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Club Car Manuals
Utility Vehicle
XRT 1200
Maintenance and service manual
Club Car XRT 1200 Maintenance And Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Section 1 - Safety
General Warning
Disabling the Vehicle
Disconnecting the Battery
Connecting the Battery
Section 2 - Vehicle Specifications
General Information
Section 3 - General Information
General Information
Engine Identification
Serial Number Identification
Storage
Preparing the Vehicle for Extended Storage
To Return Vehicle to Service
Section 4 - Body and Trim
Cleaning the Vehicle
Front Body Repair
Abrasions and Haze
Light Scratches
Large Scratches and Abrasions
Tube Bumper/Brush Guard
Tube Bumper/Brush Guard Removal
Tube Bumper/Brush Guard Installation
Front Body Components
Dashboard Removal
Dashboard Installation
Front Body Removal
Front Fender Removal
Front Fender Installation
Front Body Installation
Seat
Seat Adjustment
Front Seat Support
Front Seat Support Removal
Front Seat Support Installation
Rear Seat Support
Rear Seat Support Removal (Carryall 472/XRT 1200 SE)
Rear Seat Support Installation (Carryall 472/XRT 1200 SE)
Cargo Bed
Cargo Bed Removal
Cargo Bed Installation
Bed Stop Bumper Adjustment
Rear Fender
Rear Fender Removal
Rear Fender Installation
Tailskirt
Tailskirt Removal
Tailskirt Installation
Trailer Hitch
Trailer Hitch Removal
Trailer Hitch Installation
Receiver Hitch
Receiver Hitch Removal
Receiver Hitch Installation
Floor Mat
Floor Mat Removal
Floor Mat Installation
Section 5 - Accelerator and Brake Pedal Assemblies
Brake Pedal
Brake Pedal Removal
Brake Pedal Installation
Brake Pedal Adjustment
Accelerator Pedal
Accelerator Pedal Removal
Accelerator Pedal Installation
Accelerator Pedal Adjustment
Section 6 - Mc012C-Bs00 Transaxle: Hydraulic and Park Brake Systems
Brake System Inspection
Brake System Troubleshooting
Brake Drum Removal
Front Wheel Brake Drum Removal
Rear Wheel Brake Drum Removal
Brake Shoe Removal
Front Brake Shoe Removal
Rear Brake Shoe Removal
Brake Cluster Inspection and Cleaning
Brake Shoe Installation
Front Brake Shoe Installation
Rear Brake Shoe Installation
Brake Drum Installation
Front Wheel Brake Drum Installation
Rear Wheel Brake Drum Installation
Brake Cluster Assembly Replacement
Front Brake Cluster Assembly Removal
Front Brake Cluster Assembly Installation
Rear Brake Cluster Assembly Removal
Rear Brake Cluster Assembly Installation
Wheel Cylinder Replacement
Front Wheel Cylinder Removal
Front Wheel Cylinder Installation
Rear Wheel Cylinder Removal
Rear Wheel Cylinder Installation
Brake Shoe Adjuster Replacement
Front Brake Shoe Adjuster Removal
Front Brake Shoe Adjuster Installation
Rear Brake Shoe Adjuster Removal
Rear Brake Shoe Adjuster Installation
Hydraulic Line and Hose Replacement
Front Brake Line Removal
Front Brake Line Installation
Front Brake Hose Assembly Removal
Front Brake Hose Assembly Installation
Rear Brake Line Removal
Rear Brake Line Installation
Rear Brake Hose Removal
Rear Brake Hose Installation
Master Cylinder and Bell Crank Replacement
Bell Crank Removal
Bell Crank Installation
Master Cylinder Removal
Master Cylinder Installation
Bleeding the Hydraulic Brake System
Purging the Hydraulic System
Filling the Hydraulic System
Park Brake System
Park Brake Cable Removal
Park Brake Cable Installation
Park Brake Handle Removal
Park Brake Handle Installation
Park Brake Adjustment
Section 7 - Steering and Front Suspension
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Disassembly
Steering Column Assembly
Steering Column Installation
Rack and Pinion
Rack and Pinion Inspection
Rack and Pinion Removal
Rack and Pinion Disassembly
Rack and Pinion Assembly
Rack and Pinion Installation
Front Suspension
Lubrication
Wheel Alignment
Front Suspension Components
Kingpin and Steering Spindle Removal
Kingpin and Steering Spindle Installation
A-Arm Removal
A-Arm Installation
Shock Absorber Removal
Shock Absorber Installation
Front Wheel Bearings and Hubs
Front Wheel Free Play Inspection
Front Wheel Bearings and Hub Removal
