Club Car XRT 800 Maintenance Service Manual
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Club Car XRT 800 Maintenance Service Manual

Gasoline/electric
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2007-2008
MAINTENANCE
SERVICE
MANUAL
XRT 800, 810 and 850
GASOLINE/ELECTRIC
MANUAL NUMBER 103209106
EDITION CODE 0907D0808C

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Summary of Contents for Club Car XRT 800

  • Page 1 2007-2008 MAINTENANCE SERVICE MANUAL XRT 800, 810 and 850 GASOLINE/ELECTRIC MANUAL NUMBER 103209106 EDITION CODE 0907D0808C...
  • Page 3 This manual provides detailed information for the maintenance and repair of the Club Car XRT 800, 810 and 850 series vehicles, and should be thoroughly reviewed prior to servicing the vehicle. The procedures pro- vided must be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.
  • Page 4 There are no warranties expressed or implied in this manual. See the limited warranty found in the vehicle Owner’s Manual. Page ii 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 5: Table Of Contents

    Front Body – 800 and 810 ........................ Bumper/Brush Guard Removal ..................... Bumper/Brush Guard Installation ....................Front Body Removal ........................Molded Dash Removal ......................... Molded Dash Installation ......................Front Body Installation ........................2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page iii...
  • Page 6 Accelerator Pedal – Electric Vehicles ....................Accelerator Pedal Removal ......................Accelerator Pedal Installation ....................... 5-10 Pedal Group Adjustment – Gasoline Vehicle ................... 5-11 Pedal Group Adjustment – Electric Vehicles ..................5-16 Page iv 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 7 7-16 Kingpin and Steering Spindle Installation ..................7-16 Delta A-Plate Removal ......................... 7-16 Delta A-Plate Installation ......................7-19 Shock Absorber Removal ......................7-19 Shock Absorber Installation ......................7-19 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page v...
  • Page 8 Engine Oil And Filter Change ....................... 10-7 Oil Viscosity ..........................10-9 SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: 800 AND 810 GAS General Information ......................... 11-1 Troubleshooting Guide ........................11-1 Page vi 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 9 Voltage Limiter ..........................13-28 Light Switch ............................13-29 Battery .............................. 13-30 Ground Cables ..........................13-34 SECTION 14 – ELECTRICAL COMPONENTS: 850 GASOLINE VEHICLE Starter/Generator ..........................14-1 Voltage Regulator ..........................14-11 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page vii...
  • Page 10 Flywheel Installation ......................... 15-8 Engine Installation ..........................15-9 Torque Specifications ........................15-10 Adjustments and Settings ......................15-10 SECTION 16 – FUEL SYSTEM: GASOLINE VEHICLE General Information ......................... 16-1 Page viii 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 11 Fuel Tank Disposal ........................16-23 Fuel Tank Storage ........................16-23 Fuel Tank Installation ........................16-23 Fuel Lines ............................16-25 Fuel Shut-Off Valve .......................... 16-25 Fueling Instructions ........................... 16-26 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page ix...
  • Page 12 SECTION 20 – TORQUE CONVERTER: GASOLINE VEHICLE General Information ......................... 20-1 Troubleshooting ..........................20-1 Drive Belt ............................20-2 Drive Belt Removal ........................20-2 Drive Belt Installation ........................20-3 Page x 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 13 Faults Menu ............................22-6 Functions Menu ..........................22-11 Get Settings From Controller ......................22-11 Write Settings to Controller ......................22-12 Reset All Settings ......................... 22-13 Information ............................22-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page xi...
  • Page 14 24-7 Battery Replacement ........................24-8 Battery Care ............................. 24-9 Preventive Maintenance ....................... 24-9 Self-Discharge ..........................24-10 Electrolyte Level ........................... 24-10 Mineral Content ..........................24-11 Vibration Damage ......................... 24-11 Page xii 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 15 Motor Installation ..........................26-12 Motor Speed Sensor ......................... 26-15 SECTION 27 – MOTOR (MODEL EJ4-4001) General Information .......................... 27-1 Motor Identification ........................... 27-1 External Motor Testing ........................27-1 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page xiii...
  • Page 16 Speed Setting ..........................29-2 Fast Accel ............................ 29-3 Pedal Up Mode ..........................29-3 Speed Cal ............................ 29-3 Code A, Code B, and Code C ...................... 29-3 SECTION i – INDEX Page xiv 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 17: Section 1 - Safety

    Service only in a well-ventilated area. • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 1-1...
  • Page 18 • If wires are removed or replaced, make sure wiring and wire harness are properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death. WARNING CONTINUED ON NEXT PAGE... Page 1-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 19 2. Remove positive battery cable. 2. Remove negative battery cable. Connect battery cables in reverse order. 3. Remove positive battery cable. Connect battery cables in reverse order. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 1-3...

  • Page 21: Section 2 - Vehicle Specifications

    34.5 in (88 cm) Rear wheel tread 38.5 in. (98 cm) 874 lb. 889 lb. Weight: (without batteries) (396 kg) (403 kg) Vehicle Specifications continued on next page... 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 2-1...
  • Page 22 38 oz. (1.12 L) Unitized transaxle 27 oz. (0.8 L) Fuel tank 7 gallons (26.5 L) Tire Pressure Front and rear 18-20 psi (1.24-1.38 Bars) 18-20 psi (1.24-1.38 Bars) Page 2-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 23 Weight (dry, without battery) (425 kg) 800 lb. Vehicle rated capacity: Level surface only (363 kg) Forward speed 16 mph (26 km/h) Standard seating capacity Vehicle Specifications continued on next page... 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 2-3...
  • Page 24 Engine crankcase (with filter) 38 oz. (1.12 L) Unitized transaxle 27 oz. (0.8 L) Fuel tank 7 gallons (26.5 L) TIRE PRESSURE Front and rear 14-16 psi (0.97-1.10 Bars) Page 2-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 25: Section 3 - General Information

    The dash must be removed to view this decal. NOTE: Have the vehicle serial number available when ordering parts or making inquiries. SERIAL NUMBER XH0601-123456 P.O. BOX 204658 AUGUSTA, GA 30917 Figure 3-1 Serial Number Decal 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 3-1...

  • Page 26: Storage - Gasoline Vehicle

    2. Drain carburetor and seal the fuel tank. 2.1. XRT 800/810: Place the Forward/Reverse handle in the NEUTRAL position. Turn the fuel shut-off valve (1) to the closed (OFF) position (Figure 3-3, Page 3-4 or Figure 3-4, Page 3-4) and run the engine until fuel remaining in the carburetor and fuel lines is depleted and the engine stalls.
  • Page 27 9. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling. Figure 3-2 Fuel Tank, Vent, and Lines 1. Vent 2. Shut-off Valve 3. Vent Tubes 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 3-3...

  • Page 28: Returning The Stored Gasoline Vehicle To Service

    4. XRT 800/810: Place the Forward/Reverse handle in the NEUTRAL position. Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts. Turn the engine off. See following NOTE.

  • Page 29: Preparing The Electric Vehicle For Extended Storage

    2. Fully charge batteries. 3. Adjust tires to recommended tire pressure. See Section 2 – Vehicle Specifications. 4. Perform the Pre-Operation and Daily Safety Checklist. See the vehicle owner’s manual. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 3-5...

  • Page 31: Section 4 - Body And Trim

    More Difficult Stains: Perform previous procedure using full-strength bleach, or allow bleach to pud- dle on affected area for approximately 30 minutes. Rinse with a water dampened cloth to remove any remaining bleach concentration. See following CAUTION. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 4-1...

  • Page 32: Front And Rear Body Repair

    GOUGES, PUNCTURES, TEARS, LARGE SCRATCHES, AND ABRASIONS Touch-up is not recommended. Replace the entire body part or have it repaired by a professional paint and body repair shop with experience repairing TPO bodies. Page 4-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 33: Front Body - 800 And 810

    3. Remove screws (4) and plastic scalloped washers (6) from body and body support and slide body away from dash. 4. Remove plastic screws from sides of dash and body. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 4-3...

  • Page 34: Molded Dash Removal

    4. Attach plastic caps (5) onto dash screws. 5. Install plastic screws on the sides of the dash and body. 6. Install bumper or brush guard. See Bumper/Brush Guard Installation on page 4-3. Page 4-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 35: Front Body - 850

    • Do not operate the vehicle without an installed front bumper and brush guard that are specifically designed and approved for use on this vehicle. Instability in the vehicle could cause serious injury or death. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 4-5...

  • Page 36: Bumper/Brush Guard (Standard) Installation

    3. Install bottom screws (6) and tighten to 14 ft-lb (19 N·m). 4. Tighten lock nuts (5) to 17.5 ft-lb (24 N·m). Figure 4-4 Standard Bumper and Brush Guard – 850 (Heavy Duty Shown in Inset) Page 4-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 37: Bumper/Brush Guard (Heavy Duty) Removal

    5. Install plastic screws (5) on the sides of the dash and body. 6. Install bumper and brush guard. See Bumper/Brush Guard (Standard) Installation on page 4-6 or Bumper/Brush Guard (Heavy Duty) Installation on page 4-7. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 4-7...

