuild kit is available from Club Car (CC P/N 1014524). 1. Remove four screws (24) and lockwashers (25) from front of the fuel pump (Figure 14-12, Page 14-20).
Page 245: Fuel Pump Cleaning And Inspection (Metal Pump Only)
FUEL SYSTEM Fuel Pump FUEL PUMP CLEANING AND INSPECTION (METAL PUMP ONLY) 1. Use a nonflammable solvent to clean the front cover, pumping chamber and back cover. Be sure the vent on the front cover is clean both inside and out. 2.
Page 246: Fuel Tank
FUEL SYSTEM Fuel Tank FUEL TANK See General Warning, Section 1, Page 1-1. ý WARNING • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure. CAUT ION •...
Page 247 Page 14-24 or Figure 14-17, Page 14-25). 11. Loosen clamp (7) and remove vent tube (6) from the fuel tank. 12. Turf 272/Carryall 272/XRT 1200: 12.1. Loosen the straps (13 and 10) by removing screws (12 and 14) from the speed nuts (11) (Figure 14-16, Page 14-24).
Page 248 Gas Tank Fuel Pickup Tube Metal Fuel Pump Shown No Longer Used For 2009 and 2010 Model Year Figure 14-16 Turf 272/Carryall 272/XRT 1200 Fuel and Vent Lines Page 14-24 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 249 FUEL SYSTEM Fuel Tank For Vehicles Without Carbon Canister See Above Gas Tank Fuel Pickup Tube Metal Fuel Pump Shown No Longer Used For 2009 and 2010 Model Year Figure 14-17 Carryall 472/XRT 1200 SE Fuel and Vent Lines 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page 14-25...
Page 250: Fuel Tank Storage Or Disposal
4. Store the tank upside down, with the cap installed. Use a well-ventilated area. FUEL TANK INSTALLATION 1. Turf 272/Carryall 272/XRT 1200: 1.1. Position the retaining straps (13 and 10) and install the fuel tank (Figure 14-16, Page 14-24). 1.1.1. Position the straps in the indentions on the tank.
Page 251: Fuel Lines
13.1. Check all of the fuel line clamps at the carburetor, fuel filters, fuel pump and fuel tank for leaks. 13.2. Inspect each fuel line to ensure that the lines are not cracked, cut or worn. 14. Turn the key switch to OFF. Figure 14-18 Turf 272/Carryall 272/XRT 1200 Figure 14-19 Carryall 472/XRT 1200 SE Fuel System Fuel System 1.
Page 252: Fuel Shut-Off Valve
FUEL SYSTEM Fuel Shut-Off Valve FUEL SHUT-OFF VALVE See General Warning, Section 1, Page 1-1. The fuel shut-off valve is located on top of the fuel tank (Figure 14-20, Page 14-28 or Figure 14-21, Page 14-28). The fuel shut-off valve should always be turned to the closed (OFF) position during vehicle stor- age, towing or trailering.
Page 253: Carbon Canister Installation
FUEL SYSTEM Carbon Canister (If Equipped) Figure 14-22 Carbon Canister, Hoses and Routing 1. Carbon Canister 2. Molded Vent Tube (Fuel Tank to Canister) 3. Vent Tube (Canister to Engine) 4. Vent Tube (Canister to Atmosphere) CARBON CANISTER INSTALLATION 1. Align canister mounting tabs with slots in mounting bracket (2) and push/pull the canister (1) into bracket (Figure 14-22, Page 14-29).
Page 254 FUEL SYSTEM Carbon Canister (If Equipped) Page 14-30 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 255: Section 15 - Exhaust System
SECTION 15 – EXHAUST SYSTEM ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. MUFFLER MUFFLER REMOVAL 1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position.
Page 256 EXHAUST SYSTEM Muffler Muffler Installation, Continued: 8. Connect battery and spark plug wire(s). See Connecting The Battery on page 1-3. 9. With the Forward/Reverse handle in the NEUTRAL position, start the engine and check for exhaust leaks and proper engine operation. See following DANGER. 10.
Page 257: Section 16 - Mc012C-Bs00 Unitized Transaxle With Differential Lock
• See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The Turf 272/Carryall 272/XRT 1200 and Carryall 472/XRT 1200 SE vehicles are equipped with a heavy-duty, fully-synchronized unitized transaxle with differential lock. The unitized transaxle utilizes fully-synchronized internal gearing to change vehicle direction. Because the unitized transaxle is used to reverse vehicle direc- tion, the engine, drive clutch, belt and driven clutch rotate in the same direction;...
Page 258: Lubrication
MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK General Information Shifter Lever A shifter lever, connected to a shifter arm, is used to change the gears to one of three shift positions: FOR- WARD (F), NEUTRAL (N), or REVERSE (R) (Figure 16-2, Page 16-2). Bring the vehicle to a complete stop before changing FORWARD or REVERSE direction.
