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XRT 1550SE
Maintenance and service manual
Club Car XRT 1550SE Maintenance And Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Maintenance and Service
Table of Contents
Section 1 - Safety
General Warning
Section 2A - Vehicle Specifications: Honda Gas & Kubota Diesel Powered
295/295 SE and 1550/1550 SE Specifications
Intellitach Specifications
Section 2B - Vehicle Specifications: Kawasaki Gas & Kubota Diesel Powered
295/295 SE and 1550/1550 SE Specifications
295 Homologated Specifications
Intellitach Specifications
Section 3 - General Information
General Information
Model Identification
Storage
Preparing the Vehicle for Extended Storage
Returning the Stored Vehicle to Service
Using a Booster Battery (Jump Starting)
Section 4 - Body and Trim
Cleaning the Vehicle
Seat Cleaning
Front Body Repair
Light Scratches
Abrasions and Haze
Large Scratches and Abrasions
Front Body Components
Instrument Panel Removal
Instrument Panel Installation
Front Fascia Removal
Front Fascia Installation
Hood Removal
Hood Installation
Center Cowl Panel Removal
Center Cowl Panel Installation
Side Cowl Panel (Fender) Removal
Side Cowl Panel (Fender) Installation
Front Fender Flare Removal
Front Fender Flare Installation
Roll-Over Protective Structure (ROPS)
ROPS Removal
ROPS Installation
Seat
Seat Removal
Seat Adjustment
Seat Installation
Seat Support Removal
Seat Support Installation
Safety Belts
Safety Belt Removal
Safety Belt Installation
Cargo Bed - Electric Lift
Testing the Bed Lift Motor
Bed Lift Motor Removal
Bed Lift Motor Installation
Cargo Bed Removal
Cargo Bed Installation
Cargo Bed - Manual Lift
Cargo Bed Removal
Cargo Bed Installation
Rear Fender
Rear Fender Removal
Rear Fender Installation
Floor Mat
Floor Mat Removal
Floor Mat Installation
Section 5 - Accelerator and Brake Pedal Assemblies
Accelerator Pedal
Accelerator Pedal Removal
Accelerator Pedal Installation
Accelerator Pedal and RPM Adjustment
Brake Pedal
Brake Pedal Removal
Brake Pedal Installation
Brake Pedal Adjustment
Park Brake Pedal
Park Brake Pedal Assembly Removal
Park Brake Pedal Assembly Installation
Section 6 - Hydraulic and Park Brake Systems
Brake System Inspection
Brake System Troubleshooting
Brake Pads and Caliper
Front Brake Pad and Caliper Removal
Front Brake Pad and Caliper Installation
Rear Brake Pad and Caliper Removal
Rear Brake Pad and Caliper Installation
Brake Disc and Hub
Front Wheel Disc and Hub Removal
Front Wheel Disc and Hub Installation
Rear Wheel Disc Removal
Rear Wheel Disc Installation
Hydraulic Line Replacement
Front Brake Line Removal
Front Brake Line Installation
Rear Brake Line Removal
Rear Brake Line Installation
Master Cylinder and Reservoir
Filling the Hydraulic System
Reservoir Removal
Reservoir Installation
Master Cylinder Removal
Master Cylinder Installation
Bleeding the Hydraulic Brake System
Bleeding Brakes on a DOT 5 Fluid Filled System
Purging the Hydraulic System
Park Brake System
Park Brake Adjustment
Park Brake Cable Adjustment
Park Brake Wheel Cables
Front Park Brake Cable Removal
Front Park Brake Cable Installation
Park Brake Equalizer Removal
Park Brake Equalizer Installation
Section 7 - Steering and Front Suspension
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Installation
Rack and Pinion
Rack and Pinion Removal
Rack and Pinion Installation
Rack and Pinion Disassembly
Rack and Pinion Assembly
Front Suspension
Wheel Alignment
Front Suspension Components
Steering Upright Removal
Upper A-Arm Removal
Upper A-Arm Installation
Lower A-Arm Removal
Lower A-Arm Installation
Front Coil-Over Shock Absorber Removal
Front Coil-Over Shock Absorber Installation
Steering Upright Installation
Section 8 - Wheels and Tires
General Information
Wheels
Wheel Removal
Wheel Installation
Tires
Tire Removal
Tire Installation
Section 9 - Rear Suspension
Rear Coil-Over Shock Absorber
Swing Arms
Swing Arm Removal
Swing Arm Installation
Section 10A - Periodic Maintenance: Honda Gasoline & Kubota Diesel Powered Vehicles
Periodic Service Schedule
Periodic Lubrication Schedule
Lubricating the Attachment Arm and Interface
Brake Fluid Reservoir
Brake Fluid
Engine Oil
Oil Pressure - Gasoline Engine
Engine Oil Level Check
Engine Oil and Filter Change
Oil Viscosity
Gearcase Lubrication