  • Page 38: Cargo Bed - 800 And 810

    • Keep bed hinges as close to alignment as possible to avoid binding the pins during removal. ý WARNING • Keep hands and arms from between the bed and vehicle frame and do not allow the bed to drop. Page 4-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 39: Cargo Bed Installation

    1. Remove latch springs. 2. Remove bolts and mechanical lock nuts from latch link and catch plates (Figure 4-7, Page 4-9). 3. Remove bronze bearings from catch plates. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 4-9...
  • Page 40 4. Remove hinge support bolts and supports (Figure 4-11, Page 4-11). See following NOTE. NOTE: Note the location of the two different size bolts. It may be necessary to deflect the rear fender slightly to remove support bolts. Page 4-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 41: Bed Latch Assembly Installation

    (Figure 4-12, Page 4-11). Figure 4-12 Bed Latch Plates SEAT BACK SUPPORT BRACKET REMOVAL 1. Remove bolts from seat back and support brackets and remove seat back. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 4-11...

  • Page 42: Seat Back Support Bracket Installation

    4. Remove the two screws, nuts and washers located at the bottom edge of the seat support panel (in kick- plate just above the floormat) (Figure 4-15, Page 4-13). Page 4-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 43 8. Remove two bolts, washers and nylon lock nuts from rear fenders at frame locations (Figure 4-17, Page 4-14). 9. Lift rear body and fenders from the vehicle. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 4-13...

  • Page 44: Rear Fender Removal

    3.7. Remove the two outside body and fender bolts and separate the passenger side fender from the rear body. REAR FENDER INSTALLATION NOTE: If both fenders have been removed, attach them to the rear body first, then install the rear body with fenders attached. Page 4-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 45: Rear Body Installation

    5. Remove two screws, washers and nuts located at the bottom edge of the seat support panel (in kick-plate just above the floor mat) (Figure 4-19, Page 4-16). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 4-15...
  • Page 46 8.6. Remove the hardware (12 and 13) that secures the seat back support brackets (5 and 6) to the rear body and lift the seat back support brackets away from the vehicle. Page 4-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 47 BODY AND TRIM Rear Body – 850 Figure 4-20 Rear Seat/Handrail – 850 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 4-17...
  • Page 48 9.3. Remove the four screws (6) and flat washers (7) that attach the seat back supports (8) to the body. 9.4. Remove cargo box and seat back assembly from the vehicle. 10. Lift the rear body from the vehicle. Page 4-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 49: Rear Body Installation

    1. Reverse the removal procedure to install the floormat. If loosened, tighten rear body screws to 48 in-lb (5.4 N·m). 2. Install the brake and accelerator pedals. See Section 5 – Accelerator and Brake Pedal Group. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 4-19...

  • Page 51: Section 5 - Accelerator And Brake Pedal Group

    3.3. Remove the nut (12) and brake stop bumper (11). 3.4. Lift the pedal assembly (8) through the floorboard. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 5-1...

  • Page 52: Brake Pedal Installation

    3. Position and attach brake pedal assembly, mounting blocks (23) and washers (2) to vehicle frame as shown. Tighten the bolts and nuts to 113 in-lb (12.8 N·m). Page 5-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 53: Park Brake Removal

    3.1. To remove the park brake rod and pawl assembly (16 through 19 and 35), remove the push nut (18) and disconnect the ball joint sleeve (20) from the park brake pedal (24) (Figure 5-1, Page 5-2). See following NOTE. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 5-3...

  • Page 54: Park Brake Installation

    7. Adjust park brake ratchet/pawl gap and pawl engagement. Refer to the appropriate adjustment proce- dure: • Pedal Group Adjustment – Gasoline Vehicle on page 5-12, Step 4 • Pedal Group Adjustment – Electric Vehicles on page 5-17, Step 4 Page 5-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 55: Accelerator Pedal - Gasoline Vehicles

    10. Press the brake pedal slightly and slide the park brake ratchet (24) toward the end of the accelerator pivot rod. Rotate the ratchet and remove it from the pivot rod. 11. Remove the pivot rod (6) and spacer (20) from the accelerator pivot rod supports (21). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 5-5...
  • Page 56 13. Remove the accelerator pedal (1) from the vehicle. 14. Inspect all parts for wear and damage. Replace as necessary Page 5-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 57: Accelerator Pedal Installation

    • Pedal Group Adjustment – Gasoline Vehicle on page 5-14, Step 5 • Adjust the accelerator rod (gasoline vehicles only). Pedal Group Adjustment – Gasoline Vehicle on page 5-14, Step 6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 5-7...

  • Page 58: Accelerator Pedal - Electric Vehicles

    (15) to make installation of the pivot rod easier. 13. Remove the accelerator pedal (1) from the vehicle. 14. Inspect all parts for wear and damage. Replace as necessary. Page 5-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 59 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles Figure 5-7 Accelerator Pedal – Electric Vehicle 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 5-9...

  • Page 60: Accelerator Pedal Installation

    12. Install the MCOR (2) and drive bar (3) as instructed. See MCOR Installation, Section 23, Page 23-9. 13. Adjust the accelerator pedal height. See step 5 of Pedal Group Adjustment – Electric Vehicles on page 5-19. Page 5-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 61: Pedal Group Adjustment - Gasoline Vehicle

    Correct pedal position is 6 inches (15.2 cm) from floor mat to back of brake pedal. Figure 5-10 Brake Pedal Height Adjustment Figure 5-11 Brake Pedal Height Measurement 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 5-11...
  • Page 62 NOTE: The accelerator rod must also be checked if the ratchet/pawl gap is adjusted. See step 6 of Pedal Group Adjustment – Gasoline Vehicle on page 5-14. The accelerator rod must be disconnected before proceeding to step 4.3. Page 5-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 63 Reconnect ball joint (Figure 5-16, Page 5-14). 4.7. If the accelerator push rod was disconnected from the accelerator pedal, reconnect it. 4.8. Check for proper brake operation prior to driving the vehicle. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 5-13...
  • Page 64 “To avoid unintentionally starting...” in General Warning on page 1-2. This will prevent the possibility of the vehicle running over you when you are adjusting the accelerator rod. 6.1. Remove the electrical box screw and cover. See preceding DANGER. Page 5-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 65 3300 (± 30) RPM (800/810) or 2600 (± 30) RPM (850). 6.7. Install the electrical box cover and screw. 7. Adjust the brakes. See Brake Adjustment, Section 6, Page 6-8. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 5-15...

  • Page 66: Pedal Group Adjustment - Electric Vehicles

    Correct pedal position is 6 inches (15.2 cm) from floor mat to back of brake pedal. Figure 5-21 Brake Pedal Height Adjustment Figure 5-22 Brake Pedal Height Measurement Page 5-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 67 If the gap becomes larger as the park brake pedal is pressed, move the pivot rod supports slightly forward until gap is consistent. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 5-17...
  • Page 68 Reconnect ball joint (Figure 5-27, Page 5-19). 4.7. Check for proper brake operation prior to driving the vehicle. Page 5-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 69 26 ft-lb (35.3 N·m). 6. Adjust the brakes. See Brake Adjustment, Section 6, Page 6-8. ACCELERATOR PEDAL ADJUSTMENT TOOL (CCI P/N 101871001) RUBBER STRAP Figure 5-29 Accelerator Pedal Height Adjustment 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 5-19...

  • Page 71: Section 6 - Wheel Brake Assemblies

    5.1. On the back of each brake cluster assembly, locate the heads of two brake shoe retainer pins. It may be necessary to remove sealant material around the head of each pin. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 6-1...
  • Page 72 6.2. Pull the axle shaft (2) from the axle tube (Figure 6-2, Page 6-2). BRAKE DRUM TWO BRAKE SHOE RETAINER PIN HEADS AXLE TUBE 1/2 IN. X 5/8 IN. COLD CHISEL Figure 6-3 Shoe Retainer Pins Page 6-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 73 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES GASOLINE VEHICLE ELECTRIC VEHICLE SEE SECTION 9 – REAR SUSPENSION FOR MOUNTING Figure 6-4 Self-adjusting Wheel Brake Assembly 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 6-3...
  • Page 74 9. Remove adjuster wheel (1) with two washers (2 and 3) from the backing plate (Figure 6-7, Page 6-4). Figure 6-7 Remove Adjuster Wheel Figure 6-8 Lubricate Slide and Slide Plate Page 6-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 75: Brake Assembly Cleaning

    (Figure 6-11, Page 6-6). See preceding WARNING. 7. Install the adjuster wheel (1) and two washers (2 and 3) into the adjuster assembly (Figure 6-7, Page 6-4). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 6-5...

  • Page 76: Brake Shoe Installation

    SILVER SPRING spring is mounted with the coils to the side of the adjustment lever spring (A). Figure 6-13 Install Trailing Shoe Retainer Clip Figure 6-14 Attach Springs Page 6-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 77 Loss of control of the vehicle could result in severe personal injury or death. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 6-7...

  • Page 78: Brake Adjustment

    Although step 5 – Removing the Axle allows easier access to the brake shoes, it is not imperative to do so in order to remove the brake shoes. 5. Remove the axle. Page 6-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 79: Brake Cluster Installation

    5. Tighten lug nuts on rear wheels, using crisscross pattern, to 55 ft-lb (74.6 N·m). See Wheel Installation, Section 8, Page 8-1. 6. Adjust the brakes. See Brake Adjustment on page 6-8. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 6-9...