Page 259: Axle Shaft
MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Neutral Lockout The neutral lockout feature is not a serviceable component on key-start vehicles. The neutral lockout should remain in the correct position at all times. See Lockout Cam, Section 11, Page 11-5. Governor System The governor system regulates vehicle ground speed.
Page 260 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Axle Shaft, Bearing, and Oil Seal Removal, Continued: 5. To remove the wheel bolt flange on the MC012C transaxle (Figure 16-5, Page 16-4): 5.1. Remove rubber boot (26) from large flat washer (23). 5.2.
Page 261: Axle Shaft, Bearing, And Oil Seal Installation
MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft AXLE SHAFT, BEARING, AND OIL SEAL INSTALLATION 1. Replace the old oil seal with a new seal (89). Make sure the axle tube hub is free of debris. 2. Replace the old bearing with a new bearing (88). Slip the new bearing onto the machined journal, adja- cent to the machined seal hub on the end of the axle (Figure 16-8, Page 16-6).
Page 262: Unitized Transaxle Removal
MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal TYPICAL 8 PLACES Figure 16-8 Differential Axle and Wheel Hub Assembly UNITIZED TRANSAXLE REMOVAL See General Warning, Section 1, Page 1-1. ý WARNING • To perform this procedure, the hydraulic system must be opened. As a result, the brakes must be bled after the correct installation of the brake components.
Page 263 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal CLAMP Figure 16-9 Carburetor Vent Tube 4.2. Disconnect the air intake hose from the carburetor (Figure 16-10, Page 16-7). 4.3. Disconnect impulse line from fuel pump (Figure 16-11, Page 16-7). CLAMP IMPULSE LINE Figure 16-10 Air Intake Hose Figure 16-11 Impulse Line...
Page 264 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: Rotate the cable connector toward the driver side of the vehicle to disconnect the cable from the differential lock lever. Figure 16-12 Differential Lock Cable Bracket 1. Apply pressure to locking tabs of the cable.
Page 265 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal TOP VIEW Loosen retaining nuts to remove Remove fuel line. accelerator cable from electric box. Figure 16-14 Fuel Line Figure 16-15 Accelerator Cable ENGINE GROUND TOP VIEW RETAINING NUT SPRING RELEASE NUTS Figure 16-16 Engine Ground Wire Figure 16-17 Shifter Cable...
Page 266 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: STARTER/ GENERATOR YELLOW YELLOW WHITE OIL LEVEL SENSOR JUMPER WIRE GROUND Figure 16-18 Generator Wires Figure 16-19 Oil Level Sensor Jumper Wire WHITE/BLACK WIRE BLACK WIRE Figure 16-20 Engine Kill Switch Wire 5.15.
Page 267 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal PLASTIC WIRE TIE FLEX BRAKE HOSE Figure 16-21 Cover Brake Hose Fitting CABLE SUPPORT BRACKET Figure 16-22 Park Brake Cable Figure 16-23 Brake Hose 8. Use a hydraulic jack under the transaxle (Figure 16-25, Page 16-12) and raise the vehicle. Place jack stands, set at approximately 17-1/2 inches (44.5 cm) in height, under the frame (Figure 16-26, Page 16-12).
Page 268 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: Figure 16-24 Shock Absorbers PROPER POSITIONING PROPER POSITIONING OF FLOOR JACK OF JACK STANDS APPROX. 17-1/2" (44.5 cm) Figure 16-25 Raise Vehicle Figure 16-26 Position Jack Stands Page 16-12 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 269 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal REMOVE BOLTS, THEN ROTATE SHACKLES UP AND AWAY FROM SPRINGS. Figure 16-27 Spring Retainer Bolts Figure 16-28 Rear Shackles 13. Carefully lift the snubber out of the snubber bracket in the vehicle frame and lower it to the floor (Figure 16-29, Page 16-13).
Page 270 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: 17. Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle (Figure 16-33, Page 16-14). 18. Loosen, but do not remove, the governor arm retaining bolt. Remove the governor arm from the shaft (Figure 16-34, Page 16-14).
Page 271: Unitized Transaxle Installation
MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Figure 16-35 Forward/Reverse Shifter Bracket UNITIZED TRANSAXLE INSTALLATION See General Warning, Section 1, Page 1-1. 1. Install the wheels. See General Information, Section 8, Page 8-1. 2. Install the leaf springs. See Multi-Leaf Spring Installation, Section 9, Page 9-3. 3.
Page 272 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 6. Install the differential lock cable and bracket. 6.1. Connect the differential lock cable spring (1) to the differential lock arm on the housing (Figure 16-36, Page 16-16). 6.2.
Page 273 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation 11. Install the key onto the input shaft (Figure 16-44, Page 16-19). 12. Position the driven clutch on the transaxle input shaft and install the washer (yellow side facing out) and mounting bolt and tighten to 14 ft-lb (19.0 N·m) (Figure 16-44, Page 16-19).
Page 274 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: Figure 16-41 Shock Absorber Figure 16-42 Leaf Springs Figure 16-43 Leaf Springs and Shackles Page 16-18 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 275 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation SNUBBER SNUBBER BRACKET Figure 16-44 Driven Clutch Figure 16-45 Snubber 19. Connect the park brake cables. See Park Brake Cable Installation, Section 6, Page 6-34. 20. Use a 3/8-inch flare nut wrench to connect the brake hoses to the left and right rear brake clusters and bleed the air from the brake lines.
Page 276 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 25. Connect the 6-gauge white wire to the F2 post and the 6-gauge black ground wire to the A2 post of the starter generator and tighten to 48 in-lb (5.4 N·m). Connect the 16-gauge yellow wire to the DF post and tighten to 30 in-lb (3.4 N·m) (Figure 16-48, Page 16-20).
Page 277 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation TOP VIEW CLAMP ACCELERATOR CABLE Figure 16-51 Connect Cable to Cam Figure 16-52 Connect Fuel Line 28. Connect accelerator cable to actuator cam in the electrical box. Position the accelerator cable in mount- ing slot in the wall of the electrical box and tighten mounting nuts to 18 in-lb (2.0 N·m) (Figure 16-51, Page 16-21).
Page 278 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: CLAMP Figure 16-55 Carburetor Vent Tube 34. Install transaxle drain plug and tighten to 21 ft-lb (28.5 N·m). 35. Fill transaxle with 29 oz. (.85 liter) 80-90 WT. API Class GL-3 or 80-90 WT. AGMA Class 5 EP gear lubri- cant.
Page 279: Forward/Reverse Shifter Cable
MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Forward/Reverse Shifter Cable Push cable into the bracket. Figure 16-57 Differential Cable Installation TOP VIEW SHIFTER SHIFTER F N R LEVER Figure 16-58 Forward/Reverse Positions FORWARD/REVERSE SHIFTER CABLE See General Warning, Section 1, Page 1-1. If the Forward/Reverse shifter cable is damaged in any way, it must be replaced.
Page 280: Forward/Reverse Shifter Cable Installation
MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Forward/Reverse Shifter Cable FORWARD/REVERSE SHIFTER CABLE INSTALLATION 1. Route the cable to the transaxle shifter lever, beginning at the Forward/Reverse shifter. 2. Secure the cable with retaining nut (5) on each side of the shifter cable support bracket at the transaxle (Figure 16-59, Page 16-24) and tighten nuts to 22 ft-lb (29.8 N·m).
Page 281: Forward/Reverse Shifter Cable Adjustment
MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System FORWARD/REVERSE SHIFTER CABLE ADJUSTMENT Place the shifter lever in the NEUTRAL position (straight up) (Figure 16-58, Page 16-23). For minor adjust- ments, the nut (1) may be loosened and the ball joint socket (2) rotated to get the proper adjustment (Figure 16-59, Page 16-24).
Page 282: Differential Lock Cable Removal
MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System DIFFERENTIAL LOCK CABLE REMOVAL 1. Place the differential lock handle in the disengaged position. 2. Remove wire tie (6) securing the cable to the vertical support (Figure 16-60, Page 16-27). 3. Use a pair of pliers and apply pressure to the locking tabs of the cable end (1) where it attaches to the differential lock handle mounting bracket (Figure 16-12, Page 16-8).
Page 283 MC012C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System 1. Rotate the cable connector toward the passenger side of the vehicle to connect the cable to the differential lock lever. 2. Push plastic cable retainer toward the front of the vehicle to secure the cable to the bracket.
