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Club Car XRT 950 2009 Maintenance And Service Manual

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2009-2010 XRT 950 Maintenance
and Service Manual
XRT 950 4x2, XRT 950 4x4, XRT 950 EX 4x4
Manual Number 103472727
Edition Code 1208G0610F

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Table of Contents
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Summary of Contents for Club Car XRT 950 2009

  • Page 1 2009-2010 XRT 950 Maintenance and Service Manual XRT 950 4x2, XRT 950 4x4, XRT 950 EX 4x4 Manual Number 103472727 Edition Code 1208G0610F...
  • Page 3 If it appears that a service question is not answered in this manual, please contact your nearest authorized Club Car dealer or distributor for assistance. You may also write to us at: Club Car, Inc., P.O. Box 204658; Augusta, GA 30917-4658 USA, Attention: Technical Services.

  • Page 5: Table Of Contents

    CONTENTS SECTION 1 — SAFETY ............................. 1-1 Safety Details ..............................1-1 Personal Safety ............................1-1 Machine Safety............................1-1 Information..............................1-1 General Warning ............................1-2 Disabling the Vehicle..........................1-3 Disconnecting the Battery – Gasoline Vehicles .................... 1-4 Connecting the Battery – Gasoline Vehicles ....................1-4 SECTION 2 —...
  • Page 6 Under seat Center Panel Installation ......................4-22 Rear Fender..............................4-22 Rear Fender Removal..........................4-22 Rear Fender Installation ........................... 4-23 Cargo Bed..............................4-23 Cargo Bed Removal ..........................4-23 Cargo Bed Installation..........................4-24 SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP ................5-1 Accelerator Pedal Removal ..........................
  • Page 7 Front Wheel Free Play Inspection ......................7-13 Front Wheel Bearings and Hub Removal....................7-13 Front Wheel Bearings and Hub Installation ....................7-14 SECTION 8 — WHEELS AND TIRES ......................... 8-1 General Information ............................8-1 Wheels ................................. 8-2 Wheel Removal ............................8-2 Wheel Installation ............................
  • Page 8 Neutral Switch Removal ........................... 12-1 Neutral Switch Installation ........................12-2 Carburetor Solenoid............................. 12-2 Carburetor Solenoid Removal........................12-2 Carburetor Solenoid Installation........................ 12-3 Voltage Regulator ............................12-3 Voltage Regulator Removal ........................12-3 Voltage Regulator Installation ........................12-4 Warning Lights ............................12-5 Warning Light Removal ..........................12-5 Warning Light Installation .........................
  • Page 9 Carbon Canister Installation ........................14-10 SECTION 15 — EXHAUST SYSTEM........................ 15-1 Muffler Removal ............................15-1 Muffler Installation............................15-1 Exhaust Pipe Removal..........................15-2 Exhaust Pipe Installation ..........................15-2 SECTION 16 — FRONT DIFFERENTIAL......................16-1 Front Differential Removal ..........................16-1 Front Differential Installation ......................... 16-3 Front Halfshaft Removal..........................

  • Page 11: Section 1 - Safety

    SECTION 1 — SAFETY SAFETY DETAILS To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible 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 labeled DANGER, WARNING, or CAUTION.

  • Page 12: General Warning

    General Warning SAFETY GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. Service technicians should become familiar with these general safety statements. Also, other specific safety statements appear throughout this manual and on the vehicle. DANGER •...

  • Page 13: Disabling The Vehicle

    SAFETY General Warning WARNING • Moving parts! Do not attempt to service the vehicle while it is running. • Ensure battery connections are clean and properly tightened. See Battery on page 12-11. • Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning could result in severe burns.

  • Page 14: Disconnecting The Battery - Gasoline Vehicles

    General Warning SAFETY DISCONNECTING THE BATTERY – GASOLINE VEHICLES Disable the vehicle. See Disabling the Vehicle on page 1-3. Disconnect the battery cables, negative (–) cable first, as shown (Figure 1-1). Disconnect the spark plug wire(s) from the spark plug(s). (–) 1.

  • Page 15: Section 2 - Vehicle Specifications

    SECTION 2 — VEHICLE SPECIFICATIONS XRT 950 XRT 950 XRT 950 EX SPECIFICATIONS POWER SOURCE Gasoline Gasoline Gasoline Engine: 4-cycle OHV, 480 cc, 14.0 maximum HP @3600 RPM (per SAE J 1940/1349), • • • twin-cylinder, air-cooled, with pressure lubrication system Fuel system: Down-draft carburetor with float bowl, fixed jets, fuel filters, and impulse fuel pump •...
  • Page 16 General Warning VEHICLE SPECIFICATIONS XRT 950 XRT 950 XRT 950 EX SPECIFICATIONS Governed RPM 3950 Turning Radius 139 in. (354 cm) Load bed height 32 in. (81.3 cm) 34 x 47 x 10 in. Load bed size (box bed inside dimensions) (86.4 x 119.4 x 25.4 cm) (9.25 cubic feet) Maximum payload capacity (level surface only)

  • Page 17: Section 3 - General Information

    WARNING • See General Warning on page 1-2. Throughout this manual, important features unique to each model are highlighted. Club Car, Inc. recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).

  • Page 18: Storage

    Storage GENERAL INFORMATION SERIAL NUMBER SD0601-123456 P O BOX 204658 AUGUSTA GA 30917 Figure 3-1 Serial Number Decal STORAGE See General Warning on page 1-2. DANGER • Never attempt to drain gasoline when the engine is hot or while it is running. •...

  • Page 19: Preparing The Vehicle For Extended Storage

    4.4. Disconnect the fuel vent line from the fuel tank vent nipple. 4.5. Plug the fuel tank vent nipple so that it is air tight. Club Car recommends using a slip-on vinyl cap. Remove both spark plugs, and pour 1/2 ounce (14.2 mL) of SAE 10 weight oil through each of the two spark plug holes.

  • Page 20: Returning The Stored Vehicle To Service

    Lifting The Vehicle GENERAL INFORMATION Adjust the tires to the recommended tire pressure. Section 2 — Vehicle Specifications 10. Perform semiannual periodic lubrication. See Periodic Maintenance on page 10-1. 11. Thoroughly clean the front body, rear body, seats, cargo bed, engine compartment, and underside of vehicle. 12.

  • Page 21: Lifting Only The Rear

    GENERAL INFORMATION Lifting The Vehicle 1026 Figure 3-3 Front Jack Stand Placement LIFTING ONLY THE REAR Place vehicle on a level surface. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL and set the park brake.

  • Page 22: Lifting The Entire Vehicle

    Using a Booster Battery (Jump Starting) GENERAL INFORMATION LIFTING THE ENTIRE VEHICLE Place vehicle on a level surface. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL and set the park brake. Chock the wheels. Disconnect battery and spark plug wire(s).
  • Page 23 GENERAL INFORMATION Using a Booster Battery (Jump Starting) Connect the end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the positive (+) terminal of the solenoid (Figure 3-6, Page 3-7). Connect the end of the second cable to the negative (-) terminal of the booster battery.

  • Page 25: Section 4 - Body And Trim

    SECTION 4 — BODY AND TRIM DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. CLEANING THE VEHICLE See General Warning on page 1-2. CAUTION • Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali materials on body panels or seats.

  • Page 26: Front Body Repair

    Front Body Repair BODY AND TRIM FRONT BODY REPAIR See General Warning on page 1-2. STRESS LINES OR STREAKS Repeatedly flexing the front body may cause white stress lines or streaks in the finish. To remove them: Hold a heat gun 12 inches (30 cm) away from the affected area, with the gun on its lowest heat setting. Slowly wave the heat gun back and forth over the affected area until the streak fades.

  • Page 27: Small Scratches That Cannot Be Buffed Out

    Tears, Large Scratches, and Abrasions on page 4-3. Using the brush provided with the touch-up paint (available from Club Car Service Parts, see following color chart), apply paint to the scratch. Multiple layers of paint may be required to fill the scratch.

  • Page 28: Front Body

    Front Body BODY AND TRIM FRONT BODY See General Warning on page 1-2. FRONT FASCIA REMOVAL 1062 Figure 4-1 Front Fascia Removal – under side of outer ends of front fascia Remove the two torx-head screws that secure the front of the each fender to the under side outer ends of the fascia (Figure 4-1, Page 4-4).
  • Page 29 BODY AND TRIM Front Body 1065 Figure 4-3 Front Fascia Removal – upper front fascia Remove the two bolts from upper front fascia (Figure 4-3, Page 4-5). 1054 Figure 4-4 Front Fascia Removal – pulling fascia forward Grip fascia, lift slightly to disengage the front fascia hook and pull fascia forward slightly to expose the headlight wiring (Figure 4-4, Page 4-5).

  • Page 30: Front Fascia Installation

    Front Body BODY AND TRIM 1053 Figure 4-5 Front Fascia Removal – disconnect headlights Disconnect headlight wiring at connectors (Figure 4-5, Page 4-6). Carefully remove front fascia from vehicle. FRONT FASCIA INSTALLATION Move front fascia in place and connect headlight wiring (Figure 4-5, Page 4-6). Carefully insert molded-in lower front fascia retaining hook into receiving slot in the fascia mounting frame.
  • Page 31 BODY AND TRIM Front Body Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Remove the two torx-head screws that secure the front of each fender to the lower corner of the fascia (Figure 4-6, Page 4-6).
  • Page 32 Front Body BODY AND TRIM 1157 Figure 4-9 Front Cowl Removal – unbolting upper fascia mounting frame Remove upper front fascia mounting frame bolts (Figure 4-9, Page 4-8). 1137 Figure 4-10 Front Cowl Removal – separating cowl from dash groove Grip cowl and pull cowl forward slightly to disengage the cowl from the dash groove (Figure 4-10, Page 4-8).
  • Page 33 BODY AND TRIM Front Body 1138 Figure 4-11 Front Cowl Removal – lift rear of cowl to disengage edges of cowl from dash Lift cowl slightly and continue to disengage edges of cowl from dash (Figure 4-11, Page 4-9). 1139 Figure 4-12 Front Cowl Removal –...

  • Page 34: Front Cowl Installation

    Front Body BODY AND TRIM 1140 Figure 4-13 Front Cowl Removal – lift off cowl Lift off cowl and remove from vehicle (Figure 4-13, Page 4-10). FRONT COWL INSTALLATION Front cowl installation is reverse of cowl removal. Tighten fascia mounting frame bolts to 11 ft-lb (15 N·m). Tighten front fascia bolts to 22 in-lb (2.5 N·m).