  • Page 80: Brake Cable Removal And Installation

    (Figure 6-19, Page 6-10). 7. Remove E-clip (4) from cable at the cable support bracket (5). Remove cable from bracket. Figure 6-19 Disconnect Cables at Rear Brakes Page 6-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 81 7. Tighten the locknut (6) to 15 ft-lb (20.3 N·m). Do not allow the p-clamp to rotate while tightening the hard- ware. 8. Adjust the brakes. See Brake Adjustment on page 6-8. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 6-11...
  • Page 82 2 PLACES TYPICAL 2 PLACES REF. BRAKE CABLE IS ROUTED FROM INBOARD TO OUTBOARD, CROSSING UNDER LEAF SPRING TO BRAKE CLUSTER. Figure 6-20 Brake Cable Clip and P-Clamp Page 6-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 83: Section 7 - Steering And Front Suspension

    5.5. Remove the steering wheel puller. 5.6. Remove the steering wheel nut (27) and the steering wheel (25) from the steering column (20) (Figure 7-3, Page 7-3). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 7-1...

  • Page 84: Steering Wheel Installation

    4.3. Disconnect the wires from the electrical components mounted on the dash panel. Do not allow wires to touch. 4.4. Slide dash panel up and away from the steering column. Page 7-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 85 STEERING AND FRONT SUSPENSION Steering Column TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-3 Steering Column 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 7-3...

  • Page 86: Steering Column Disassembly

    1-3/16 inches (3.3 cm) and a minimum inside diameter of 7/8 inch (2.2 cm). Be sure the bearing is installed in the bearing seat as shown (Figure 7-4, Page 7-5) so the wedge (16) will ride against the inner race of the bearing. Page 7-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 87: Steering Column Installation

    6. Tighten the two nuts (9) and bolts (8) to 17 ft-lb (23 N·m). 7. Tighten the bolt (2) on the upper universal joint to 15 ft-lb (20 N·m). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 7-5...

  • Page 88: Steering Adjustment

    (Figure 7-8, Page 7-8). Also inspect front suspension assemblies; e.g., A-Plates (1) (Figure 7-19, Page 7-17) urethane bushings (2) (Figure 7-19, Page 7-17) and leaf springs (6) (Figure 7-20, Page 7-18). Replace components as necessary. Page 7-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 89: Rack And Pinion

    3. Remove both bellows clamps (2) (plastic wire ties). 4. Remove the hex nut (29) and slide off the dust seal bellows (1). 5. Remove the retaining ring (21), then slide off dust seal bellows (20). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 7-7...
  • Page 90 10. Install the universal joint onto the pinion and place a large open end wrench under the universal joint (Figure 7-9, Page 7-9). Use the wrench as a lever to pull the pinion from the housing. TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 7-8 Steering Gear Page 7-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 91 14. Inspect the bushing inside the steering box assembly (6) for excessive wear. If wear is excessive, replace the steering box assembly (CCI P/N 101878302) (Figure 7-8, Page 7-8). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 7-9...

  • Page 92: Rack And Pinion Assembly

    10. Apply a small amount of grease to the rack guide (13) where it comes into contact with the rack (17) (Figure 7-8, Page 7-8). ® 11. Place a few drops of Loctite 222 on the threads of the screw (16) (Figure 7-8, Page 7-8). Page 7-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 93 • The tie rod and drag link have right-hand threads on one end and left-hand threads on the other end. Right-hand threads are identified by a groove in the tie rod or drag link. 18. Install the ball joint (23). See preceding CAUTION. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 7-11...

  • Page 94: Rack And Pinion Installation

    2. Install ball joint ends (6 and 13) into the left and right-hand spindle arms (23), then install the retaining nuts (20) and cotter pins (22) (Figure 7-19, Page 7-17). Page 7-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 95: Front Suspension

    Page 7-14. 6. Tighten the hex nut (8) on the adjustment eccentric (7) to 10 ft-lb (13.5 N·m) (Figure 7-20, Page 7-18) See also Figure 7-16, Page 7-14. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 7-13...
  • Page 96 5. Subtract the measurement on the front of the tires from the measurement on the rear of the tires. The difference is the toe-in. Proper toe-in is 1/8 to 3/8 of an inch (3.2 to 9.5 mm). Page 7-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 97: Front Suspension Components

    5. Lower the vehicle and finish tightening lug nuts (using a crisscross pattern) to 55 ft-lb (74.6 N·m). 6. Adjust camber and toe-in as instructed on page 7-13. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 7-15...

  • Page 98: Kingpin And Steering Spindle Removal

    4. Remove the lower shock absorber mounting nut (9), then slide the shock absorber free of the Delta A- Plate. 5. Remove the Delta A-Plate (1). 6. Inspect the bushings (2) and sleeves (3 and 4) in the Delta A-Plate and replace them if necessary. Page 7-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 99 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-19 Upper Front Suspension Assembly A. Number of spacer plates used on vehicle: Three on the 850; Five on the 800/810 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 7-17...
  • Page 100 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-20 Lower Front Suspension Assembly * Number of spacer plates used on vehicle: Three on the 850; Five on the 800/810 Page 7-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 101: Delta A-Plate Installation

    5. Inspect the surface of the spindle shaft for surface damage. It should be clean and smooth. If severe pit- ting from rust or corrosion has occurred, replace the spindle assembly. See Kingpin and Steering Spin- dle Removal on page 7-16. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 7-19...

  • Page 102: Front Hub Installation

    7.1. For vehicles with steel wheels, tighten the lug nuts to 55 ft-lb (74.6 N·m). 7.2. For XRT 850 vehicles with alloy mag wheels, tighten the lug nuts to 65 ft-lb (88 N·m). Page 7-20 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 103: Section 8 - Wheels And Tires

    2.2. For XRT 850 vehicles with alloy mag wheels, tighten the lug nuts to 65 ft-lb (88 N·m). TIRES See General Warning on page 1-1. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 8-1...

  • Page 104: Tire Repair

    2. When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal on page 8-1. Page 8-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 105: Tire Installation

    Over-inflation could cause tire to explode, possibly resulting in severe personal injury. Figure 8-2 Inflate Tire 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 8-3...
  • Page 106 8. Adjust air pressure in tire to recommended pressure. See Section 2 – Vehicle Specifications. 9. Immerse the wheel and tire assembly in water to make sure there are no leaks. Page 8-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 107: Section 9 - Rear Suspension

    1. To install, reverse the removal procedure. 2. On the upper and lower shock absorber mounting stems, tighten the nuts until the rubber bushing expands to the size of the cup washer. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 9-1...

  • Page 108: Leaf Springs

    6. Remove the nuts (14) and the U-bolt (11) securing the spring to the jounce bumper bracket (20) and spacer (17) to the transaxle. Remove the shock mount bracket (16), angle bracket (13) and the U-bolt. Page 9-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 109 9. Inspect the bushings (4) and spacers (3) in the spring eyes and replace them if they are worn or dam- aged. Figure 9-3 Rear Suspension Assembly and Mounting – 800 and 810 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 9-3...

  • Page 110: Leaf Spring Installation - All Vehicles

    4. Tighten the nuts (5) until the rubber bushing (10) expands to the size of the cup washer (9). 5. 850 Models: Tighten the stabilizer bar hardware. See Stabilizer Bar Installation on page 9-7. Page 9-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 111 REAR SUSPENSION Leaf Springs Figure 9-4 Rear Suspension Assembly and Mounting – 850 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 9-5...
  • Page 112 REAR SUSPENSION Leaf Springs Figure 9-5 Rear Stabilizer Bar Mounting – 850 Page 9-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 113: Stabilizer Bar Removal

    5.1. For vehicles with steel wheels, tighten the lug nuts to 55 ft-lb (74.6 N·m). 5.2. For XRT 850 vehicles with alloy mag wheels, tighten the lug nuts to 65 ft-lb (88 N·m). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 9-7...

  • Page 115: Section 10 - Periodic Maintenance

    Both the Periodic Service Schedule and Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 10-1...
  • Page 116 Motor controller output regulator (MCOR) only (or every 100 hours of operation, other damage. whichever comes first) If batteries are not performing as Batteries expected, see Section 24 – Batteries: Electric Vehicles Page 10-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 117 Check for loose hardware and tighten if General vehicle necessary. Two year service by trained technician only (or every 200 hours of operation, Fuel filters Replace. Dispose of used filters properly. whichever comes first) 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 10-3...

  • Page 118: Periodic Lubrication Schedules

    22 oz. (0.67 L) SAE 30 WT. API Class Check/fill transaxle to plug level 100 hours of operation, SE, SF, or SG Oil (or higher) whichever comes first) Figure 10-1 Lubrication Points – Electric Vehicles Page 10-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 119 200 hours of Change engine oil and oil filter L) with filter operation, or annually, whichever comes first. Figure 10-2 Lubrication Points – 800 and 810 Gasoline Vehicles 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 10-5...