Page 285: Section 17 - Torque Converter
Maintaining proper adjustment of the engine and governor, as well as the torque converter, is essential to the troubleshooting process. If these adjustments are within Club Car specifications and, when climbing a steep hill, the engine begins to lose RPM before the drive belt reaches the top of the driven clutch, there is a torque converter problem.
Page 286 TORQUE CONVERTER Troubleshooting 2. Inspect both clutches for dirt and debris buildup on component parts. Clean the exterior surfaces of both with water to remove any dust or dirt, then drive the vehicle and check for proper operation. 3. If cleaning both clutches does not solve the problem, disassemble and thoroughly clean all parts in the drive clutch.
Page 287: Drive Belt
TORQUE CONVERTER Drive Belt DRIVE BELT See General Warning, Section 1, Page 1-1. The drive belt should be inspected semiannually for wear and glazing. If it is excessively worn, frayed, or glazed, replace the belt. As the drive belt wears, the engine RPM will increase to compensate for the change in torque converter ratio. This will keep the vehicle’s maximum ground speed correct at 17-19 mph (27-31 km/h).
Page 288: Drive Clutch
TORQUE CONVERTER Drive Clutch DRIVE CLUTCH See General Warning, Section 1, Page 1-1. CAUT ION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. DRIVE CLUTCH REMOVAL 1.
Page 289: Drive Clutch Cleaning And Inspection
TORQUE CONVERTER Drive Clutch Use Club Car clutch holder while tightening or loosening drive VEHICLE BODY clutch retaining bolt. REMOVED FOR CLARITY CLUTCH HOLDER DRIVEN CLUTCH DRIVE CLUTCH DRIVE CLUTCH RETAINING BOLT Hook clutch holder on boss of pully Insert drive clutch...
Page 290: Drive Clutch Disassembly
TORQUE CONVERTER Drive Clutch DRIVE CLUTCH DISASSEMBLY CAUT ION • The drive clutch is balanced as an assembly. Before disassembly, make match marks on the clutch cover and on the moveable face assembly so they can be reassembled in the same positions (Figure 17-5, Page 17-6).
Page 291: Inspection Of Drive Clutch Parts
TORQUE CONVERTER Drive Clutch 5. Remove the clutch weights. 5.1. Remove the screws and flat washers attaching the weights (Figure 17-9, Page 17-9). 5.2. Pull the weight assemblies, with pins, from the clutch. 5.3. Remove the plastic washers, weights and wave washer from the pins. Before removing, note the orientations of the wave washer and of the primary and secondary weights to one another (Figure 17-12, Page 17-10 and Figure 17-13, Page 17-10).
Page 292 TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES Figure 17-7 Drive Clutch Assembly Page 17-8 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 293 TORQUE CONVERTER Drive Clutch Remove these items from ribs: 1/4-20 SCREW 10-24 SCREW FLAT WASHER FLAT WASHER WEIGHT DRIVE BUTTON DRIVE BUTTON TAKE UP SPRING RIBS WEIGHT SLOTS IN HUB CASTING Figure 17-8 Drive Button Mounting Figure 17-9 Weight Position PRESS RAM Use a scribe to remove spiral back-up rings from both...
Page 294: Drive Clutch Assembly
TORQUE CONVERTER Drive Clutch DRIVE CLUTCH ASSEMBLY 1. Press idler bearing (3) onto the shaft of the fixed face assembly (2). Press on the inner race of the bearing only. Make sure that the cup side of bearing is facing away from the fixed face (Figure 17-7, Page 17-8). 2.
Page 295: Drive Clutch Installation
TORQUE CONVERTER Drive Clutch Install white washers on each side of pin. Pin should protrude an equal amount on both sides. Figure 17-14 Install White Washers 12. Install the 1/4-20 screws and washers (1) and tighten them to 10 ft-lb (13 N·m) (Figure 17-7, Page 17-8). See following NOTE.
Page 296: Driven Clutch
TORQUE CONVERTER Driven Clutch DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED Figure 17-15 Correct Orientation of Drive Button Take-up Spring 4. Install the drive belt as instructed. See Drive Belt Installation on page 17-3. 5. Connect battery and spark plug wire(s). See Connecting The Battery on page 1-3. 6.
Page 297: Driven Clutch Inspection