  • Page 35: Instrument Panel Installation

    BODY AND TRIM Front Body Figure 4-14 Choke Cable Clamp – loosen Figure 4-15 Choke Cable Disengage Remove wire ties that secure the choke cable to the frame. Loosen instrument panel by removing four screws that secure the top of the instrument panel to the top of the instrument panel support frame (Figure 4-16, Page 4-11) and removing the two bolts that secure the bottom of the instrument to the frame (Figure 4-17, Page 4-11).

  • Page 36: Front Fender Removal

    Front Body BODY AND TRIM FRONT FENDER REMOVAL Remove cowl. See Front Cowl Removal on page 4-6. Remove ROPS. See ROPS Removal on page 4-17. Loosen instrument panel by removing four screws that secure the top of the instrument panel to the top of the instrument panel support frame (Figure 4-18, Page 4-12) and removing the two bolts that secure the bottom of the instrument to the frame (Figure 4-19, Page 4-12).

  • Page 37: Front Fender Installation

    BODY AND TRIM Front Body 1178 Figure 4-21 Front Fender Hardware – rivet removal Pull the instrument panel back enough to free front fender. Remove front fender from vehicle. FRONT FENDER INSTALLATION Install front fender in the reverse order of removal. Tighten front fender hardware to 22 in-lb (2.5 N·m).

  • Page 38: Under Pedal Closeout Panel Installation

    Under Seat Closeout Panels BODY AND TRIM 1179 Figure 4-22 Under Pedal Closeout Panel Removal UNDER PEDAL CLOSEOUT PANEL INSTALLATION Install under pedal closeout panel in the reverse order of removal. UNDER SEAT CLOSEOUT PANELS See General Warning on page 1-2. UNDER SEAT CLOSEOUT PANEL REMOVAL Raise the cargo bed and engage the cargo bed lock pin (1) located at the driver side cargo bed hinge (2).
  • Page 39 BODY AND TRIM Under Seat Closeout Panels 1. Locking Pin 2. Bed Locking Pin Holes Figure 4-23 Bed Locking Pin 1134 Figure 4-24 Center Closeout Panel Removal – flex and lift front lower lip Remove the two bolts that secure the top of the side panels and the under seat closeout panels to the frame (Figure 4-25, Page 4-15).

  • Page 40: Under Seat Closeout Panel Installation

    Under Seat Closeout Panels BODY AND TRIM Figure 4-27 Closeout Panel Removal – rotate to remove Remove outer closeout panels from vehicle. UNDER SEAT CLOSEOUT PANEL INSTALLATION Install under seat closeout panels in the reverse order of removal. Tighten bolts to 22 in-lb (2.5 N·m). Connect battery and spark plug wire(s).

  • Page 41: Rops (Roll Over Protective Structure)

    BODY AND TRIM ROPS (Roll Over Protective Structure) ROPS (ROLL OVER PROTECTIVE STRUCTURE) See General Warning on page 1-2. ROPS REMOVAL See General Warning on page 1-2. NOTE: ROPS removal and installation will be easier with a assistant. Raise the cargo bed and engage the cargo bed lock pin (1) located at the driver side cargo bed hinge (2) (Figure 4-28, Page 4-17).
  • Page 42 ROPS (Roll Over Protective Structure) BODY AND TRIM K-00107.eps Figure 4-29 ROPS Page 4-18 2009-2010 XRT 950 Maintenance and Service Manual...

  • Page 43: Rops Installation

    BODY AND TRIM ROPS (Roll Over Protective Structure) ROPS INSTALLATION NOTE: Do not tighten the hardware until after the ROPS assembly is competed. K-00103.eps K-00104.eps Figure 4-30 Side-Tube and Front Support Figure 4-31 Side-Tube and Seat Back Support Position the ROPS side-tube (1) to the drivers-side of the vehicle (Figure 4-29, Page 4-18). Tilt the top of the side-tube (1) forward while inserting the side tube support (2) into the (vehicle) frame support (3) (to the outside of the dashboard (4) (Figure 4-30, Page 4-19).

  • Page 44: Side Panel

    Side Panel BODY AND TRIM CAUTION • Exceeding the maximum torque value could result in damage to the ROPS tubing and stripped thread on the hardware. SIDE PANEL See General Warning on page 1-2. SIDE PANEL REMOVAL 1. Locking Pin 2. Bed Locking Pin Holes K-00221 Figure 4-32 Bed Locking Pin Raise the cargo bed and engage the cargo bed lock pin (1) located at the driver side cargo bed hinge (2) (Figure...

  • Page 45: Side Panel Installation

    BODY AND TRIM Under Seat Center Panel Remove ROPS. See ROPS Removal on page 4-17. 1159 Figure 4-34 Side Panel Removal Remove the hardware securing the cargo bed rubber bumper. Remove the bumper to release the side panel support bracket (Figure 4-34, Page 4-21). Remove side panel from vehicle.

  • Page 46: Under Seat Center Panel Installation

    Rear Fender BODY AND TRIM 1040 1041 Figure 4-35 Under Seat Center Panel Removal Figure 4-36 Under Seat Center Panel Removed From Vehicle UNDER SEAT CENTER PANEL INSTALLATION Install under seat center panel in the reverse order of removal. Tighten bolts to 22 in-lb (2.5 N·m). REAR FENDER See General Warning on page 1-2.

  • Page 47: Rear Fender Installation

    BODY AND TRIM Cargo Bed 1. Locking Pin 2. Bed Locking Pin Holes K-00221 1154 Figure 4-37 Bed Locking Pin Figure 4-38 Rear Fender Removal Remove fender from vehicle. REAR FENDER INSTALLATION Install rear fender in the reverse order of removal. Tighten bolts to 35 in-lb (4.0 N·m).

  • Page 48: Cargo Bed Installation

    Cargo Bed BODY AND TRIM 1393 Figure 4-39 Cargo Bed Pivot Bolts Lower the cargo bed into the lowest position, but do not engage the cargo bed latch. Remove the two cargo bed mounting lock nuts, washers and pivot bolts. With the help of an assistant, lift the cargo bed and remove from vehicle.

  • Page 49: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. ACCELERATOR PEDAL REMOVAL See General Warning on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Remove the under-pedal closeout panel.
  • Page 50 Accelerator Pedal Removal ACCELERATOR AND BRAKE PEDAL GROUP 1023 Figure 5-3 Bed Locking Pin Figure 5-4 Remove Exhaust Pipe Heat Shield Detach accelerator cable extension spring(s) (Figure 5-5, Page 5-2). See following NOTE. NOTE: Later models have a second spring attached to a unique cable end bolt that is taller and grooved. Loosen cable clamp that secures accelerator cable (Figure 5-6, Page 5-2).

  • Page 51: Accelerator Pedal Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal Installation 1195 Figure 5-7 Remove Bow-Tie Locking Pin and Washer Remove rue pin and clevis pin securing master cylinder push rod to brake pedal (Figure 5-20, Page 5-8). 10. Remove hardware securing the pedal group assembly to chassis (Figure 5-8, Page 5-3) and (Figure 5-9, Page 5-3).

  • Page 52: Accelerator Cable Removal

    Accelerator Cable Removal ACCELERATOR AND BRAKE PEDAL GROUP Adjust accelerator cable. See Accelerator Cable Adjustment on page 5-7. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles on page 1-4. 2 1/4 in. (57 mm) 1287 Figure 5-10 Accelerator Pedal Return Spring Height ACCELERATOR CABLE REMOVAL See General Warning on page 1-2.
  • Page 53 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Cable Removal 1. Locking Pin 2. Bed Locking Pin Holes K-00221 1023 Figure 5-11 Bed Locking Pin Figure 5-12 Remove Exhaust Heat Shield Detach accelerator cable extension spring(s) (Figure 5-13, Page 5-5). See following NOTE. NOTE: Later models have a second spring attached to a unique cable end bolt that is taller and grooved.

  • Page 54: Accelerator Cable Installation

    Accelerator Cable Installation ACCELERATOR AND BRAKE PEDAL GROUP Figure 5-15 Disconnect Cable End From Engine (bolt may Figure 5-16 Disconnect Z-Shaped Cable End From Pedal differ from shown) ACCELERATOR CABLE INSTALLATION NOTE: A replacement accelerator cable (CCI P/N 103789401) is now available for vehicles that may exhibit intermittent binding or sticking during operation in cold environments if moisture gets into the cable housing.

  • Page 55: Accelerator Cable Adjustment

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Cable Adjustment CAUTION • Failure to remove burrs will damage the cable bellows during installation. 2.5. Paint the inside of the enlarged hole to prevent corrosion. 2.6. Secure the hydraulic brake hose in its original location with clamp. 2.7.

  • Page 56: Brake Pedal Removal

    Brake Pedal Removal ACCELERATOR AND BRAKE PEDAL GROUP 2315 2316 Figure 5-17 Fully Turn Throttle Bellcrank Until It Contacts Figure 5-18 Correct Throttle Bellcrank Position With Accelerator Pedal To Floor BRAKE PEDAL REMOVAL See General Warning on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Remove the under-pedal closeout panel.

  • Page 57: Brake Pedal Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal Installation Remove bow-tie locking pins and washers securing each end of brake pedal pivot rod to bracket (Figure 5-21, Page 5-9). Slide pedal to one side and remove from vehicle. 1192 Figure 5-21 Remove Brake Pedal Bow-Tie Locking Pins BRAKE PEDAL INSTALLATION Maneuver brake pedal into position in bracket and secure with washers and bow-tie locking pins.

  • Page 59: Section 6 - Brakes

    If any repair or servicing needs to be performed, we recommend that it be performed by an authorized Club Car distributor/dealer using Club Car OEM parts. TROUBLESHOOTING See General Warning on page 1-2.
  • Page 60 Troubleshooting BRAKES TROUBLESHOOTING GUIDE – HYDRAULIC SYSTEM COMPONENTS SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Adjust push rod. See Brake Pedal Improperly adjusted master cylinder push rod Adjustment, Section 5, Page 5-9. Replace brake discs. See Brake Discs on Cracked or thin disc page 6-14.
  • Page 61 BRAKES Troubleshooting TROUBLESHOOTING GUIDE – HYDRAULIC SYSTEM COMPONENTS SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Replace the brake discs. See Brake Discs Warped or worn brake discs on page 6-14. Pulsating brake pedal Bent wheel Replace the wheel. Replace bearings. See Steering and Front Worn or damaged wheel bearings Suspension Section.