Lubrication Level Check for Front Differential, Transmission, and Rear Differential
Lubrication Change for Front Differential, Transmission, and Rear Differential
Hydraulic System - Intellitach Vehicle
Engine Coolant - Diesel Vehicles
Engine Coolant Level Check
Fueling Instructions
Draining Water from Fuel Filter
Battery
Section 10B - Periodic Maintenance: Kawasaki Gasoline & Kubota die
Periodic Service Schedule
Periodic Lubrication Schedule
Lubricating the Attachment Arm and Interface
Brake Fluid Reservoir
Brake Fluid
Engine Oil
Oil Pressure - Gasoline Engine
Engine Oil Level Check
Engine Oil and Filter Change
Oil Viscosity
Spark Plugs
Spark Plug Cleaning and Inspection
Spark Plug Gap Inspection
Gearcase Lubrication
Lubrication Level Check for Front Differential, Transmission, and Rear Differential
Lubrication Change for Front Differential, Transmission, and Rear Differential
Hydraulic System - Intellitach Vehicle
Engine Coolant - Diesel Vehicles
Engine Coolant Level Check
Fueling Instructions
Draining Water from Fuel Filter
Battery
Section 11A - Troubleshooting and Electrical System: Kawasaki Powered Gasoline Vehicles
Troubleshooting Guide
Wiring Diagram
Test Procedures
Test Procedures
Index of Test Procedures
Cles
Section 12B - Electrical Components: Honda Powered Gasoline Vehi-
Starter and Starter Solenoid
Neutral Switch
Carburetor Heater
Voltage Regulator
Warning Lights
Fuel Gauge/Hour Meter
Key Switch
Volt Accessory Receptacle
Bed Lift Switch
Light Switch
Reverse Warning Buzzer (if Equipped)
Reverse Warning Buzzer Limit Switch (if Equipped)
Front Differential Limit Switch
Fuel Level Sending Unit
Oil Pressure Sensor
Wire Harness Diodes
Battery
Starter and Starter Solenoid
Neutral Switch
Voltage Regulator
Warning Lights
Fuel Gauge/Hour Meter
Key Switch
Volt Accessory Receptacle
Bed Lift Switch
Light Switch
Reverse Warning Buzzer
Reverse Warning Buzzer Limit Switch
Fuel Level Sending Unit
Charge Coil
Wire Harness Diodes
Battery
Preventive Maintenance
Section 12C - Electrical Components: Diesel Vehicles
Starter and Starter Solenoid
Neutral Switch
Amp Fusible Link
Warning Lights
Fuel Gauge/Hour Meter
Key Switch
Bed Lift Switch
Bed Lift Circuit Breaker
Fuse
Reverse Warning Buzzer Limit Switch (if Equipped)
Front Differential Limit Switch
Electric Fuel Pump
Oil Pressure Sensor
Thermostat Switch
Wire Harness Diodes
Battery
Gasoline Engine
Engine Installation
Oil Filter Hoses
Exhaust System
Intermediate Pipe Removal
Muffler Installation
Fuel System
Fuel Filter
Fuel Level Sending Unit
Fuel Tank
Fuel Shut-Off Valve
Engine Control Linkages
Choke Cable
Engine Governor Arm
Engine RPM Adjustment
Air Intake System
Air Canister Removal
Air Filter Intake Hose Removal
Air Filter Outlet Hose Removal
Clutches
Drive Belt
Drive Clutch
Driven Clutch
Clutch Cover
Clutches
Section 13B - Honda Gasoline Engine, Muffler, Fuel System, and
Gasoline Engine
Engine Installation
Exhaust System
Intermediate Pipe Installation
Fuel System
Fuel Lines
Fuel Level Sending Unit
Fuel Tank
Fuel Shut-Off Valve
Oil Filter Hoses
Governor Guard
Accelerator Cable Retention Clip Adjustment
Ground Speed (Transmission) Governor Arm Adjustment
Engine Governor Arm
Choke and Air Intake System
Choke Cable Removal
Choke Cable Installation
Air Canister Installation
Air Filter Intake Hose Installation
Air Filter Outlet Hose Installation
Clutch Troubleshooting
Drive Clutch
Driven Clutch
Clutch Cover
Diesel Engine
Engine Installation
Exhaust System
Manifold Pipe Removal
Muffler Installation
Fuel System
Fuel Lines
Electric Fuel Pump
Fuel Level Sending Unit
Fuel Tank
Engine Control Linkages
Engine RPM Adjustment
Air Intake System
Air Canister Installation
Air Filter Intake Hose Installation
Air Filter Outlet Hose Removal
Clutches
Drive Belt
Drive Clutch
Driven Clutch
Driven Clutch Disassembly
Clutch Cover
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2007 Carryall 295/295SE
and XRT 1550/1550SE
Maintenance and Service
Manual
Gasoline, Diesel and IntelliTach, and Homologated Vehicles
Manual Number 103209114
Edition Code 1006F1208E
Table of
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Table of Contents
Troubleshooting
Brake System Troubleshooting
63
SECTION 11A - TROUBLESHOOTING AND ELECTRICAL SYSTEM: KAWASAKI POWERED GASOLINE VEHICLES
155
Clutch Troubleshooting
420
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