TORQUE CONVERTER Driven Clutch ý WARNING • Do not place fingers under the cam when removing the cam. The moveable face may spin when the cam buttons release from the cam ramps, resulting in severe personal injury. 2. Insert a puller plug (CC P/N 1014507) (Figure 17-18, Page 17-15) into the shaft bore and use a driven clutch cam puller (CC P/N 1014508) to remove the cam (4) from the fixed face shaft (8).
Page 298 TORQUE CONVERTER Driven Clutch TYPICAL 3 PLACES Figure 17-16 Driven Clutch Assembly Page 17-14 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 299 TORQUE CONVERTER Driven Clutch Place puller plug in bore of cam (A). Then clamp driven clutch cam puller onto three flat surfaces of the cam. Using external snap DRIVEN CLUTCH ring pliers, remove CAM PULLER retaining ring. PULLER PLUG Figure 17-17 Remove Retaining Ring Figure 17-18 Driven Clutch Disassembly 5.1.
Page 300 TORQUE CONVERTER Driven Clutch NOTE: This process is for field or remote assembly requirements where hydraulic and pneumatic press equipment is not available. Use the Cam Installation Tool (CC P/N 101808401) for this process (Figure 17-20, Page 17-16). CAM PRESS TOOL Figure 17-19 Cam Press Tool Figure 17-20 Cam Installation Tool 5.2.1.
Page 301: Driven Clutch Installation
TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH INSTALLATION 1. To install the driven clutch, reverse the removal procedure. Make sure that the washer (12) is mounted with the flat portion of the washer against the driven clutch as shown (Figure 17-16, Page 17-14). Secure with a new bolt (11).
Page 303 INDEX bumper, tube installation ............4-2 accelerator removal ..............4-2 pedal adjustment .............5-6 removal ............5-5 cargo bed air filter ..............14-18 bumper adjustment ..........4-13 axle CAUTION bearing definition of ............1-1 installation ...........16-5 cleaning removal ............16-3 vehicle body ............4-1 column, steering assembly ............7-4 battery hydrometer test ..........11-11 installation ............12-43 DANGER...
Page 304 INDEX fuel level sending unit testing ............11-33 key switch hour meter circuit engine kill circuit testing ......... 11-30 testing ............11-37 installation ...........12-24, 12-26 operation ............12-31 removal ............12-24 fuel gauge/hour meter (gasoline vehicles) starter circuit testing ........11-15 kill circuit, engine operation ............
Page 305 INDEX suspension, front a-arm safety installation ...........7-16 statements ............1-1 kingpin and steering spindle serial number, vehicle ..........3-1 installation ...........7-15 shock absorber toe-in adjustment ..........7-13 see suspension, front and suspension, rear suspension, rear solenoid shock absorber testing ............11-17 removal and inspection .........9-1 spark plug snubber gap adjustment ..........13-2...
Page 306 tube bumper see bumper, tube voltage regulator testing ............11-22 WARNING definition of ............1-1 wheel cylinder see brakes, wheel cylinder wire continuity testing ........11-20 wiring diagram ............ 11-6...
Page 307 5. If you are reviewing a Kit Instruction, were all indicated parts included in your kit? Yes / No Your Comments and Suggestions: Please send a copy of this page to: Fax: (706) 228-2662 or Thank You! E-mail: Tech_Pubs@clubcar.com Club Car’s Technical Publications Department 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual...
Page 309 Club Car NOTES...
Page 310 Club Car NOTES...
Page 312 Club Car, LLC 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...

This manual is also suitable for:

Carryall 272 Carryall 472 Xrt 1200Xrt1200 se

Club Car Turf 272 Maintenance And Service Manual

Section 1 - Safety

Section 2 - Vehicle Specifications

Section 3 - General Information

Section 4 - Body and Trim

Section 5 - Accelerator and Brake Pedal Assemblies

Section 6 - Mc012C-Bs00 Transaxle: Hydraulic and Park Brake Systems

Section 7 - Steering and Front Suspension

Section 8 - Wheels and Tires

Section 9 - Rear Suspension

Section 10 - Periodic Maintenance

Section 11 - Troubleshooting and Electrical System: Fe400, Key-Start Engine

Section 12 - Electrical Components: Fe400, Key-Start Engine

Section 13 - Fe400 Engine

Section 14 - Fuel System

Section 15 - Exhaust System

Section 16 - Mc012C-Bs00 Unitized Transaxle with Differential Lock

Section 17 - Torque Converter

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