  • Page 62: Brake System Inspection

    Troubleshooting BRAKES BRAKE SYSTEM INSPECTION See General Warning on page 1-2. The hydraulic brake system and park brake system should be inspected immediately after any service to either of the brake systems. Brake Pedal Inspection • When the brakes are applied during vehicle operation, the vehicle should come to a smooth, straight stop. If the vehicle swerves or fails to stop, have the brake system checked and adjusted as required.
  • Page 63 BRAKES Troubleshooting Park Brake Inspection • Engage the park brake handle. When latched, the park brake should lock the wheels and hold the vehicle stationary (on incline of 20% or less). If not, adjust the park brake. See Park Brake Adjustment on page 6-26. •...

  • Page 64: Hydraulic And Mechanical Components

    Hydraulic and Mechanical Components BRAKES HYDRAULIC AND MECHANICAL COMPONENTS CAUTION • When repairing hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

  • Page 65: Brake Fluid Reservoir

    BRAKES Hydraulic and Mechanical Components BRAKE FLUID RESERVOIR 1. Full Level 2. Safe Level 3. Low Level Figure 6-2 Brake Fluid Access Figure 6-3 Brake Fluid Reservoir The brake fluid reservoir (5) is located under the hood and under the round access panel (Figure 6-2). Raise the hood and remove the round access panel to check the brake fluid level.
  • Page 66 Hydraulic and Mechanical Components BRAKES Front Brake Hose Removal NOTE: If any portion of the brake hose is found to be damaged, the entire hose assembly must be replaced. Lift and support the front of vehicle and remove the wheel. See Lifting The Vehicle, Section 3, Page 3-4. Use a flare-nut wrench to disconnect the front brake hose at the master cylinder (Figure 6-4, Page 6-8).
  • Page 67 BRAKES Hydraulic and Mechanical Components Figure 6-6 Front Brake Hose Clamps and Tee Figure 6-7 Remove Brake Hose Wire Ties Front Brake Hose Installation Feed the new brake hose assembly into the front of the vehicle at each caliper and the master cylinder. Carefully insert the flared end of the brake hose into the master cylinder and tighten the fitting to 146 in-lb (16.5 N·m) (Figure 6-4, Page 6-8).
  • Page 68 Hydraulic and Mechanical Components BRAKES Remove the banjo bolt, copper washers and rear brake hose from each rear caliper assembly (Figure 6-9, Page 6-10). Discard the copper washers. See following NOTE. NOTE: Place a pan under each rear caliper assembly to collect the brake fluid. Place a plastic bag around each caliper to prevent debris from entering the brake line ports.
  • Page 69 BRAKES Hydraulic and Mechanical Components Figure 6-12 Rear Brake Hose Routing Under Seat Figure 6-13 Rear Brake Hose Tee Rear Brake Hose Installation Feed the new brake hose assembly from the rear of the vehicle forward to the master cylinder following the original route.

  • Page 70: Brake Pads And Caliper

    Hydraulic and Mechanical Components BRAKES BRAKE PADS AND CALIPER See General Warning on page 1-2. Brake Pad and Caliper Removal WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components.
  • Page 71 BRAKES Hydraulic and Mechanical Components Figure 6-16 Caliper Slide-Pin Bolts Figure 6-17 Brake Pads Brake Pad and Caliper Installation WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components.

  • Page 72: Brake Discs

    Hydraulic and Mechanical Components BRAKES WARNING • Use the top bleeding port on each caliper to bleed that respective front wheel. • Ensure hydraulic hoses cannot contact any moving parts that will cause wear and damage. Repeat procedure for the opposite brake if necessary. Install the tire and wheel.

  • Page 73: Master Cylinder Replacement

    BRAKES Hydraulic and Mechanical Components MASTER CYLINDER REPLACEMENT See General Warning on page 1-2. Master Cylinder Removal 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. Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic system.

  • Page 74: Bleeding The Hydraulic Brake System

    Bleeding the Hydraulic Brake System BRAKES Figure 6-20 Master Cylinder Mounting Hardware Master Cylinder Installation Install master cylinder in reverse order of removal. Tighten locknuts to 168 in-lb (19 N·m). Tighten the front and rear brake hose fittings to 146 in-lb (16.5 N·m) Check brake pedal adjustment.

  • Page 75: Vacuum Bleeding Of Brakes On A Dot 5 Fluid Filled System

    BRAKES Bleeding the Hydraulic Brake System VACUUM BLEEDING OF BRAKES ON A DOT 5 FLUID FILLED SYSTEM Turn the key switch OFF and remove the key. Place the Forward/Reverse switch in NEUTRAL. Check the brake pedal and master cylinder push rod for proper adjustment before the brake system is bled. See Brake Pedal Adjustment, Section 5, Page 5-9.

  • Page 76: Refilling The Hydraulic System

    Bleeding the Hydraulic Brake System BRAKES The following procedure will enable correct bleeding: Turn the key switch OFF and remove the key. Place the Forward/Reverse switch in NEUTRAL. Check the brake pedal and master cylinder push rod for proper adjustment before the brake system is bled. See Brake Pedal Adjustment, Section 5, Page 5-9.

  • Page 77: Park Brake System

    BRAKES Park Brake System PARK BRAKE SYSTEM See General Warning on page 1-2. 1170 Figure 6-21 Park Brake System PARK BRAKE CABLE REMOVAL Chock the wheels to prevent the vehicle from rolling. Remove handle grip and loosen the set screw that locks the adjustment knob at the end of the park brake handle (Figure 6-22, Page 6-20).
  • Page 78 Park Brake System BRAKES 1039 1030 Figure 6-22 Adjustment Knob Set Screw Figure 6-23 Remove Cable Clamp from Trailing Arm Remove the e-clip securing the cable sheath to the rear caliper assembly (Figure 6-24, Page 6-20). Slide the cable forward to release the sheath ferrule from the caliper bracket (Figure 6-25, Page 6-20). Move the cable down and toward the rear of the vehicle to remove the cable end from the caliper park brake lever (Figure 6-26, Page 6-21).
  • Page 79 BRAKES Park Brake System 1035 1040 Figure 6-26 Remove Cable From Lever Figure 6-27 Remove Seat Panel Pull handle up to the engaged position. Remove the seat and the six screws that secure the seat panel to the chassis (Figure 6-27, Page 6-21). Remove seat panel and set aside.
  • Page 80 Park Brake System BRAKES 1049 1048 Figure 6-30 Spacer Located In Handle Assembly Figure 6-31 Remove and Retain Spacer 1036 1045 Figure 6-32 Remove Cotter Pin from Clevis Pin Figure 6-33 Remove Clevis Pin from Compensator Link 13. Remove the locknut, washer, bolt and short spacer securing the cables to the park brake handle (Figure 6-34, Page 6-23).

  • Page 81: Park Brake Cable Installation

    BRAKES Park Brake System 1047 1037 Figure 6-34 Remove the Hardware and Short Spacer Figure 6-35 Remove E-Clip At Compensator Link Securing the Cables 15. Remove the cable from the vehicle. 16. Remove the remaining park cable in the same manner. PARK BRAKE CABLE INSTALLATION WARNING •...
  • Page 82 Park Brake System BRAKES 1038 1043 Figure 6-36 Assemble Cable End to Compensator Link Figure 6-37 Orient Cable Clamps in Handle Assembly 1044 1047 Figure 6-38 Cable Clamps and Short Spacer Assembled Figure 6-39 Install Nut To Retain Clamps And Short Spacer But Do Not Tighten Attach the compensator link to the park brake handle with clevis pin, washer and cotter pin (Figure 6-40, Page 6-25) and (Figure 6-41, Page 6-25).

  • Page 83: Park Brake Handle Removal

    BRAKES Park Brake System 1045 1046 Figure 6-40 Attach Compensator Link With Clevis Pin Figure 6-41 Install Washer and Cotter Pin PARK BRAKE HANDLE REMOVAL Chock the wheels to prevent the vehicle from rolling. Pull handle up to the engaged position. Remove the seat and the six screws that secure the seat panel to the chassis (Figure 6-27, Page 6-21).

  • Page 84: Park Brake Adjustment

    Park Brake System BRAKES PARK BRAKE ADJUSTMENT NOTE: The hydraulic portion of the brake system has an automatically adjusting brake pad system. The park brake system does not have an automatically adjusting system and requires regular adjustment depending on use. Rear Caliper Park Brake Lever Adjustment Chock the wheels, release the park brake, and place the Forward/Reverse handle in the NEUTRAL position.
  • Page 85 BRAKES Park Brake System 5.2. Tighten adjustment bolt two full revolutions. 5.3. Tighten the jam nut on the caliper lever to 55 in-lb (6.2 N·m) while holding the adjustment bolt stationary. 5.4. At park brake handle, loosen adjustment knob one full revolution and check park brake. 5.5.

  • Page 87: Section 7 - Steering And Front Suspension

    SECTION 7 — STEERING AND FRONT SUSPENSION DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. STEERING WHEEL See General Warning on page 1-2. STEERING WHEEL REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Rotate steering wheel to a straight ahead position.

  • Page 88: Steering Wheel Installation

    Steering Column STEERING AND FRONT SUSPENSION 1180 1181 Figure 7-1 Steering Wheel Removal Figure 7-2 Steering Wheel Puller Installed STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft splines and taper before installing the steering wheel.
  • Page 89 STEERING AND FRONT SUSPENSION Steering Column 000896-001 000896-001 Figure 7-3 Steering System 2009-2010 XRT 950 Maintenance and Service Manual Page 7-3...

  • Page 90: Steering Column Installation

    Steering Column STEERING AND FRONT SUSPENSION 1081 Figure 7-4 Intermediate Shaft to Steering Column Bolt Remove the four lock nuts and bolts (4 and 5) securing the steering column (11) to the chassis (Figure 7-3, Page 7-3). Remove steering column from vehicle. STEERING COLUMN INSTALLATION For ease of assembly and to prevent corrosion, apply a light coat of anti-seize or lubricating compound to the end of the steering column shaft.