  • Page 120: Engine Oil - Gasoline Vehicles

    (safe level). 4. Reinsert dipstick into the oil filler tube. NOTE: Properly recycle or dispose of used oil in accordance with local, state, and federal regulations. Page 10-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 121: Engine Oil And Filter Change

    7. Use a 14 mm socket or wrench and replace the front oil drain plug, turning it clockwise, and tighten to 18 ft-lb (24.4 N·m). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 10-7...
  • Page 122 14. Connect the battery cables, positive (+) cable first, and tighten terminals to 12 ft-lb (16 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 15. Lower the cargo bed. See WARNING “For vehicles with cargo beds...” on page 1-3. Page 10-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 123: Oil Viscosity

    NOTE: Using multi-grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. Check oil level more frequently when using them. SAE 30 SAE 10W-30/ SAE 10W-40 SAE 5W-30 Figure 10-8 Oil Viscosity Chart 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 10-9...
  • Page 124 PERIODIC MAINTENANCE Engine Oil – Gasoline Vehicles Page 10-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 125: Section 11 - Troubleshooting And Electrical System: 800 And 810 Gas

    Carburetor improperly adjusted Vehicle Section 13 – Electrical Components: 800 Starter/generator belt is slipping and 810 Gasoline Vehicles Belt Tension Adjustment on page 13-10 Troubleshooting Guide continued on next page... 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-1...
  • Page 126 Section 16 – Fuel System: Gasoline Air filter is dirty or clogged Vehicle Section 16 – Fuel System: Gasoline Governor is improperly adjusted Vehicle Troubleshooting Guide continued on next page... Page 11-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 127 Lockout limit switch failed System: 800 and 810 Gas, Test Procedure Loose or broken wire in starter/generator Starter/Generator on page 13-1 circuit Troubleshooting Guide continued on next page... 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-3...
  • Page 128 Section 11 – Troubleshooting and Electrical Kill circuit wire is disconnected from the System: 800 and 810 Gas, Test Procedure ignition coil Troubleshooting Guide continued on next page... Page 11-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 129: Electrical System

    NOTE: Be sure the cam is in the correct position. The cam should activate the limit switch only when the Forward/Reverse handle is in the NEUTRAL position (Figure 11-1, Page 11-5). Figure 11-1 OPERATE (Neutral) Position for Cam 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-5...

  • Page 130: Wiring Diagrams

    18_RED(W33) HEAD LIGHT LEFT IGN. KILL 16_BLK(W24) SWITCH ELECTRICAL COMPONENT BOX 18_ORG(W25) 18_RED(W04) 18_RED(W04) 14_YEL(W10) 14_YEL(W10) 16_ORG(W31) 16_BLK(W28) 16_BLK(W17) 000234-001 Figure 11-2 Wiring Diagram for Key-Start Gasoline Vehicles Page 11-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 131 WHITE STARTER GENERATOR 18_BLU(W11) SOLENOID VOLTAGE REGULATOR 18_YEL(W45) 16_BLK(W42) 18_BLK(W40) FUSE BLOCK ELECTRICAL COMPONENT BOX 18_ORG(W25) 18_RED(W04) 14_YEL(W10) 16_ORG(W31) 000234-001 Figure 11-3 Wiring Diagram for Key-Start Gasoline Vehicles 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-7...

  • Page 132: Test Procedures

    23. Lockout Cam 24. Battery Test (Under Load) 25. Fuel Level Sending Unit 26. Fuel Gauge 27. Hour Meter 28. Light Switch 29. Headlight Diode 30. Voltage at Headlight Socket Page 11-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 133 5. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the bottom of the rubber bulb. Remove the hydrometer from the cell and release the pressure from the bulb. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-9...
  • Page 134 If the difference between the cells is 0.020 or more, the low cell should be suspected. It may require a catch- up charge or it may be a weak cell. When the variations between cells reach 0.050 or more, the battery should be replaced. Page 11-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 135 5. Remove fuse to be tested from the fuse block. See Fuse Removal, Section 13, Page 13-16. The red 10 amp fuse protects the solenoid for the starter (cranking) circuit. The 20 amp fuse at the yellow wire connection protects the headlights. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-11...
  • Page 136 If the reading is incorrect, check that terminal connections are clean and tight. If the connections are good and the reading is incorrect, repair or replace the wire. Page 11-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 137 (B) terminal and the black (–) probe on the (L) terminal of the key switch, the reading should be continuity. If either reading is incorrect, replace the key switch. See Key Switch Removal, Section 13, Page 13-14. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-13...
  • Page 138 See Key Switch Removal, Section 13, Page 13-14. 6-GAUGE WHITE 16-GAUGE WIRE ASSEMBLY RED WIRE ASSEMBLY 18-GAUGE WHITE WIRE ASSEMBLY COVER ELECTRICAL COMPONENT SOLENOID Figure 11-11 Remove Solenoid Wires Page 11-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 139 This limit switch is located on the Forward/Reverse switch assembly. A black wire and a green wire are con- nected to this limit switch. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-15...
  • Page 140 ON. METER READS IS OUT. METER APPROXIMATELY READS 1. ZERO OHMS. 200nA 200nA 1000 --- 1000 --- FUSED FUSED 750V 750V Figure 11-14 Test Lockout Cam Limit Switch Page 11-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 141 If the reading is incorrect, a possible grounded DF terminal and/or grounded field coil may be the cause. The starter/generator will need to be removed from the vehicle and disassembled by a qualified techni- cian. See Starter/Generator Removal, Section 13, Page 13-1. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-17...
  • Page 142 3.2. Remove the cover retaining screw (5) and electrical component box cover (6) (Figure 11-17, Page 11-19). 3.3. Remove the locknuts (7) from the two large solenoid posts and disconnect the diode wires from the solenoid. Page 11-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 143 WHITE FROM FUSE BLOCK DIODE WHITE FROM STARTER/ RED FROM GENERATOR BATTERY VIEWED FROM INSIDE DRIVER SIDE FRAME OUTER I-BEAM Figure 11-17 Electrical Control Box and Diode Orientation 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-19...
  • Page 144 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2. Check that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Page 11-20 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 145 2. Disconnect the engine-kill white/black wire at the bullet connector located next to the RPM limiter (Figure 11-22, Page 11-22). NOTE: Disconnecting the engine-kill wire removes it from the start/stop circuit. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-21...
  • Page 146 IGNITION GAP SPARK PLUG TEST TOOL WIRE SPARK PLUG FRAME Disconnect white/black LIMITER engine kill wire. Figure 11-21 Ignition Spark Test Figure 11-22 Disconnect White/Black Engine Kill Wire Page 11-22 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 147 RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK FEMALE BULLET KILL CIRCUIT WIRE TERMINAL BLACK WIRE Figure 11-23 RPM Limiter 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-23...
  • Page 148 750V Figure 11-24 Primary Coil Resistance – In Vehicle Test WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-25 Secondary Coil Test – In Vehicle Test Page 11-24 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 149 (Figure 11-27, Page 11-25). 5.3. Using a multimeter set to 20k ohms, place the red (+) probe of the multimeter into the end of the 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-25...
  • Page 150 6 on page 11-28. If the resistance is not between 12.0k - 14.0k ohms, the spark plug cap and secondary coil must be tested independently from each other. Page 11-26 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 151 200nA 1000 --- FUSED 750V 200nA 1000 --- FUSED 750V Figure 11-30 Primary Coil Resistance – Bench Test Figure 11-31 Secondary Coil and Cap Resistance – Bench Test 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-27...
  • Page 152 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning on page 1-2. 3. Remove the instrument panel. See Key Switch Removal, Section 13, Page 13-14. Page 11-28 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 153 There should be no continuity when the key switch is in the ON or START position. If there is continuity, check for worn insulation on the white/black wire that is allowing the wire to ground to the frame. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-29...
  • Page 154 6. Fill the engine with new oil and install a new oil filter before returning the vehicle to service. See Engine Oil – Gasoline Vehicles, Section 10, Page 10-6. Page 11-30 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 155 4. If all of the test results are good and the voltage reading is zero, there may be a broken or damaged 6- gauge white wire from the solenoid to the starter/generator. See Test Procedure 8 – Starter/Generator (Starter Function) on page 11-17. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-31...
  • Page 156 8. If the readings are correct according to the position of the float, but give an incorrect reading on the fuel gauge/hour meter, test the fuel gauge/hour meter. See Test Procedure 26 – Fuel Gauge on page 11-33. Page 11-32 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 157 Test Procedure 26A – Fuel Gauge (Through mid-2007) 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-33...
  • Page 158 5. Set a multimeter to 20 volts DC and place the red (+) probe of the multimeter on the positive post of the battery. Place the black (–) probe on the negative post of the battery. Record the voltage reading. Page 11-34 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 159 3. Start the engine and let it idle. See following DANGER. ý DANGER • Do not operate vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-35...
  • Page 160 If the headlight diode is functioning correctly, the wires and fuse show continuity and the readings are still incorrect, replace the switch. See Light Switch Removal, Section 13, Page 13-29. Page 11-36 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 161 NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 11-37...
  • Page 162 12 volts, the black wire has continuity. BLACK WIRE WAVETEK BLUE WIRE 1000 WIRE HARNESS 2000 200k 200nA LEFT 1000 --- FUSED 750V HEADLIGHT Figure 11-43 Check Voltage to Headlight Socket Page 11-38 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 163: Section 12 - Troubleshooting And Electrical System: 850 Gas

    Section 16 – Fuel System: Gasoline Carburetor improperly adjusted Vehicle See Belt Tension Adjustment on Starter/generator belt is slipping page 14-11. Troubleshooting Guide continued on next page... 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-1...
  • Page 164 Spark plug heat range is incorrect Section 15 – Engine Section 16 – Fuel System: Gasoline Unsuitable or contaminated fuel Vehicle Troubleshooting Guide continued on next page... Page 12-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 165 Float needle valve not functioning Section 16 – Fuel System: Gasoline properly Vehicle Section 16 – Fuel System: Gasoline Carburetor vent is clogged Vehicle Troubleshooting Guide continued on next page... 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-3...
  • Page 166 Voltage regulator failed Electrical System: 850 Gas Test Procedure 11 Section 12 – Troubleshooting and Battery failed Electrical System: 850 Gas Test Procedure 1 Troubleshooting Guide continued on next page... Page 12-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 167 Carburetor is too lean; check main and Section 16 – Fuel System: Gasoline pilot jet sizes Vehicle Carburetor throttle stop screw out of Section 16 – Fuel System: Gasoline adjustment Vehicle 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-5...

