Brake System Inspection - Club Car XRT 950 2009 Maintenance And Service Manual

6
Troubleshooting

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.
• Apply and release the brake pedal several times. If noise or binding occurs, the brake pedal or hydraulic brake
system may require service. Pedal movement should be smooth, and when the pedal is released, it should return
quickly and quietly.
• Move the brake pedal from side to side to check for worn parts. Excessive side movement indicates loose or
worn pedal mounting parts. If worn parts are found, replace the worn parts and adjust the brake pedal. See See
Section 5 – Accelerator and Brake Pedal Group. .
• Apply heavy pressure to the pedal and check for sponginess and excessive pedal travel. The pedal should be firm
and the back of the pedal should be a minimum of 1.25 inches (3.2 cm) from the floor. Brake adjustment must be
maintained so the brake pedal cannot be pressed to the floorboard under any circumstance. If the brake pedal feels
"spongy," perform the brake bleeding procedure. See Bleeding the Hydraulic Brake System on page 6-16.
• Hold the brake pedal down with medium foot pressure (25 - 35 lb. (11.3 - 15.9 kg)) for 15 seconds. The pedal
should not continue dropping when pressed with a steady amount of pressure. If the pedal goes to the floor, inspect
the hydraulic system for leaks and repair any worn or damaged components. After repair, bleed the hydraulic brake
system. See Bleeding the Hydraulic Brake System on page 6-16.
Master Cylinder Inspection
• Inspect the exterior of the master cylinder (1) (Figure 6-1, Page 6-6). Replace any leaking components and bleed
the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6-16.
• Check the brake fluid level. See Brake Fluid Reservoir on page 6-7.
• Remove the reservoir cap and inspect the brake fluid. If the brake fluid is contaminated, purge the brake fluid and
refill the hydraulic system. See Bleeding the Hydraulic Brake System on page 6-16.
• Check the vent holes in the reservoir cap and clean or replace as necessary.
• Check the diaphragm inside the reservoir cap and replace if damaged.
Brake Line Inspection
• Inspect the brake lines (2 and 4) and fittings for leakage (Figure 6-1, Page 6-6). They must be flexible and free of
leaks, cuts, cracks or bulges. Replace as needed. See Brake Hose Replacement on page 6-7.
• Turn the steering wheel all the way from left to right and back again. Contact between the brake hoses and any
other components, especially the tires, wheels or half-shafts, will damage the brake hoses.
• Check each brake caliper (3 and 5) for signs of brake fluid leakage. If there is evidence of leakage, determine
the cause and repair or replace as needed. See Brake Pads and Caliper on page 6-12. Also see Brake Hose
Replacement on page 6-7.
Page 6-4 2009-2012 XRT 950 Maintenance and Service Manual
BRAKES