  • Page 91: Rack And Pinion

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION See General Warning on page 1-2. RACK AND PINION REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Lift and support front of vehicle and remove the wheels. See Lifting The Vehicle, Section 3, Page 3-4. Remove the tie rod ball joint retaining nuts (Figure 7-5, Page 7-5).

  • Page 92: Rack And Pinion Installation

    Rack and Pinion STEERING AND FRONT SUSPENSION RACK AND PINION INSTALLATION For ease of assembly and to prevent corrosion, apply a light coat of anti-seize and lubricating compound to the splines of the pinion shaft. Insert the pinion shaft into the universal joint and install the bolt (3) in the universal joint but do not tighten (Figure 7-3, Page 7-3).

  • Page 93: Front Suspension

    STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warning on page 1-2. WHEEL ALIGNMENT Wheel alignment only consists of adjusting the toe-out of the front wheels. See Toe-Out Measurement on page 7-7. See following NOTE. NOTE: Unlike most vehicles, this vehicle is intended to have toe-out. Before any front suspension adjustments are made, inspect components for wear or damage and repair or replace as necessary.

  • Page 94: Strut Removal And Inspection

    Front Suspension STEERING AND FRONT SUSPENSION Rotate both of the tie rods equally. To decrease the toe-out, rotate both tie rods counterclockwise. To increase the toe-out, rotate both tie rods clockwise. Maintain an equal distance from the ball joint to the end of the threads on each tie rod (Figure 7-10, Page 7-8).

  • Page 95: Strut Installation

    STEERING AND FRONT SUSPENSION Front Suspension 1014 Figure 7-13 Pry Open Steering Knuckle To Remove Strut STRUT INSTALLATION Install the strut by reversing the removal procedure. See following NOTE. NOTE: Ensure tab on strut is aligned with the slot in the steering knuckle (Figure 7-14, Page 7-9). When installing struts and shocks, make sure front struts have identical part numbers and rear shocks have identical part numbers.
  • Page 96 Front Suspension STEERING AND FRONT SUSPENSION Pry out the thin axle nut flange where it is staked to the groove in the halfshaft (Figure 7-15, Page 7-10) and loosen the axle nut (Figure 7-16, Page 7-10). 1066 Figure 7-15 Undo Staked Flange Of Axle Nut Figure 7-16 Loosen Axle Nut Lift and support the front of the vehicle on jack stands and remove the front wheels.

  • Page 97: Steering Knuckle Installation

    STEERING AND FRONT SUSPENSION Front Suspension 1077 1010 Figure 7-17 Tie Rod Ball Joint Lock Nut Figure 7-18 A-arm Ball Joint Lock Nut 11. Push the halfshaft out of the steering knuckle. 12. Pry open the slot in the steering knuckle, to help it slide off the strut, and remove the knuckle from the vehicle (Figure 7-13, Page 7-9).

  • Page 98: A-Arm Installation

    Front Suspension STEERING AND FRONT SUSPENSION Lift and support the front of the vehicle on jack stands and remove the front wheel. See Lifting The Vehicle, Section 3, Page 3-4. Remove the A-arm ball joint locknut and separate the ball joint from the knuckle (Figure 7-19, Page 7-12). Remove the two bolts and lock nuts securing the A-arm to the chassis and remove A-arm from vehicle (Figure 7-20, Page 7-12).

  • Page 99: Ball Joint Installation

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs BALL JOINT INSTALLATION Apply a 1/8 inch (3.2 mm) wide bead of Loctite 641 all the way around the face of the ball joint. Once the Loctite is applied, force the ball joint into the steering knuckle. Make sure the ball joint is seated up to its shoulder and wipe off any excess Loctite.

  • Page 100: Front Wheel Bearings And Hub Installation

    Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION 1189 Figure 7-21 Front Wheel Bearing and Hub FRONT WHEEL BEARINGS AND HUB INSTALLATION Thoroughly clean and lubricate bore of steering knuckle. Press new bearing into bore until fully seated (Figure 7-21, Page 7-14). See following CAUTION. CAUTION •...

  • Page 101: Section 8 - Wheels And Tires

    SECTION 8 — WHEELS AND TIRES DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. GENERAL INFORMATION These vehicles are equipped with either all-terrain or mud tires. Tire size varies whether the vehicle is a two-wheel drive model or a four-wheel drive model.

  • Page 102: Wheels

    Wheels WHEELS AND TIRES • Keep lug nuts properly tightened to 85 ft-lb (115 N·m). • Keep the front and rear tires properly aligned and adjusted. • Inspect the brake hoses at all four wheels. The hoses should not come in contact with any component. •...

  • Page 103: Tire Removal

    WHEELS AND TIRES Tires When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal on page 8-3. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. Remove the tire and wheel assembly from the vehicle as instructed above.
  • Page 104 Tires WHEELS AND TIRES NOTE: Because tubeless tires require a perfect seal in order to seat, keeping the tire and rim clean is very important. Apply a liberal amount of tire-mounting lubricant (soap and water solution) to both tire beads and rim flanges. Install the tire on the rim from the valve stem side.

  • Page 105: Section 9 - Rear Suspension

    SECTION 9 — REAR SUSPENSION DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. REAR SHOCK REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Lift and support the rear of the vehicle on jack stands and remove the rear wheel.

  • Page 106: Rear Shock Installation

    Rear Shock Installation REAR SUSPENSION REAR SHOCK INSTALLATION Installation is the reverse of removal. Tighten the upper hardware, using a new lock nut, and lower bolt to 70 ft-lb (95 N·m). Place bed locking pin in the stowed position and lower the cargo bed. See Cargo Bed, Section 4, Page 4-23. Install wheel and lower vehicle.

  • Page 107: Trailing Arm Removal

    REAR SUSPENSION Trailing Arm Removal 1293 Figure 9-6 Rear Lateral Link to Chassis Hardware Orientation TRAILING ARM REMOVAL See General Warning on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Pry out the thin axle nut flange where it is staked to the groove in the halfshaft (Figure 9-7, Page 9-3) and loosen the axle nut (Figure 9-8, Page 9-3).

  • Page 108: Trailing Arm Installation

    Trailing Arm Installation REAR SUSPENSION 1124 1296 Figure 9-9 Detach Brake Cable and Hose Clamp From Figure 9-10 Trailing Arm to Chassis Hardware Trailing Arm Remove the rear brake caliper. See Brake Pad and Caliper Removal on page 6-12. Support the brake caliper from the chassis with a wire hanger or wire tie. Ensure that there is no strain on the brake hose.

  • Page 109: Rear Wheel Bearings And Hubs

    REAR SUSPENSION Rear Wheel Bearings and Hubs REAR WHEEL BEARINGS AND HUBS See General Warning on page 1-2. REAR WHEEL FREE PLAY INSPECTION Raise the rear of the vehicle but do not remove the wheels. See Lifting The Vehicle, Section 3, Page 3-4. Using your hands, rotate the wheel.

  • Page 110: Rear Wheel Bearings And Hub Installation

    Rear Wheel Bearings and Hubs REAR SUSPENSION 1197 Figure 9-11 Hub/Bearing Assembly And Trailing Arm 1196 Figure 9-12 Rear Wheel Bearing and Hub REAR WHEEL BEARINGS AND HUB INSTALLATION Thoroughly clean and lubricate bore of casting. Press new bearing into bore until fully seated (Figure 9-12, Page 9-6). See following CAUTION. CAUTION •...

  • Page 111: Wheel Alignment

    REAR SUSPENSION Wheel Alignment Secure hub/bearing assembly to trailing arm with four new bolts (Figure 9-11, Page 9-6). Tighten bolts to 44 ft-lb (60 N·m). Tighten the axle nut to 142 ft-lb (193 N·m) and then stake the nut to the groove in the halfshaft. Install the brake disc and caliper.

  • Page 113: Section 10 - Periodic Maintenance

    Any vehicle not functioning correctly should not be used until it is properly repaired. This will prevent further damage to the vehicle and help prevent injury to occupants resulting from unsafe conditions. Contact your local Club Car dealer/distributor for repairs and semiannual and annual periodic service. WARNING •...

  • Page 114: Pre-Operation And Daily Safety Checklist

    See Figure 1-2. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with the controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.

  • Page 115: Performance Inspection

    FORWARD position, the vehicle should accelerate smoothly to full speed as the accelerator pedal is pressed. When the pedal is released it should return to the original position, and the engine should idle. Club Car vehicles operate at reduced speed in reverse.
  • Page 116 Periodic Service Schedule PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist on page 10-2. Daily service by owner Performance Inspection See Performance Inspection on page 10-3. Engine/exhaust area Remove/clean grass and debris from area Check engine oil level;...
  • Page 117 Stratton Vanguard Model 2900000 Service Engine Manual. Inspect, clean, and gap spark plug; replace if necessary. See authorized Club Car dealer or trained technician for service. Replace air filter element. See Air Intake Annual service by trained technician only System on page 10-13.

  • Page 118: Periodic Lubrication Schedule

    Periodic Lubrication Schedule PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS First change 5 - 8 hours 1 - 1/2 qt. (1.4L) with filter, 10W-30 API –additional change every 100 Change engine oil and oil filter classification SJ See Oil Viscosity hours of operation or annually, on page 10-10.

  • Page 119: Brake Fluid Reservoir

    PERIODIC MAINTENANCE Brake Fluid Reservoir BRAKE FLUID RESERVOIR CAUTION • Use only DOT 5 (silicone) brake fluid. Use of any other type brake fluid is not recommended. See Brake Fluid Reservoir on page 6-7. ENGINE OIL Even though the low oil pressure warning light on the instrument panel should illuminate if the oil level becomes low, the engine oil level should be checked daily.

  • Page 120: Engine Oil And Filter Change

    Engine Oil PERIODIC MAINTENANCE 1. Full Level 2. Safe Level 3. Low Level Figure 10-2 Engine Oil Level Check Figure 10-3 Center Access Panel ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 5 to 8 hours of operation. After that, the oil should be changed every 100 hours of operation or annually, whichever comes first.
  • Page 121 PERIODIC MAINTENANCE Engine Oil Figure 10-4 Engine Oil Drain Plug and Oil Filter Wrench Engine Oil Filter Change Drain the engine oil. See Engine Oil Draining on page 10-8. Place the oil drain pan under the engine oil filter (Figure 10-5). Remove the engine oil filter.