  • Page 168: Wiring Diagram

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: 850 GAS Wiring Diagram WIRING DIAGRAM HEAD LIGHT RIGHT FUEL/HOUR METER GUAGE 16_BLK(W24) HEAD LIGHT LEFT LIGHT SWITCH 14_YEL(W10) 14_YEL(W10) 16_BLK(W17) Figure 12-1 Wiring Diagram for Pedal-Start Gasoline Vehicles Page 12-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 169 TROUBLESHOOTING AND ELECTRICAL SYSTEM: 850 GAS Wiring Diagram Figure 12-2 Wiring Diagram for Pedal-Start Gasoline Vehicles 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-7...

  • Page 170: Electrical System

    10. Starter/Generator (Generator Function) 11. Voltage Regulator 12. Disconnected Kill Wire 13. Ignition Spark 14. RPM Limiter 15. Ignition Coil 16. Kill Limit Switch 17. Key Switch (Engine Kill Circuit) Page 12-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 171 A fully charged battery should read between 1.250 and 1.280 at 80 °F (27 °C). Never add acid to the battery to obtain a higher specific gravity (Figure 12-3, Page 12-10). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-9...
  • Page 172 For each 10 °F (5.6 °C) above 80 °F (27 °C), add 0.004 to the reading. For each 10 °F (5.6 °C) below 80 °F (27 °C), subtract 0.004 from the reading. Page 12-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 173 40 °F (4 °C) 9.3 V 30 °F (-1 °C) 9.1 V 20 °F (-7 °C) 8.9 V 10 °F (-12 °C) 8.7 V 0 °F (-18 °C) 8.5 V 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-11...
  • Page 174 Figure 12-5 Starter/Generator Ground Cable Test Figure 12-6 Engine Ground Cable Test 1. Ground to Chassis 2. A2 Terminal Place test probes at each end of ground cable. Page 12-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 175 (–) probe on the (1) terminal of the key switch. The reading should be continuity. If the reading is incorrect, replace the key switch (Figure 12-8, Page 12-14). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-13...
  • Page 176 Figure 12-9 Solenoid Wire Removal 1. Cover 2. Electrical Component Box 3. 6 Ga. White Wire 4. 18 Ga. White Wire 5. 18 Ga. Red Wire 6. Solenoid Page 12-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 177 WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V Figure 12-10 Solenoid Continuity Test Figure 12-11 Solenoid Ground Test 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-15...
  • Page 178 If the readings are incorrect, the starter/generator will need to be removed from the vehicle and disassembled by a qualified technician. See Starter/Generator Removal on page 14-1. Page 12-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 179 Figure 12-13 Check Starter Terminal Continuity Figure 12-14 Jumper Wire Ground – DF to A2 1. Yellow Wire 2. 200 Ohm Setting 1. Yellow Wire 2. Jumper Wire 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-17...
  • Page 180 Place the black (–) probe on the negative (–) battery post (Figure 12-15, Page 12-19). Turn the key switch to the ON position. Press the accelerator to start the engine and run it at full governed speed. If Page 12-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 181 It will be necessary to pull and hold the choke handle until the engine stops running. 5. If the engine does not run, proceed to Test Procedure 13 – Ignition Spark on page 12-20. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-19...
  • Page 182 (–) probe on one of the black wire female bullet connectors. The reading should be no continuity. If the reading is not correct, replace the RPM Limiter. Page 12-20 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 183 2.2. If the resistance is not between 0.6 - 1.7 ohms, bench test the ignition coil. See Test Procedure 15B – Ignition Coil – Bench Test on page 12-25. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-21...
  • Page 184 Figure 12-19 Primary Coil Resistance – In Vehicle Test 1. 200 Ohm Setting WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 12-20 Secondary Coil Test – In Vehicle Test 1. 20k Ohm Setting Page 12-22 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 185 (Figure 12-23, Page 12-24). If the resistance is not between 4.5k - 6.0k ohms, the cap has failed and must be replaced. Proceed to the next step with the spark plug cap still removed. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-23...
  • Page 186 1. 20k Ohm Setting 2. Spark Plug Cap WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 12-24 Secondary Coil Test Without Cap 1. 20k Ohm Setting Page 12-24 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 187 3.1. Place the red (+) probe of the meter into the end of the spark plug cap (3) that normally connects to the spark plug and place the black (–) probe on the core (2) (Figure 12-26, Page 12-25). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-25...
  • Page 188 6. If the preceding tests indicate that the ignition coil resistance readings are within acceptable ranges, but the coil fails to function properly, replace the ignition coil and cap. Page 12-26 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 189 5. Connect wires to the key switch. Make sure wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. 6. Install dash panel in reverse order of removal. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-27...
  • Page 190 Press the lever and the reading should be continuity. If either reading is incorrect, replace limit switch. See Reverse Buzzer Limit Switch Removal on page 14-19. Page 12-28 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 191 5. Install a new oil filter and fill the engine with new oil before returning the vehicle to service. See Engine Oil – Gasoline Vehicles on page 10-6. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-29...
  • Page 192 (with the accelerator pedal pressed, the battery is under load). 3.1. If the voltage reading is over 9.6 volts, with an electrolyte temperature of 70 °F (21 °C), check the Page 12-30 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 193 Lower position (tank empty) 240 ± 20 ohms Empty Center position (tank half full) 120 ± 20 ohms Half full Upper position (tank full) 60 ± 20 ohms Full 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-31...
  • Page 194 TEST PROCEDURE 26 – FUEL GAUGE See General Warning on page 1-1. Figure 12-32 Fuel Gauge/Hour Meter Terminals 1. Black(Jumper Wire From 6) 2. Blue 4. Orange 6. Black 7. White Page 12-32 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 195 2. With the key switch OFF, check the hour meter display. It is powered by an internal battery and should always be on, even with the engine off and the key removed. 3. Start the engine and let it idle. See following DANGER. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-33...
  • Page 196 If the voltage limiter is functioning correctly, the wires and fuse show continuity and the readings are still incorrect, replace the switch. See Light Switch Removal, Section 13, Page 13-29. Page 12-34 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 197 NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 12-35...
  • Page 198 12 volts, the black wire has continuity. BLACK WIRE WAVETEK BLUE WIRE 1000 WIRE HARNESS 2000 200k 200nA LEFT 1000 --- FUSED 750V HEADLIGHT Figure 12-37 Check Voltage to Headlight Socket Page 12-36 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 199 5. Support the starter/generator so that when the pivot bolts are removed the starter/generator will not fall to the ground. Remove the two pivot nuts (7) and bolts (5) from the mounting bracket. 6. Remove the starter/generator. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-1...

  • Page 200: Section 13 - Electrical Components: 800 And 810 Gasoline Vehicles

    NOTE: To clean and inspect the armature/commutator and the bearings, see Disassembly of the Starter/Generator to Service the Armature/Commutator on page 13-4. Figure 13-2 Commutator End Cover Figure 13-3 Brush Covers and Brushes Page 13-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 201: Starter/Generator

    Replace springs which apply a force of less than 24 ounces (6.67 N). Figure 13-5 Brush Spring Tension Test 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-3...
  • Page 202 Replace if there is extensive wear or pitting on the balls or rolling surfaces. Do not remove bearings unless they are to be replaced. Page 13-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 203 NOTE: Do not remove the insulators or the field coils unless an electrical test indicates that it is necessary (Figure 13-10, Page 13-6). See Test Procedure 8, Section 11, Page 11-17. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-5...
  • Page 204 • Worn, burned or glazed commutator • Loose or raised commutator bars • Bruised or damaged armature core laminations • Worn armature bearing or shaft • Dirty or oily commutator Page 13-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 205 Burned, blackened, charred or scorched coil insulation indicates the starter/generator has overheated due to overloads, grounding or shorted coil windings and should be replaced. Be sure the insulators are tight in the housing. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-7...
  • Page 206 Install a flat washer, lockwasher and nut onto each threaded terminal on the outside of the housing. Tighten nuts to 47.5 in-lb (5.4 N·m) (Figure 13-10, Page 13-6). See following CAUTION. Page 13-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 207 5. Connect the yellow wire from the voltage regulator to the DF terminal on the starter/generator. Install a flat washer, lockwasher and nut onto the terminal and tighten the nut to 31 in-lb (3.5 N·m). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-9...

  • Page 208: Belt Tension Adjustment

    8. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16.3 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 13-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 209: Voltage Regulator

    6. With the Forward/Reverse handle in the NEUTRAL position, start the engine and check regulator for proper functioning as described in the voltage regulator test procedure. See Test Procedure 12, Section 11, Page 11-20. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-11...

  • Page 210: Diode

    1. Thoroughly clean and dry the area of the I-beam where the new diode is to be attached. 2. Peel the protective film from both sides of the new thermal pad (1) (Figure 13-16, Page 13-13). See fol- lowing CAUTION. Page 13-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 211 • Incorrect wiring could result in severe injury or death. • Diode and solenoid connections must have correct polarity. • Keep all persons clear of engine belts when making final connections. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-13...