Front Wheel Bearings and Hub Installation
Section 8 - Wheels and Tires
General Information
Section 9 - Rear Suspension
Shock Absorbers
Shock Absorber Removal and Inspection
Shock Absorber Installation
Multi-Leaf Springs
Multi-Leaf Spring Removal
Multi-Leaf Spring Installation
Snubber
Snubber Removal
Snubber Installation
Section 10 - Periodic Maintenance
Periodic Service Schedule
Periodic Lubrication Schedule
Master Cylinder
Brake Fluid
Engine Oil
Engine Oil Level Check
Engine Oil and Filter Change
Oil Viscosity
Fueling Instructions
Battery
Section 11 - Troubleshooting and Electrical System: Fe400, Key-Start Engine
Troubleshooting Guide
Electrical System
Lockout Cam
Circuit Testing
Wiring Diagrams
Test Procedures
Index of Test Procedures
Section 12 - Electrical Components: Fe400, Key-Start Engine
Starter/Generator (Model G425419)
Starter/Generator (Model 114-01-4005)
Voltage Regulator
Diode
Key Switch
Solenoid
Fuse
Lockout Cam Limit Switch
Lockout Cam
Reverse Warning Buzzer
Reverse Buzzer Limit Switch
Oil Warning Light
Fuel Gauge/Hour Meter
Fuel Level Sending Unit
RPM Limiter
Ignition Coil
Oil Level Sensor
Headlights
Headlight Diode
Light Switch
Battery
Ground Cables
Section 13 - Fe400 Engine
General Information
Before Servicing
Lubrication System
Spark Plug
Cylinder
Breather Valve (Reed Valve)
Valve Clearance Check and Adjustment
Crankcase
Engine Removal
Crankcase Cover Removal
Oil Level Sensor
Ignition Coil and Flywheel
Crankcase Cover Installation
Flywheel Installation
Engine Installation
Torque Specifications
Adjustment and Settings
Section 14 - Fuel System
General Information
Carburetor
Main Jet Elevation/Size Chart
Changing the Main Jet
Engine Control Linkage
General Information
Accelerator Rod
Governor Cable
Accelerator Cable
Closed Throttle or Idle Adjustment
Engine RPM Adjustment
Choke and Air Intake System
Choke Cable Removal
Choke Cable Installation
Air Box Removal
Air Box Installation
Intake Duct Repair
Intake Duct Removal
Intake Duct Installation
Air Filter
Fuel Filters
Fuel Filter Removal
Fuel Filter Installation
Fuel Pump
General Information
Fuel Pump Removal
Fuel Pump Disassembly (Metal Pump Only)
Fuel Pump Cleaning and Inspection (Metal Pump Only)
Fuel Pump Assembly (Metal Pump Only)
Fuel Pump Installation
Fuel Tank
Fuel Tank Removal
Fuel Tank Storage or Disposal
Fuel Tank Installation
Fuel Lines
Fuel Shut-Off Valve
Carbon Canister (if Equipped)
Carbon Canister Removal
Carbon Canister Installation
Section 15 - Exhaust System
Muffler
Muffler Removal
Muffler Installation
Section 16 - Mc012C-Bs00 Unitized Transaxle with Differential Lock
General Information
Lubrication
Axle Shaft
Axle Shaft, Bearing, and Oil Seal Removal
Axle Shaft, Bearing, and Oil Seal Installation
Unitized Transaxle Removal
Unitized Transaxle Installation
Forward/Reverse Shifter Cable
Forward/Reverse Shifter Cable Removal
Forward/Reverse Shifter Cable Installation
Forward/Reverse Shifter Cable Adjustment
Differential Lock System
Differential Lock System Inspection
Differential Lock Cable Removal
Differential Lock Cable Installation
Section 17 - Torque Converter
General Information
Troubleshooting
Drive Belt
Drive Belt Removal
Drive Belt Installation
Drive Clutch
Drive Clutch Removal
Drive Clutch Cleaning and Inspection
Drive Clutch Disassembly
Inspection of Drive Clutch Parts
Drive Clutch Assembly
Drive Clutch Installation
Driven Clutch
Driven Clutch Removal
Driven Clutch Disassembly
Driven Clutch Inspection
Driven Clutch Assembly
Driven Clutch Installation
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2006-2010 Turf/Carryall
272/472, XRT1200/SE
Maintenance and Service
Manual
Turf 272, Carryall 272, Carryall 472,
XRT 1200, and XRT1200 SE
Gasoline Vehicles
Manual Number 102907711
Edition Code 1007B0810A
Table of
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Table of Contents
Troubleshooting
Brake System Troubleshooting
55
SECTION 11 - TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE
129
SECTION 17 - TORQUE CONVERTER
285
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