  • Page 122: Oil Viscosity

    Engine Oil PERIODIC MAINTENANCE filter before attaching it to the oil filter port (Figure 10-6). Install the new oil filter onto the engine oil filter port. See following NOTE. NOTE: Use only engine-compatible oil filters designed for your engine. Tighten the oil filter by hand 2/3 turn after gasket contact. Do not use a band wrench or channel lock pliers. Figure 10-7 Add Engine Oil Engine Oil Filling Add engine oil;...

  • Page 123: Spark Plugs

    PERIODIC MAINTENANCE Spark Plugs NOTE: Use a high quality detergent engine oil with API classification SF, SG, SH, SJ or higher for gasoline engines. See Briggs and Stratton Vanguard Model 2900000 Service Manual for further information regarding oil recommendation. Using multi-grade oils (5W-30, 10W-30, and 10W-40) may increase oil consumption. If multi-grade oil is used, check the oil level more frequently.

  • Page 124: Lubrication Change - Front Differential And Rear Transaxle

    Gearcase Lubrication PERIODIC MAINTENANCE The rear transaxle is equipped with a fill plug/dipstick (1) located on the top of the rear transaxle (Figure 10-11). When the vehicle is on a level surface, use the fill plug/dipstick (1) to determine the lubricant level (Figure 10-12) and (Figure 10-13).

  • Page 125: Air Intake System

    PERIODIC MAINTENANCE Air Intake System Figure 10-10 Rear Transaxle Drain Plug Figure 10-11 Rear Transaxle Check/Fill Plug 1. Full Level 2. Safe Level 3. Low Level Figure 10-12 Rear Transaxle Dipstick Figure 10-13 Rear Transaxle Lubricant Level Check AIR INTAKE SYSTEM AIR FILTER REPLACEMENT The air filter should be inspected periodically and replaced when necessary.

  • Page 126: Fueling Instructions

    Fueling Instructions PERIODIC MAINTENANCE Remove knob (1) and plate (2). Carefully remove the foam pre-cleaner (3) and air filter cartridge (4) assembly to prevent debris from entering carburetor. See following NOTE. NOTE: To clean foam pre-cleaner, separate it from cartridge and wash in liquid detergent and water. Squeeze dry in a clean cloth.

  • Page 127: Battery

    PERIODIC MAINTENANCE Battery NOTE: Use unleaded gasoline only. Whenever possible, avoid using oxygenated fuels and fuels that are blended with alcohol. Replace the fuel cap. Ensure that the cap is tightened securely. Clean any spilled fuel from the cap or around the fuel cap area. Figure 10-15 Fuel Tank BATTERY See Battery, Section 12, Page 12-11.

  • Page 129: Section 11 - Troubleshooting And Electrical System

    SECTION 11 — TROUBLESHOOTING AND ELECTRICAL SYSTEM DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. GENERAL INFORMATION This section contains the information required to correctly troubleshoot this vehicle. A troubleshooting guide is provided for general troubleshooting.

  • Page 130: Wiring Diagram

    Wiring Diagram TROUBLESHOOTING AND ELECTRICAL SYSTEM WIRING DIAGRAM Diode 1 HEAD LIGHTS WD1031003A-L Figure 11-1 Wiring Diagram – XRT 950 Initial Production Page 11-2 2009-2010 XRT 950 Maintenance and Service Manual...
  • Page 131 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagram Diode 4 W35 16 _ BLK WD1031003A-R Figure 11-2 Wiring Diagram – XRT 950 Initial Production (Continued) 2009-2010 XRT 950 Maintenance and Service Manual Page 11-3...
  • Page 132 Wiring Diagram TROUBLESHOOTING AND ELECTRICAL SYSTEM HEAD LIGHTS Diode 1 WD1031003B-L Figure 11-3 Wiring Diagram – XRT 950 Page 11-4 2009-2010 XRT 950 Maintenance and Service Manual...
  • Page 133 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagram Diode 4 W35 16 _ BLK WD1031003B-R Figure 11-4 Wiring Diagram – XRT 950 (Continued) 2009-2010 XRT 950 Maintenance and Service Manual Page 11-5...

  • Page 134: Troubleshooting Guide

    Troubleshooting Guide TROUBLESHOOTING AND ELECTRICAL SYSTEM 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. The procedures used in making these checks can be found in the referenced sections of this maintenance and service manual.
  • Page 135 TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine turns but fails to start. Fuel tank is empty Fuel System section Fuel line or filters clogged Fuel System section Fouled spark plug See Spark Plugs on page 10-11. See the Briggs &...
  • Page 136 Troubleshooting Guide TROUBLESHOOTING AND ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Spark plug fouls repeatedly. Incorrect plug See Spark Plugs on page 10-11. Unsuitable fuel, or incorrect (rich) fuel mixture Fuel System section See the Briggs & Stratton Vanguard engine Spark plug wire is damaged manual (CCI P/N 103568101).
  • Page 137 TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Charge coil does not charge battery. Test Procedure 5 – Starter Control Circuit on Loose or broken wire in the starter circuit page 11-16 Test Procedure 10 – Charge Coil on page Charge coil is shorted (failed closed) 11-26 25-amp fuse is blown...

  • Page 138: Test Procedures

    Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Hour meter adds increments with key See the Briggs & Stratton Vanguard engine Oil pressure switch failed open switch ON and engine not running. manual (CCI P/N 103568101). 10-amp fuse blows repeatedly.
  • Page 139 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures DANGER rubber gloves when working on or near batteries. For added protection, cover top of the battery when servicing the vehicle. • Battery – Poison! Contains acid! Causes severe burns! Avoid contact with skin, eyes, or clothing. –...
  • Page 140 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM 1.250 1.280 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 MM) above plates or to level View at eye level. indicator. Figure 11-5 Hydrometer Test Figure 11-6 Battery Electrolyte Level Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 °F (27 °C).
  • Page 141 TROUBLESHOOTING AND ELECTRICAL SYSTEM 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, the battery voltage with no electrical load, should be at least 12.4 volts.
  • Page 142 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM WARNING • If a fuse is blown, determine the cause of the failure and make necessary repairs before installing a new fuse. Use the appropriately rated fuse; if a fuse with a higher amp rating is used, damage to the vehicle electrical system may occur.
  • Page 143 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 1022 1021 Figure 11-8 Frame Ground Cable Figure 11-9 Engine Ground Cable WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. Disconnect the 6-gauge black wire from the battery. Place red (+) probe on disconnected end of cable. 2.
  • Page 144 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM With the key switch still in the ON position, place the red (+) probe of the multimeter on the (B) terminal and the black (–) probe on the (S) terminal of the key switch. The reading should indicate no continuity. If the reading indicates continuity, replace the key switch.
  • Page 145 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 1076 Figure 11-13 Solenoid Coil Wire If the readings differ from those described in step 5, perform the following test procedures: – Check the battery. See Test Procedure 1 – Battery on page 11-10. –...
  • Page 146 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM 1076 1067 Figure 11-14 Disconnect Solenoid Coil Wire Figure 11-15 Disconnect Solenoid Contact Wires Test for continuity between the small coil terminal (light green wire was connected to) and ground (Figure 11-16, Page 11-18). If no continuity, replace the solenoid. Test for no continuity between the two large terminals (Figure 11-17, Page 11-18).
  • Page 147 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 7 – Wire Harness Diodes See General Warning on page 1-2. A diode is designed to conduct current in one direction only. Depending on the application, diodes are used in the vehicle to control electrical system logic, or to help protect relay and switch contacts from excessive arcing. See following NOTE.
  • Page 148 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM DIODE TROUBLESHOOTING GUIDE DIODE IN-LINE WIRE FUNCTION FAILURE CONDITION SYMPTOM/COMMENT LOCATION (WIRES) Diode 1 w111 and w123 Blocking diode for Open Engine will shut off carburetor solenoid shortly after key switch control (powers carburetor is moved from START to solenoid when key switch ON position.
  • Page 149 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable. If the readings obtained in the previous steps are incorrect, replace the diode. See Diode Removal on page 12-11.
  • Page 150 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM 1148 1147 Figure 11-21 Test Diode 2 Figure 11-22 Test Diode 2 – Probes Reversed Test Diode 3 on wire 131 and 132 See General Warning on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Raise the hood, remove the access panel and disconnect the multi-pin connector from the key switch.
  • Page 151 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Figure 11-25 Disconnect Charge Coil Plug Figure 11-26 Disconnect Engine Kill Wire 1076 Figure 11-27 Disconnect Solenoid Coil Wire Set the multimeter to the diode test function. Connect the black (–) probe of the multimeter to the frame (ground) (Figure 11-28, Page 11-24). Connect the red (+) probe of the multimeter to the end of the 16-gauge green wire (w110).
  • Page 152 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM 1150 1142 Figure 11-28 Test Diode 3 Figure 11-29 Test Diode 3 – Probes Reversed Test Diode 4 on wire 112 and 130 See General Warning on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Disconnect the white bullet connector in the carburetor solenoid red wire (Figure 11-30, Page 11-24).
  • Page 153 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 8 – Neutral Switch (Transaxle) See General Warning on page 1-2. The neutral switch is located on top of the transaxle housing. Remove load from cargo bed first, raise bed and secure bed in raised position with bed locking pin.
  • Page 154 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM If any of the continuity readings are incorrect, replace the neutral switch. See Warning Light Removal on page 12-5. TEST PROCEDURE 9 – Wire Continuity See General Warning on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. To test a wire for continuity, disconnect either end from the electrical component to which it is attached.
  • Page 155 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Turn the key switch OFF. Place the Forward/Reverse handle in NEUTRAL and set the park brake. Chock the wheels. Ensure that the voltage regulator wires are connected correctly and are tight. If they are not, rewire or tighten as necessary.
  • Page 156 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM There should be no continuity when the key switch is in the ON or START position. If continuity is indicated, check for worn insulation on the white/black wire that grounds the wire to the frame. See Test Procedure 14 – Grounded Kill Wire on page 11-28.
  • Page 157 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Raise the hood and remove the access panel. Remove the wire harness connector from the key switch. Place the red (+) probe on the (M) terminal and the black (–) probe on the (G) terminal. With the key switch OFF, the reading should indicate continuity.
  • Page 158 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM 1076 Figure 11-40 Disconnect Carburetor Solenoid Red Wire Figure 11-41 Disconnect Starter Solenoid Coil Wire 1.4. Set the multimeter to 20 VDC. 1.5. Place the probes to measure the voltage between the end of the red wire (w122) and the frame ground (Figure 11-42, Page 11-31).
  • Page 159 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 1145 1146 Figure 11-42 Check for Voltage Between Harness and Figure 11-43 Measure Resistance of Carburetor Solenoid Ground Coil TEST PROCEDURE 17 – Low Oil Warning Light Circuit See General Warning on page 1-2. If the low oil warning light stays on, test the oil pressure switch.
  • Page 160 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM TEST PROCEDURE 18 – Fuel Level Sending Unit See General Warning on page 1-2. WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure.
  • Page 161 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 19 – Fuel Gauge See General Warning on page 1-2. 1. Black/Orange 2. Blue 4. Orange 6. Black/White 7. White Figure 11-45 Fuel Gauge/Hour Meter Terminals NOTE: Keep the battery connected during this test procedure. Fuel Gauge Disable the vehicle.
  • Page 162 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V 1. 20 VDC Setting 2. Orange 3. Black 4. White 5. Blue 1. 20 VDC Setting 2. Orange Figure 11-46 Fuel Gauge Voltage Test - Terminal 2 Figure 11-47 Fuel Gauge Voltage Test - Terminal 4 TEST PROCEDURE 20 –...
  • Page 163 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Use a multimeter set to 20 volts DC and place alligator clips on the multimeter probes. Connect the red (+) probe to the light switch terminal where the blue wire (w55) is connected (Figure 11-48, Page 11-35). Connect the black (–) probe of the multimeter to the negative (–) post of the battery.
  • Page 164 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM 7.2. Place the black (–) probe of multimeter into the black wire terminal (w44) of the wire harness and use an alligator clip to attach the red (+) probe onto the positive (+) battery terminal. If the multimeter reading is approximately 12 volts, the black wire has continuity.