  • Page 212: Key Switch

    4. Remove the key switch. 4.1. Remove the key switch nut (1) (Figure 13-17, Page 13-14). 4.2. Remove key switch (2) from back side of instrument panel. Figure 13-17 Key Switch Removal Page 13-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 213: Solenoid

    3. Remove the air intake hose from the carburetor. 4. Remove electrical component box cover. 5. Disconnect all the wires from the solenoid. 6. Remove the two screws securing the solenoid in place. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-15...

  • Page 214: Fuse

    3. Remove the air intake hose from the carburetor. 4. Remove electrical component box cover. 5. Remove the fuse from the fuse block. Fuse Installation 1. Install the fuse. See following WARNING. Page 13-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 215: Lockout Cam Limit Switch

    5. Turn the key switch to the START position. The engine should crank only when the Forward/Reverse handle is in the NEUTRAL position. 6. Test drive the vehicle in both forward and reverse for proper operation. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-17...

  • Page 216: Lockout Cam

    4. Connect battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16.3 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 13-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 217: Reverse Warning Buzzer

    5. Connect battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16.3 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). BLACK GROUND RED/WHITE Figure 13-21 Front Reverse Warning Buzzer 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-19...

  • Page 218: Reverse Buzzer Limit Switch

    1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle is in the NEUTRAL position. Chock the wheels. 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning on page 1-2. Page 13-20 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 219: Fuel Gauge/Hour Meter

    ON position and the engine is on. When recording, the hour- glass icon on the left blinks (slowly on Early 2007 vehicles). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-21...

  • Page 220: Fuel Level Sending Unit

    The fuel level sending unit is an integral part of the fuel tank and should never be removed. Thoroughly test the fuel level sending unit before replacing the fuel tank. Testing the Fuel Level Sending Unit See Test Procedure 25, Section 11, Page 11-32. Page 13-22 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 221: Rpm Limiter

    Battery Terminal Protector Spray (CCI P/N 1014305). DAMPER RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK KILL CIRCUIT WIRE FEMALE BULLET TERMINAL BLACK WIRE Figure 13-23 RPM Limiter Assembly 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-23...

  • Page 222: Ignition Coil

    10. Disconnect the 18-gauge black wire (12) from the spade terminal (13) on the ignition coil (11) and remove the coil by removing two bolts (10) (Figure 13-25, Page 13-25). Page 13-24 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 223 11. Connect 18-gauge black (12) wire to the spade terminal (13) on the coil (Figure 13-25, Page 13-25). 12. Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch on the housing. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-25...
  • Page 224 23. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16.3 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 13-26 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 225: Oil Level Sensor

    4. Remove the wire harness/halogen bulb assembly (4 and 6) from the headlight lens (7). 5. Lift the retaining tabs on the connector (4) and remove halogen bulb assembly (6). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-27...

  • Page 226: Voltage Limiter

    NOTE: Identify terminal for solid black wire and terminal for black/white wire. 5. Remove the mounting hardware (2) from the voltage limiter and remove it from the vehicle. Page 13-28 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 227: Light Switch

    5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16.3 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-29...

  • Page 228: Battery

    144 in-lb (16 N·m), coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to prevent future corrosion. See preceding WARNINGS and following CAUTION. Page 13-30 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 229 Figure 13-31 Battery Electrolyte Level 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 MM) above plates or to level indicator. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-31...
  • Page 230 Do not exceed this 45° angle when lifting, carrying or installing battery. The battery acid could cause severe personal injury when accidentally coming in contact with the skin or eyes, and could damage clothing. Page 13-32 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 231: Charging The Battery

    5. Check the state of charge periodically. A battery that is discharged and left in a cold environment can freeze and crack. If the specific gravity drops below 1.220, the battery should be recharged. See follow- ing WARNING. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-33...

  • Page 232: Ground Cables

    WARNING • Do not jump-start a dead battery using another battery and jumper cables. GROUND CABLES Testing the Ground Cables See Test Procedure 3, Section 11, Page 11-12. Page 13-34 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 233 4. Remove the mounting/adjustment nut (12), washer (9) and bolt (11). Lower the starter/generator and remove the belt (4) from the pulley (10). A1 TERMINAL TERMINAL TERMINAL TO BATTERY GROUND POST Figure 14-1 Starter/Generator Removal 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-1...

  • Page 234: Section 14 - Electrical Components: 850 Gasoline Vehicle

    2. Check the wear line on the side of the brush. If the end of the brush is within 1/16 inch (1.6 mm) of the wear line, replace all four brushes (Figure 14-4, Page 14-2). STARTER/GENERATOR BRUSH BRUSH HOLDER WEAR LINE Figure 14-4 Inspect Brushes Page 14-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 235 (30) that has the drain hole in it next to the A2 terminal. Install the remaining three brush cov- ers (29) in the openings in the commutator end cover (23) (Figure 14-3, Page 14-2). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-3...
  • Page 236 3. To separate armature (33) from output end cover (36), remove nut (41), lock washer (40), pulley (39), shaft key (34), spacer (37), and bearing retainer screws (43) (Figure 14-7, Page 14-4). Figure 14-7 Armature and Output End Cover Assembly Page 14-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 237 TOOL inner race Press on of bearing. armature shaft. Use a 1/2 inch WEDGE socket or pipe. ATTACHMENT TOOL BEARING IS SECTIONED FOR CLARITY Figure 14-9 Bearing Removal 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-5...
  • Page 238 • Worn armature bearing or shaft • Dirty or oily commutator POLE PIECE SCREW RETAINING NUT POLE PIECE INSULATOR HOUSING FIELD COIL FIELD COIL TERMINAL Figure 14-10 Field Coil Assembly Page 14-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 239 (–) probe on the armature core. The reading should be no continuity. If the reading is incorrect, replace the armature and the two bearings (Figure 14-12, Page 14-8). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-7...
  • Page 240 Dielectric strength 500 VAC for one minute Armature insulation resistance 0.2M ohms at 500 VDC Starter field coil resistance 0.006-0.01 ohms Generator field coil resistance 4.5-5.5 ohms Page 14-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 241 11. Slide the spacer (37) onto the end of the shaft. Insert the shaft key (34) into the shaft. Install the belt pulley (39) onto the shaft, and install the lock washer (40) and M14 nut (41). Tighten the nut to 28 ft-lb (38.0 N·m) (Figure 14-7, Page 14-4). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-9...
  • Page 242 7. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m) (Figure 1-1, Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. END VIEW Figure 14-13 Starter/Generator Installation Figure 14-14 Belt Tension Gauge Page 14-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 243: Voltage Regulator

    (7) from the (NO) terminal of the kill limit switch and at the battery frame ground (Figure 14-15, Page 14-12). 4. Remove the voltage regulator mounting screw (8) and remove the voltage regulator (9). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-11...

  • Page 244: Key Switch

    2. Remove the center dash panel. 2.1. Remove the plastic cap (1) covering the mounting screw (2) on each side of the center dash panel (3) (Figure 14-16, Page 14-13). Page 14-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 245 2. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m) (Figure 1-1, Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-13...

  • Page 246: Solenoid

    1. Disconnect battery cables as instructed. See WARNING “To avoid unintentionally starting...” in Gen- eral Warning on page 1-2. 2. Remove electrical component box cover. 3. Remove the fuse from the fuse block. Page 14-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 247: Kill Limit Switch

    4. Disconnect the two white/black wires and the black wire from the kill limit switch (12). 5. Remove the kill limit switch (12). TYPICAL 2 PLACES TYPICAL 2 PLACES TO VOLTAGE REGULATOR TYPICAL 2 PLACES Figure 14-17 Accelerator Starter and Kill Limit Switches 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-15...

  • Page 248: Neutral Lockout Limit Switch

    3. Use a wrench and a pair of needle-nosed pliers to remove the two nuts and washers, and remove the limit switch (Figure 14-19, Page 14-17). Page 14-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 249 5. Test drive the vehicle in both forward and reverse to check for proper operation. Figure 14-18 Neutral Lockout, Reverse Buzzer and Figure 14-19 Removal of Limit Switches Starter Solenoid Limit Switches 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-17...

  • Page 250: Reverse Warning Buzzer

    Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED Figure 14-20 Front Reverse Warning Buzzer Page 14-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 251: Reverse Buzzer Limit Switch

    Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. 6. Turn the key switch to the ON position. Shift the Forward/Reverse handle to the REVERSE position. The buzzer should sound. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-19...

  • Page 252: Low Oil Warning Light

    Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. Figure 14-21 Low Oil Warning Light Figure 14-22 Fuel Gauge/Hour Meter Installation Page 14-20 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 253: Fuel Gauge/Hour Meter

    6. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m) (Figure 1-1, Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-21...

  • Page 254: Fuel Level Sending Unit

    (Figure 14-23, Page 14-22). DAMPER RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK KILL CIRCUIT WIRE FEMALE BULLET TERMINAL BLACK WIRE Figure 14-23 RPM Limiter Page 14-22 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 255: Ignition Coil

    9. Disconnect the 18-gauge black wire (12) from the spade terminal on the ignition coil (11) and remove the coil by removing two bolts (10) (Figure 14-26, Page 14-24). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-23...
  • Page 256 (Figure 14-27, Page 14-25). 2. Remove the cap (2) from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire. Page 14-24 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 257 15. Install the stiffener with four hex-head bolts and lock nuts. Tighten the hardware to 23 ft-lb (30.5 N·m). 16. Install the fan shroud with four pan-head bolts (5). Tighten to 50 in-lb (5.7 N·m) (Figure 14-25, Page 14-24). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-25...