  • Page 165: Section 12 - Electrical Components

    SECTION 12 — ELECTRICAL COMPONENTS DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. STARTER AND STARTER SOLENOID See General Warning on page 1-2. Refer to the engine manual for testing, removal, disassembly, and installation procedures. See the Briggs & Stratton Vanguard engine manual (CCI P/N 103568101).

  • Page 166: Neutral Switch Installation

    Carburetor Solenoid ELECTRICAL COMPONENTS 1151 Figure 12-1 Neutral Switch Removal NEUTRAL SWITCH INSTALLATION Install the neutral switch in the transaxle housing. Tighten to 20.5 in-lb (27.8 N·m). Connect the two-pin connector between the neutral switch and the wire harness. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles on page 1-4. CARBURETOR SOLENOID See General Warning on page 1-2.

  • Page 167: Carburetor Solenoid Installation

    ELECTRICAL COMPONENTS Voltage Regulator 1163 Figure 12-2 Disconnect Carburetor Solenoid Red Wire Figure 12-3 Carburetor Solenoid Removal CARBURETOR SOLENOID INSTALLATION Install the carburetor solenoid and tighten to 168 in-lb (19 N·m). See the Briggs & Stratton Vanguard engine manual (CCI P/N 103568101). Connect the white bullet connector in the carburetor solenoid red wire.

  • Page 168: Voltage Regulator Installation

    Voltage Regulator ELECTRICAL COMPONENTS Figure 12-4 Disconnect Voltage Regulator Yellow 2-Pin Figure 12-5 Disconnect Voltage Regulator Red Wire Connector 1070 Figure 12-6 Remove Voltage Regulator VOLTAGE REGULATOR INSTALLATION Position the voltage regulator on the mounting plate and install the mounting screws (Figure 12-6, Page 12-4). Tighten screws to 30 in-lb (3.4 N·m).

  • Page 169: Warning Lights

    ELECTRICAL COMPONENTS Warning Lights WARNING LIGHTS See General Warning on page 1-2. TESTING THE WARNING LIGHTS See Test Procedure 17 – Low Oil Warning Light Circuit on page 11-31. WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Raise the hood and remove the access panel.

  • Page 170: Fuel Gauge/Hour Meter

    Fuel Gauge/Hour Meter ELECTRICAL COMPONENTS FUEL GAUGE/HOUR METER See General Warning on page 1-2. TESTING THE FUEL GAUGE/HOUR METER See Test Procedure 19 – Fuel Gauge on page 11-33. With the key switch in the OFF position, the fuel gauge field is blank; however, the hour meter field is always ON. When the key switch is turned to ON, the fuel gauge field activates.

  • Page 171: Key Switch

    ELECTRICAL COMPONENTS Key Switch KEY SWITCH See General Warning on page 1-2. TESTING THE KEY SWITCH See Test Procedure 4 – Key Switch (Starter Circuit) on page 11-15. KEY SWITCH REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Raise the hood and remove the access panel.

  • Page 172: Light Switch Installation

    Fuse ELECTRICAL COMPONENTS LIGHT SWITCH INSTALLATION Match the terminal numbers molded onto the connector and switch and reconnect the wire harness. Push the light switch into the instrument panel until fully seated. Install the access panel and lower and secure the hood. Connect battery and spark plug wire(s).

  • Page 173: Fuel Level Sending Unit

    ELECTRICAL COMPONENTS Fuel Level Sending Unit FUEL LEVEL SENDING UNIT See General Warning on page 1-2. TESTING THE FUEL LEVEL SENDING UNIT See Test Procedure 18 – Fuel Level Sending Unit on page 11-32. FUEL LEVEL SENDING UNIT REMOVAL See Fuel System section. FUEL LEVEL SENDING UNIT INSTALLATION See Fuel System section.

  • Page 174: Headlights

    Headlights ELECTRICAL COMPONENTS HEADLIGHTS See General Warning on page 1-2. TESTING THE HEADLIGHT BULB AND SOCKET See Test Procedure 22 – Voltage at Headlight Socket on page 11-35. HEADLIGHT BULB REMOVAL Disable the vehicle. See Disabling the Vehicle on page 1-3. From the front of the vehicle, reach under the cowl and turn the connector harness/halogen bulb assembly clockwise one-quarter turn (Figure 12-8, Page 12-10).

  • Page 175: Wire Harness Diodes

    ELECTRICAL COMPONENTS Wire Harness Diodes WIRE HARNESS DIODES See General Warning on page 1-2. The wire harness is equipped with several in-line diodes. TESTING THE WIRE HARNESS DIODES See Test Procedure 7 – Wire Harness Diodes on page 11-19. DIODE REMOVAL Disconnect battery and spark plug wire(s).

  • Page 176: General Information

    Battery ELECTRICAL COMPONENTS DANGER rubber gloves when working on or near batteries. For added protection, cover top of the battery when servicing the vehicle. • Battery – Poison! Contains acid! Causes severe burns! Avoid contact with skin, eyes, or clothing. •...
  • Page 177 ELECTRICAL COMPONENTS Battery to leak from the vent caps and corrosion to build up on surrounding metal parts. The acid that is lost reduces the capacity of the battery and cannot be replaced. Mineral Content For the longest battery life, distilled water should be used in the battery. However, if tap water is going to be used, contact your local water department to be sure mineral contents are below the levels listed in the following table.
  • Page 178 Battery ELECTRICAL COMPONENTS WARNING • Do not disconnect the charger DC leads from the battery when the charger is on. The resulting arcing between the DC leads and battery post could cause an explosion. • If the charger must be stopped, disconnect the AC supply cord from the wall outlet before disconnecting the DC leads from the battery.

  • Page 179: Section 13 - Engine

    SECTION 13 — ENGINE DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. This section contains information on removing and installing the Briggs & Stratton gasoline engine. For complete instructions on engine disassembly, repair, rebuilding, and reassembly, refer to the engine manual. See the Briggs & Stratton Vanguard engine manual (CCI P/N 103568101).
  • Page 180 Engine Removal ENGINE 11. Remove the clutch cover intake hose and the clutch cover. See Outer Clutch Cover Removal, Section 18, Page 18-2. 12. Remove the drive belt. See Drive Belt Removal, Section 18, Page 18-3. 13. Remove the drive clutch. See Drive Clutch Removal, Section 18, Page 18-5. 14.
  • Page 181 ENGINE Engine Removal 1067 1061 Figure 13-7 Disconnect Red Battery Cable From Starter Figure 13-8 Disconnect Black Ground Cable From Engine Solenoid Block 18. Disconnect the accelerator cable from the governor (Figure 13-9, Page 13-4), (Figure 13-10, Page 13-4) and (Figure 13-11, Page 13-4). NOTE: Note the orientation and location of the washer and retain for reassembly.
  • Page 182 Engine Removal ENGINE Figure 13-9 Remove Bolt Securing Accelerator Cable End Figure 13-10 Disconnect Spring From Accelerator Cable (bolt may differ from shown) End (later models have a second spring attached to special cable end bolt) Figure 13-11 Loosen Clamp To Release Cable Sheath 19.
  • Page 183 ENGINE Engine Removal Figure 13-12 Loosen Anchor To Release Cable Sheath Figure 13-13 Maneuver Choke Cable End Out Of Choke Lever 20. Disconnect fuel hose from fuel pump, plug the end of hose to prevent fuel spillage, and secure hose out of the way. 21.

  • Page 184: Engine Installation

    Engine Installation ENGINE ENGINE INSTALLATION Carefully set engine onto subframe and loosely install the mounting hardware (Figure 13-14, Page 13-5). Fill engine with appropriate quantity and type of oil. See Engine Oil Filling, Section 10, Page 10-10. Install the exhaust pipe with new gaskets. See Exhaust Pipe Installation, Section 15, Page 15-2. Install the inner clutch cover and tighten bolts to specified torque.

  • Page 185: Idle Speed Adjustment

    ENGINE Engine RPM Adjustment What To Do If normal condition exists, operate the vehicle as usual and the movement should gradually lessen and soon come to an end. If abnormal conditions exist, perform the following steps in the order shown: Do a quick check of throttle bellcrank movement: 1.1.
  • Page 186 Engine RPM Adjustment ENGINE Visually inspect the linkage (1) for movement and proper throttle position (Figure 13-17, Page 13-8). It should rotate and return when the accelerator pedal is pressed and released. 1457 1458 Figure 13-17 Visual Inspection of Linkage Figure 13-18 Verify Gap At Idle Stop Screw Visually confirm the current idle adjustment.
  • Page 187 ENGINE Engine RPM Adjustment 1459 Figure 13-19 Remove Carburetor Cover Plate Engage the park brake, place the shifter in NEUTRAL, start the engine and connect a tachometer. Use long needle nose pliers to bend the idle spring tang (1) (Figure 13-20, Page 13-9) until the idle is 1250 RPM. Be careful not to touch the hot exhaust manifold.

  • Page 188: High Speed Adjustment

    Engine RPM Adjustment ENGINE 1462 Figure 13-22 Verify Proper Idle Stop Screw Adjustment 10. After the adjustments are completed, install the carburetor cover plate and tighten the screws to 40 in-lb (4.5 N·m). 11. Install the heat shield and tighten the hardware to 78 in-lb (8.8 N·m). 12.
  • Page 189 ENGINE Engine RPM Adjustment Remove the exhaust pipe heat shield. Do a quick check of throttle bellcrank movement: 4.1. Push accelerator pedal to the floor and hold. 4.2. Verify the throttle bellcrank makes a positive stop against the mounting bracket tab (Figure 13-23, Page 13-11).

  • Page 190: Governor Lever Reset Adjustment

    Engine RPM Adjustment ENGINE GOVERNOR LEVER RESET ADJUSTMENT WARNING • To prevent injury or vehicle damage, perform the governor reset procedure prior to starting or running the engine. • To prevent engine overspeeding, the governor and high speed RPM must be adjusted correctly. Engine overspeeding could result in engine damage, personal injury or property damage.
  • Page 191 ENGINE Engine RPM Adjustment Push governor lever (2) toward carburetor until carburetor is at full throttle and hold lever at this position. See following CAUTION. CAUTION • Do not bend governor link (3) or distort governor lever (2). Using a flat-tip screwdriver, rotate governor shaft (4) counter-clockwise as far as it can turn and hold shaft at this position.

  • Page 193: Section 14 - Fuel System

    SECTION 14 — FUEL SYSTEM DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. FUEL LINES See General Warning on page 1-2. The fuel lines must be properly routed and all hose clamps must be tight. The fuel lines should be kept clean. See following NOTE and WARNING.

  • Page 194: Carburetor

    Carburetor FUEL SYSTEM CARBURETOR See General Warning on page 1-2. Before suspecting the carburetor as the cause of poor engine performance, make sure the fuel and ignition systems are in proper operating condition. Check the following items: • Spark plug and gap condition. See Spark Plugs, Section 10, Page 10-11. •...

  • Page 195: Fuel Level Sending Unit

    FUEL SYSTEM Fuel Level Sending Unit FUEL LEVEL SENDING UNIT See General Warning on page 1-2. FUEL LEVEL SENDING UNIT REMOVAL DANGER • Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. WARNING •...
  • Page 196 Fuel Level Sending Unit FUEL SYSTEM 000883-001 000883-001 Figure 14-1 Fuel Tank and Components Page 14-4 2009-2010 XRT 950 Maintenance and Service Manual...

  • Page 197: Fuel Level Sending Unit Installation

    FUEL SYSTEM Fuel Level Sending Unit FUEL LEVEL SENDING UNIT INSTALLATION DANGER • Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. WARNING • Do not use electrically powered tools to remove or install the fuel level sending unit. Failure to heed this warning could result in a fire or explosion.
  • Page 198 Fuel Level Sending Unit FUEL SYSTEM 1198 Figure 14-2 Fuel Level Sending Unit Alignment Carefully thread each hex-head screw (2) by hand, with the ring terminal on the black ground wire (7) under one of the screw heads (Figure 14-1, Page 14-4). See following CAUTION. CAUTION •...

  • Page 199: Fuel Tank

    FUEL SYSTEM Fuel Tank FUEL TANK See General Warning on page 1-2. WARNING • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure. FUEL TANK REMOVAL Turn the fuel shut-off valve to the closed (OFF) position (Figure 3-2, Page 3-3). Run the engine until all fuel in the carburetor, fuel pump, and fuel lines is used and the engine stalls.

  • Page 200: Fuel Tank Storage Or Disposal

    Fuel Tank FUEL SYSTEM Figure 14-3 Fuel Tank In Vehicle 10. Remove lock nut securing end of fuel tank strap in floorboard (Figure 14-4, Page 14-8). 11. Retract bolt/rubber bumper that secures side of fuel tank (Figure 14-5, Page 14-8). 12.

  • Page 201: Fuel Tank Installation

    FUEL SYSTEM Carbon Canister (If Equipped) WARNING • Dispose of wastewater and fuel tank in accordance with federal, state, and local laws and ordinances. Store the tank upside down with the cap installed in a well-ventilated area. FUEL TANK INSTALLATION Install the fuel tank in the vehicle.

  • Page 202: Carbon Canister Removal

    Carbon Canister (If Equipped) FUEL SYSTEM WARNING • If the carbon canister is damaged, replace it. Do not attempt to repair it. See the following canister removal procedure. 1. Carbon Canister 2. Molded Vent Tube (Fuel Tank to Canister) 3. Vent Tube (Canister to Engine) 4. Vent Tube (Canister to Atmosphere) 1644 Figure 14-6 Carbon Canister, Hoses and Routing CARBON CANISTER REMOVAL...

  • Page 203: Section 15 - Exhaust System

    SECTION 15 — EXHAUST SYSTEM DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. MUFFLER REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Loosen the clamp securing the exhaust pipe in the muffler (Figure 15-1, Page 15-1). See following WARNING. WARNING •...

  • Page 204: Exhaust Pipe Removal

    Exhaust Pipe Removal EXHAUST SYSTEM EXHAUST PIPE REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Raise the cargo bed and secure with the bed locking pin. See Cargo Bed Removal on page 4-23. Loosen the clamp securing the exhaust pipe in the muffler (Figure 15-1, Page 15-1).

  • Page 205: Section 16 - Front Differential

    SECTION 16 — FRONT DIFFERENTIAL DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. This section contains information on removing and installing the front differential. FRONT DIFFERENTIAL REMOVAL See General Warning on page 1-2. Disconnect battery and spark plug wire(s).
  • Page 206 Front Differential Removal FRONT DIFFERENTIAL 1185 1183 Figure 16-3 Front Differential – drive shaft on differential Figure 16-4 Front Differential – differential vent hose input shaft Remove the four front differential mounting bolts (Figure 16-5, Page 16-2). Carefully slide the differential towards the driver side until the passenger side half-shaft can be easily disengaged from the differential output shaft splines (Figure 16-6, Page 16-2).

  • Page 207: Front Differential Installation

    FRONT DIFFERENTIAL Front Differential Installation 1006 1007 Figure 16-7 Front Differential – driver side half-shaft Figure 16-8 Front Differential – half-shaft swung out of disengagement 13. Remove the differential from vehicle by passing it through the passenger side opening in the frame(Figure 16-9, Page 16-3).
  • Page 208 Front Differential Installation FRONT DIFFERENTIAL 1008 Figure 16-11 Front Differential – differential installation Position the front differential to align the splined center drive shaft coupling with the differential input shaft splines. Press the center drive shaft coupling onto the input shaft until it seats positively. Carefully slide the differential towards the passenger side of the vehicle until the driver side half-shaft can be easily engaged onto the driver side differential output shaft splines.

  • Page 209: Front Halfshaft Removal

    FRONT DIFFERENTIAL Front Halfshaft Removal 12. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles on page 1-4. FRONT HALFSHAFT REMOVAL See General Warning on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Pry out the thin axle nut flange where it is staked to the groove in the halfshaft (Figure 16-13, Page 16-5) and loosen the axle nut (Figure 16-14, Page 16-5).

  • Page 210: Front Halfshaft Installation

    Front Halfshaft Installation FRONT DIFFERENTIAL FRONT HALFSHAFT INSTALLATION Installation is the reverse of removal. See following NOTE. NOTE: Apply a small amount of anti-seize compound to the halfshaft splines before it is installed. Tighten the axle nut to 142 ft-lb (193 N·m) and then stake the nut to the groove in the halfshaft. Install wheel and lower vehicle.

  • Page 211: Section 17 - Transaxle

    SECTION 17 — TRANSAXLE DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. GENERAL INFORMATION The UV30C model transaxle is designed for both forward and reverse power with splined input and output shafts (Figure 17-1, Page 17-1 and Figure 17-2, Page 17-1) .
  • Page 212 Transaxle Removal TRANSAXLE Remove the cargo bed. See Cargo Bed Removal, Section 4, Page 4-23. Remove the driver side rear shock absorber. See Rear Shock Removal, Section 9, Page 9-1. Remove the bolt securing the brake hose and cable to the driver side trailing arm (Figure 17-4, Page 17-2). 1114 1124 Figure 17-3 Rear Of Vehicle Ready For Transaxle Removal...
  • Page 213 TRANSAXLE Transaxle Removal 1121 1122 Figure 17-7 Disconnect Four-Wheel Drive Cable From Figure 17-8 Disconnect Differential Lock Cable From Transaxle Transaxle 12. Remove the screws securing the shifter cable bracket assembly to the transaxle (Figure 17-9, Page 17-3). Do not remove the cables from the bracket. 1086 Figure 17-9 Remove Shifter Cable Bracket Assembly From Transaxle...
  • Page 214 Transaxle Removal TRANSAXLE 1092 1091 Figure 17-10 Pry Driveshaft Free Of Cir-Clip Figure 17-11 Remove Universal Joint Bolt 1093 1094 Figure 17-12 Push Driveshaft Further Into Universal Joint Figure 17-13 Pull Driveshaft Off Transaxle Output Shaft 14. Loosen the lock nuts securing the transaxle to the subframe but do not remove the hardware at this time (Figure 17-14, Page 17-5) and (Figure 17-15, Page 17-5).
  • Page 215 TRANSAXLE Transaxle Removal 1106 1295 Figure 17-14 Front Transaxle Mount Hardware Figure 17-15 Rear Transaxle Mount Hardware 15. Place a floor jack under the transaxle/subframe to support it while removing the rear subframe hardware (Figure 17-16, Page 17-5). It will also be used to lower the subframe. 16.
  • Page 216 Transaxle Removal TRANSAXLE 1085 1095 Figure 17-18 Remove Rear Subframe Hardware Figure 17-19 Lower Subframe With Floorjack 18. Carefully lower the subframe to the floor (Figure 17-19, Page 17-6). 19. Use a pry bar to disconnect the halfshafts from the transaxle (Figure 17-20, Page 17-6) and (Figure 17-21, Page 17-6).