  • Page 258: Oil Level Sensor

    3. Remove the wire harness/halogen bulb assembly (4 and 6) from the headlight lens (7). 4. Lift the retaining tabs on the connector (4) and remove halogen bulb assembly (6). Page 14-26 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 259 4. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m) (Figure 1-1, Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-27...

  • Page 260: Voltage Limiter

    5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16.3 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). SET SCREW Figure 14-30 Voltage Limiter Figure 14-31 Light Switch Page 14-28 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 261: Headlight Switch

    5. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m) (Figure 1-1, Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-29...

  • Page 262: Battery

    144 in-lb (16 N·m), coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to prevent future corrosion. See preceding WARNINGS and following CAUTION. Page 14-30 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 263 Figure 14-32 Battery Electrolyte Level 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 MM) above plates or to level indicator. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-31...
  • Page 264 Do not exceed this 45° angle when lifting, carrying or installing battery. The battery acid could cause severe personal injury when accidentally coming in contact with the skin or eyes, and could damage clothing. Page 14-32 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 265 5. Check the state of charge periodically. A battery that is discharged and left in a cold environment can freeze and crack. If the specific gravity drops below 1.220, the battery should be recharged. See follow- ing WARNING. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 14-33...

  • Page 266: Ground Cables

    • Do not jump-start a dead battery using another battery and jumper cables. GROUND CABLES Testing the Ground Cables See Test Procedure 3 – Ground Cables on page 12-12. Page 14-34 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 267: Section 15 - Engine

    Remove all dirt from plug base in the cylinder head before removing plug. Use a 13/16-inch deep well socket wrench or 13/16-inch spark plug wrench to loosen the plug. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 15-1...
  • Page 268 “gauling” and thread seizing for future replacements. 1. Install the spark plug by threading it in until finger tight, then tighten the spark plug to 20 ft-lb (27 N·m). Page 15-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 269: Cylinder Head

    1. Remove yellow jumper wire (11) from cord connector (12) (Figure 15-2, Page 15-4). 2. Remove nuts and clamps at two-ended bolts (1 and 2) (Figure 15-3, Page 15-4). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 15-3...
  • Page 270 Figure 15-2 Oil Level Sensor Wire Figure 15-3 Crankcase Cover TYPICAL SPACERS PROVIDED 4 PLACES 2 PLACES FOR FE290 WASHERS PROVIDED 2 PLACES FOR FE350 TYPICAL 2 PLACES Figure 15-4 Engine Mounting Plate Page 15-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 271: Oil Level Sensor

    • Do not reuse the gasket. Install a new one. • Install and tighten crankcase cover bolts as instructed. Failure to do so could cause the cover to become warped. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 15-5...

  • Page 272: Ignition Coil And Flywheel

    2. Disconnect the ignition coil (1) from its primary lead wire at the connector (2). Remove the two bolts (3) and take out the ignition coil (Figure 15-8, Page 15-7). Page 15-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 273 4. Remove the flywheel with a puller (CCI P/N 1016627). 5. Remove the flywheel key from its groove. 0.012" (0.304 mm) Figure 15-9 Flywheel Nut Figure 15-10 Adjust Ignition Coil Air Gap 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 15-7...

  • Page 274: Flywheel Installation

    • Be careful not to damage the fan blades. Use a strap wrench to hold flywheel. Do not place screwdriver or pry bar between fan blades. 3. Install the fan housing and tighten the screws to 90 in-lbs (10 N·m). Figure 15-11 Fan and Flywheel Installation Page 15-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 275: Engine Installation

    See Figure 1-1, Page 1-3. Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. 12. Adjust the engine RPM setting. See Engine RPM Adjustment on page 16-12. 13. Test-drive vehicle to ensure all systems are functional and correctly adjusted. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 15-9...

  • Page 276: Torque Specifications

    0.027 to 0.031 in. (0.69 to 0.79 mm) Ignition coil air gap (standard) 0.012 in. (0.304 mm) Compression pressure (min.) 156 psi (1076 kPa) Engine RPM 2700 (±30) RPM Page 15-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 277: Section 16 - Fuel System: Gasoline Vehicle

    No adjustment is required for the pilot jet. If the vehicle idles roughly, turn the pilot air screw out until the vehicle idles smoothly. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-1...
  • Page 278 FUEL SYSTEM: GASOLINE VEHICLE Carburetor Figure 16-1 Carburetor Mounting Page 16-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 279: Main Jet Elevation/Size Chart

    4. Mark the body of the carburetor and the carburetor fuel bowl with an indelible ink marker so that, after removal, the bowl can be installed again in the same position (Figure 16-3, Page 16-4). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-3...
  • Page 280 NOTE: Make sure the fuel nozzle (7) does not fall out of the carburetor body after removal of the main jet. This is best accomplished by positioning the carburetor upside down during main jet removal (Figure 16-4, Page 16-4). Figure 16-4 Carburetor Components Page 16-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 281 12.1. Attach the throttle return spring (11) to the carburetor and then to the throttle bracket (4) just before positioning the carburetor and securing it to the engine (Figure 16-1, Page 16-2). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-5...

  • Page 282: Engine Control Linkage

    See following CAUTION. ý CAUTION • Improper adjustment can result in poor vehicle performance and/or damage to the engine components. Page 16-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 283: Accelerator Rod

    • Be sure that approximately an equal number of threads are exposed at each end of the accelerator rod. 6. Install the accelerator rod on the bell crank ball joint on the electrical component box (Figure 16-8, Page 16-8). See following CAUTION and NOTE. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-7...
  • Page 284 13. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m) (Figure 1-1, Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. Page 16-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 285: Governor Cable

    6. While holding the arm and shaft in the fully counterclockwise position, tighten the governor arm lever nut to 36 in-lb (4.0 N·m). 7. Check engine RPM adjustment. See Engine RPM Adjustment on page 16-12. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-9...

  • Page 286: Accelerator Cable

    4. Disconnect the spring (16) from the engine governor arm. 5. Remove the accelerator cable from the accelerator cable bracket (5). Remove the cable assembly from the vehicle. Page 16-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 287: Closed Throttle Or Idle Adjustment

    1. Loosen the carburetor idle screw so that it is not touching the throttle lever (Figure 16-10, Page 16-11). 2. Slowly tighten the idle screw until it lightly touches the throttle lever, then tighten it an additional 3/4 turn. Figure 16-10 Idle Screw 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-11...

  • Page 288: Engine Rpm Adjustment

    Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. 3. XRT 800/810: Place the Forward/Reverse handle in the NEUTRAL position and chock the wheels. 4. XRT 850: Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neu- tral lockout switch in the MAINTENANCE position.

  • Page 289: Air Box Removal

    3. Remove the steering joint assembly (Figure 16-11, Page 16-13). TYPICAL 3 PLACES Figure 16-11 Compound Steering Joint 4. Drill out the two pop rivets (27) securing the intake duct to the floorboard (Figure 16-12, Page 16-15). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-13...

  • Page 290: Intake Duct Installation

    5. Install front left wheel. Tighten the lug nuts to 55 ft-lb (75 N·m) for vehicles with steel wheels. For XRT 850 vehicles with alloy mag wheels, tighten the lug nuts to 65 ft-lb (88 N·m). 6. Install front body. Page 16-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 291 FUEL SYSTEM: GASOLINE VEHICLE Choke and Air Intake System REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 16-12 Air Intake and Choke Assemblies 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-15...

  • Page 292: Air Filter

    7. Install hose (21) and hose clamp (26) (Figure 16-12, Page 16-15). If equipped with screw clamp, tighten to 17 in-lb (1.9 N·m). Make sure clamp ends are located in the 12:00 o’clock position. Page 16-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 293: Fuel Filters

    Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. 6. XRT 800/810: Place the Forward/Reverse handle in the NEUTRAL position and chock the wheels. See following DANGER. 7. XRT 850: Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neu- tral lockout switch in the MAINTENANCE position.
  • Page 294 Vent tube (Carburetor) 11.0 in. (27.9 cm) Vent tube (Gas Tank) 18.0 in. (45.7 cm) Impulse line 16.0 in. (43.2 cm) Total: 46.5 in. (118.1 cm) 29.0 in. (99.1 cm) Page 16-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 295: Fuel Pump

    2. Remove four screws (24) and lock washers (25) from front of the fuel pump (Figure 16-14, Page 16-20). 3. Remove the front cover of the fuel pump while holding the rest of the pump intact. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-19...

  • Page 296: Fuel Pump Cleaning And Inspection

    (Figure 16-14, Page 16-20). 4. Install the gasket (29), clear impulse diaphragm (28), and the paper impulse gasket (27) to the pumping chamber (30). Page 16-20 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 297: Fuel Pump Installation

    6. Turn the fuel shut-off valve on top of the fuel tank to the open position (Figure 16-18, Page 16-25 or Figure 16-19, Page 16-25). 7. XRT 800/810: Place the Forward/Reverse handle in the NEUTRAL position and chock the wheels. See following DANGER.

  • Page 298: Fuel Tank Removal

    1. Remove the cargo bed, rear body and seat back support. See Cargo Bed Removal, Section 4, Page 4-8. 2. XRT 800/810: Place the Forward/Reverse handle in the NEUTRAL position and chock the wheels. 3. XRT 850: Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neu- tral lockout switch in the MAINTENANCE position.