  • Page 217: Transaxle Installation

    TRANSAXLE Transaxle Installation TRANSAXLE INSTALLATION Carefully set transaxle onto subframe and loosely install the mounting hardware. If removed, loosely install engine mounting hardware but do not torque at this time. Install the exhaust pipe. See Exhaust Pipe Installation, Section 15, Page 15-2. Install the inner clutch cover and tighten bolts to specified torque.

  • Page 218: Rear Halfshaft Installation

    Rear Halfshaft Installation TRANSAXLE 1066 Figure 17-22 Undo Staked Flange Of Axle Nut Figure 17-23 Loosen Axle Nut Lift and support the rear of vehicle and remove the wheel. See Lifting The Vehicle, Section 3, Page 3-4. Raise the cargo bed and secure with the bed locking pin. See Cargo Bed, Section 4, Page 4-23. Remove the rear shock absorber.

  • Page 219: Four-Wheel Drive Cable Adjustment

    TRANSAXLE Four-Wheel Drive Cable Adjustment Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. At Shifter: Loosen ball joint socket jam nut and screw socket onto cable end threads until it bottoms out. Thread jam nut against ball joint socket and tighten to 55 in-lb (6.4 N·m).
  • Page 220 Differential Lock Cable Adjustment TRANSAXLE Raise the cargo bed and engage the cargo bed lock pin (1) located at the driver side cargo bed hinge (2) (Figure 17-25, Page 17-10). Lift and support the rear of vehicle. See Lifting The Vehicle, Section 3, Page 3-4. At the instrument panel, place differential lock handle in the UNLOCK position (Figure 17-24, Page 17-10).
  • Page 221 TRANSAXLE Differential Lock Cable Adjustment Release the park brake and rotate the passenger side rear tire by hand. The driver side rear tire should rotate in the opposite direction. At the instrument panel, place differential lock handle in the LOCK position (Figure 17-27, Page 17-10). The spring (1) at the transaxle should stretch (gaps between the coils) and pull the lever (2) towards the front of the vehicle (Figure 17-28, Page 17-11).

  • Page 223: Section 18 - Clutches

    SECTION 18 — CLUTCHES DANGER • See General Warning on page 1-2. WARNING • See General Warning on page 1-2. To remove, disassemble and assemble the drive and driven clutches properly, the following tools should be used: Drive clutch tool: •...

  • Page 224: Outer Clutch Cover

    Outer Clutch Cover CLUTCHES OUTER CLUTCH COVER OUTER CLUTCH COVER REMOVAL See General Warning on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Lift and support the rear of the vehicle on jack stands and remove the driver side rear wheel. See Lifting The Vehicle, Section 3, Page 3-4.

  • Page 225: Outer Clutch Cover Installation

    CLUTCHES Drive Belt 1118 Figure 18-3 Remove Outer Clutch Cover OUTER CLUTCH COVER INSTALLATION If reinstalling cover, clean thoroughly before proceeding. Inspect cover seal, if equipped, and repair or replace as needed. Place outer clutch cover against the inner clutch cover and align holes (Figure 18-3, Page 18-3). Secure with bolts previously removed and tighten to 78 in-lb (8.8 N·m) (Figure 18-2, Page 18-2).
  • Page 226 Drive Belt CLUTCHES Thread an M6 x 1.0 service bolt into this hole and continue turning until the driven clutch sheaves are open enough to reduce belt tension(Figure 18-5, Page 18-4). Remove the drive belt (Figure 18-6, Page 18-4). 1. Drive Belt 2.

  • Page 227: Drive Belt Installation

    CLUTCHES Drive Clutch DRIVE BELT INSTALLATION Place belt in drive clutch sheaves. With service bolt installed in driven clutch, work the belt onto the driven clutch. Rotate driven clutch, if necessary, to aid belt installation. See following WARNING. WARNING • Avoid pinching fingers between the belt and clutch while installing belt. Remove service bolt from driven clutch.

  • Page 228: Drive Clutch Cleaning And Inspection

    Drive Clutch CLUTCHES 1071 1101 Figure 18-7 Remove Drive Clutch Bolt Figure 18-8 Install and Tighten Drive Clutch Puller Tool 1102 Figure 18-9 Remove Drive Clutch DRIVE CLUTCH CLEANING AND INSPECTION Use only compressed air and a dry, lint-free cloth to clean clutch parts. See following CAUTION. CAUTION •...

  • Page 229: Drive Clutch Disassembly

    CLUTCHES Drive Clutch DRIVE CLUTCH DISASSEMBLY WARNING • The drive clutch contains a compressed spring. To prevent injury during disassembly, take measures to secure and control the cap (8) while removing the large M20 x 1.5 hex nut that holds the drive clutch together (Figure 18-10, Page 18-8).
  • Page 230 Drive Clutch CLUTCHES 000901-001 Figure 18-10 Drive Clutch – Exploded Page 18-8 2009-2010 XRT 950 Maintenance and Service Manual...

  • Page 231: Drive Clutch Installation

    CLUTCHES Drive Clutch DRIVE CLUTCH INSTALLATION Ensure the mating surface in the drive clutch and on the crankshaft are clean. Place drive clutch onto crankshaft and install the washer and bolt. Tighten bolt to 36 ft-lb (49 N·m). If the bolt will not tighten due to the crankshaft spinning while attempting to tighten, hold the large flywheel nut on the front of the engine.

  • Page 232: Driven Clutch

    Driven Clutch CLUTCHES DRIVEN CLUTCH DRIVEN CLUTCH REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4. Remove the exhaust pipe heat shield. Remove the driver side rear shock absorber. See Rear Shock Removal, Section 9, Page 9-1. Remove the clutch cover intake hose and the clutch cover.
  • Page 233 CLUTCHES Driven Clutch 000901-002 Figure 18-17 Driven Clutch – Exploded 2009-2010 XRT 950 Maintenance and Service Manual Page 18-11...

  • Page 234: Driven Clutch Disassembly

    Driven Clutch CLUTCHES DRIVEN CLUTCH DISASSEMBLY The following service tool is required to disassemble and assemble the driven clutch. It is available from a service parts representative: • Driven Clutch Disassembly Tool (CCI P/N 103601701) 1199 1200 Figure 18-18 Disassembly Tool Base In Vise Figure 18-19 Place Driven Clutch Onto Tool Base Secure Driven Clutch Disassembly Tool in a vise by gripping the large nut, located under base of tool, in jaws of vise (Figure 18-18, Page 18-12).
  • Page 235 CLUTCHES Driven Clutch 1201 1204 Figure 18-22 Use Spring Compression Handle To Figure 18-23 Remove Snap Ring Compress Spring Thread the spring compression handle down onto the threaded rod enough to release the pressure on the snap ring (8) (Figure 18-22, Page 18-13). Remove snap ring (8) (Figure 18-23, Page 18-13).

  • Page 236: Driven Clutch Assembly

    Driven Clutch CLUTCHES 1207 1208 Figure 18-26 Remove Sheave Figure 18-27 Remove Washer 10. Remove the moveable sheave (4) (Figure 18-26, Page 18-14) and washer (3) from the fixed sheave (2) (Figure 18-27, Page 18-14). See following NOTE. DRIVEN CLUTCH ASSEMBLY Place the fixed sheave (2) onto the tool base.

  • Page 237: Inner Clutch Cover

    CLUTCHES Inner Clutch Cover Tighten bolt to 36 ft-lb (49 N·m). It may be necessary to let the torque wrench rest on the rear suspension trailing arm and then grasp the driven clutch and turn it against the wrench until the specified torque is achieved. Install the drive belt.

  • Page 238: Inner Clutch Cover Installation

    Inner Clutch Cover CLUTCHES INNER CLUTCH COVER INSTALLATION Ensure the mating surfaces on the inner clutch cover, engine and transaxle are clean. Set the inner clutch cover into place on the transaxle and engine. Install new bolts finger-tight into the transaxle first, starting with the upper left hole (Figure 18-29, Page 18-15). Install four new bolts into the larger pattern of engine holes finger-tight.
  • Page 239 INDEX inspection............6-4 brake line, front a-arm installation ............6-9 installation ............7-12 removal ............6-8 removal ............7-11 brake line, rear adjustment installation ............. 6-11 accelerator cable..........5-7 removal ............6-9 brake pedal............5-9 brake pad, front differential lock cable ......... 17-9 installation .............
  • Page 240 INDEX outer ............. 18-2 drive ..............18-5 electrical system assembly............18-7 circuits.............. 11-1 cleaning and inspection ........18-6 key-start ............11-1 component inspection ........18-7 emissions disassembly ..........18-7 evaporative installation ............. 18-9 carbon canister ..........14-9 removal ............18-5 engine driven .............
  • Page 241 INDEX halfshaft lateral link front installation ............9-2 installation ............. 16-6 removal .............. 9-2 removal ............16-5 lifting rear jacking instructions ..........3-4 installation ............. 17-8 light switch removal ............17-7 installation ............12-8 headlight bulb removal ............12-7 installation ............12-10 low oil warning light removal ............
  • Page 242 INDEX cable adjustment ..........17-8 19 fuel gauge ...........11-33 shocks 2 fuse ..............11-13 rear 20 hour meter ..........11-34 installation ............9-2 21 headlight switch...........11-34 removal ............9-1 22 headlight .............11-35 side panel 3 ground cables ..........11-14 installation ............4-21 4 key switch removal ............
  • Page 243 INDEX see also tire ............8-3 wheel alignment front ..............7-7 rear ..............9-7 wheel bearings and hub front inspection............7-13 installation ............. 7-14 removal ............7-13 rear inspection............9-5 installation ............9-6 removal ............9-5 wheel, steering see steering wheel ..........7-1 wire continuity testing...........11-26 wiring diagram............

  • Page 245: Section I - Index

    2. Ease of Finding Information 3. Clarity of Illustrations 4. Index Usability 5. Troubleshooting Chart Usability Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2009-2010 XRT 950 Maintenance and Service Manual...

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