  • Page 299: Fuel Tank Disposal

    4. Install seat back support if removed. See Seat Back Support Bracket Installation, Section 4, Page 4-12. 5. Connect the vent tube (6) to the fuel tank vent (Figure 16-13, Page 16-18). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-23...
  • Page 300 11. Check to be sure the fuel shut-off valve on top of the fuel tank is in the open (ON) position (Figure 16-18, Page 16-25 or Figure 16-19, Page 16-25). 12. XRT 800/810: Place the Forward/Reverse handle in the NEUTRAL position and chock the wheels. See following DANGER.

  • Page 301: Fuel Lines

    NOTE: When selecting valve position, ensure that it NOTE: When selecting valve position, ensure that it is fully opened or fully closed. is fully opened or fully closed. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 16-25...

  • Page 302: Fueling Instructions

    3. The fuel tank is located on passenger side of vehicle. Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only. See preceding CAUTION. 4. Replace fuel cap on tank. Ensure cap is tightened securely. 5. Replace seat bottom. Page 16-26 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 303 7. Tighten the muffler clamp (6) to 40 in-lb (4.5 N·m). NOTE: Removing and installing the governor cable bracket may change the RPM setting. See Engine RPM Adjustment on page 16-12. 8. Connect the spark plug wire. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 17-1...
  • Page 304 See Figure 1-1, Page 1-3. Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion 10. XRT 800/810: Place the Forward/Reverse handle in the NEUTRAL position and chock the wheels. 11. XRT 850: Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neu- tral lockout switch in the MAINTENANCE position.
  • Page 305 Lubricant TOP VIEW should be level with bottom of level indicator hole. SHIFTER SHIFTER F N R DRAIN LEVER PLUG Figure 18-1 Shifter Positions Figure 18-2 Lubricant Level 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-1...
  • Page 306 6. Use 90° internal snap ring pliers (0.090-in. tip) to remove internal retaining ring (1) from axle tube (Figure 18-3, Page 18-3). 7. Carefully pull the axle shaft (2) straight out of the axle tube (Figure 18-3, Page 18-3). Page 18-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 307 (CCI P/N 1012812) on the axle shaft between the wheel mounting flange and the bearing (Figure 18-6, Page 18-4). See also Figure 18-7, Page 18-6. See following CAUTION. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-3...
  • Page 308 (70) is smaller than the outer diameter of the bearing (71), the ring must be in place on the axle before a new bearing and collar are pressed on. Figure 18-6 Differential Gear Case/Axle Tubes Page 18-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 309 4. Install the bearing retaining ring (70) in the axle tube (Figure 18-6, Page 18-4). See also Figure 18-3, Page 18-3. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-5...
  • Page 310 4. Detach all wires, hoses, etc. connecting the powertrain to the vehicle. 4.1. Disconnect the carburetor vent tube from the carburetor (Figure 18-9, Page 18-7). 4.2. Disconnect the air intake hose from the carburetor (Figure 18-10, Page 18-7). Page 18-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 311 Disconnect the cable from the actuator cam and remove it from the box (Figure 18-13, Page 18-8). 4.6. Remove retaining nut and disconnect the engine ground wire from the oil filler tube mounting bracket (Figure 18-14, Page 18-8). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-7...
  • Page 312 4.11. Cut away the wire ties securing the engine kill wire at the lower right front of the engine (below the exhaust header), the wire harness at the governor cable bracket, and the wire harness to the plate beneath the muffler. Page 18-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 313 5.1. Remove bow tie pins (1), brake cable clevis pins (2), and E-clips (3) (Figure 18-19, Page 18-9). 5.2. Remove the cable from the cable support bracket (Figure 18-19, Page 18-9). AS SEEN FROM DRIVER-SIDE OF VEHICLE REAR OF VEHICLE Figure 18-19 Brake Cable 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-9...
  • Page 314 10. Continue raising vehicle until frame or trailer hitch is higher than the top of the unitized transmission (enough to allow transaxle and engine to be rolled under and out of vehicle) (Figure 18-24, Page 18-11). Page 18-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 315 15. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor (Figure 18-28, Page 18-12). See following NOTE. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-11...

  • Page 316: Drive Clutch

    Do not disconnect cables. RETAINING BOLT Figure 18-30 Driven Clutch Figure 18-31 Governor Arm 19. Remove screws (1) securing the governor cable bracket to transaxle (Figure 18-32, Page 18-13). Page 18-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 317 WOODEN TRANSAXLE BLOCKS MOUNTING NUT (TYPICAL 2 PLACES) Figure 18-34 Transaxle Mounting Figure 18-35 Gear Case and Cable Bracket UNITIZED TRANSAXLE INSTALLATION See General Warning on page 1-1. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-13...
  • Page 318 Tighten the mounting bolt to 14 ft-lb (19.0 N·m) (Figure 18-38, Page 18-15). 11. Install the drive belt. See Drive Belt Installation, Section 20, Page 20-3. Page 18-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 319 15. Adjust the vehicle height with the floor jack to position the leaf springs for mounting in the shackles. Install the mounting bolts, and lock nuts (Figure 18-41, Page 18-15). Figure 18-40 Leaf Springs Figure 18-41 Leaf Springs and Shackles 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-15...
  • Page 320 30 in-lb (3.4 N·m) (Figure 18-45, Page 18-16). GROUND WIRE YELLOW WIRE STARTER GENERATOR WHITE WIRE YELLOW OIL SENDING UNIT JUMPER WIRE Figure 18-44 Oil Level Sensor Jumper wire Figure 18-45 Starter/Generator Page 18-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 321 26. Remove the 1/4-inch bolt from the fuel line and connect the fuel line to the carburetor and secure with a hose clamp (Figure 18-49, Page 18-17). TOP VIEW RETAINING NUTS Figure 18-48 Connect Cable to Cam Figure 18-49 Connect Fuel Line 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-17...
  • Page 322 31. Fill transaxle with 27 oz. (0.8 liter) 80-90 Wt. API class GL-3 or 80-90 WT. AGMA class EP gear lube. Install and tighten the level indicator hole plug to 21 ft-lb (28.5 N·m). 32. Ensure that all wiring is secured properly. See following WARNING. Page 18-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 323 3. Secure the cable with a retaining nut (5) on each side of the shifter cable support bracket at the Forward/ Reverse assembly. Tighten nuts to 43 in-lb (4.9 N·m). 4. Install the ball joint socket (10) on the shifter lever ball stud (11) on the transaxle. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-19...
  • Page 324 • Be sure threads of cable are engaged in ball joint socket at least 1/4 inch (6.35 mm). If ball joint socket comes loose from the cable, the Forward/Reverse shifter will not operate properly. Page 18-20 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 325 22 ft-lb (29.8 N·m); retighten nuts at the Forward/Reverse assembly to 43 in-lb (4.9 N·m). TOP VIEW SHIFTER SHIFTER F N R LEVER Figure 18-55 Forward/Reverse Positions 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 18-21...
  • Page 327 C l u b C a r Figure 19-1 Shifter Positions (Top View) Figure 19-2 Lubricant Level (should be level with bot- tom of hole) and Drain Plug 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-1...
  • Page 328 6. Use 90° internal snap ring pliers (0.090-in. tip) to remove internal retaining ring (1) from axle tube (Figure 19-3, Page 19-3). 7. Carefully pull the axle shaft (2) straight out of the axle tube (Figure 19-3, Page 19-3). Page 19-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 329 (CCI P/N 1012812) on the axle shaft between the wheel mounting flange and the bearing (Figure 19-6, Page 19-4). See also Figure 19-7, Page 19-6. See following CAUTION. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-3...
  • Page 330 (70) is smaller than the outer diameter of the bearing (71), the ring must be in place on the axle before a new bearing and collar are pressed on. Figure 19-6 Differential Gear Case and Axle Tubes Page 19-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 331 4. Install the bearing retaining ring (70) in the axle tube (Figure 19-6, Page 19-4). See also Figure 19-3, Page 19-3. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-5...
  • Page 332 4. Detach all wires, hoses, etc. connecting the powertrain to the vehicle. 4.1. Disconnect the carburetor vent tube from the carburetor (Figure 19-9, Page 19-7). 4.2. Disconnect the air intake hose from the carburetor (Figure 19-10, Page 19-7). Page 19-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 333 Disconnect the cable from the actuator cam and remove it from the box (Figure 19-13, Page 19-8). 4.6. Remove retaining nut and disconnect the engine ground wire from the oil filler tube mounting bracket (Figure 19-14, Page 19-8). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-7...
  • Page 334 4.11. Cut away the wire ties securing the engine kill wire at the lower right front of the engine (below the exhaust header), the wire harness at the governor cable bracket, and the wire harness to the plate beneath the muffler. Page 19-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 335 5.1. Remove bow tie pins (1), brake cable clevis pins (2), and E-clips (3) (Figure 19-19, Page 19-9). 5.2. Remove the cable from the cable support bracket (Figure 19-19, Page 19-9). Figure 19-19 Brake Cable (Rear View) 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-9...
  • Page 336 10. Continue raising vehicle until frame or trailer hitch is higher than the top of the unitized transmission (enough to allow transaxle and engine to be rolled under and out of vehicle) (Figure 19-24, Page 19-11). Page 19-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 337 14. Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle (Figure 19-27, Page 19-11). Figure 19-26 Snubber and Bracket Figure 19-27 Remove Powertrain 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-11...
  • Page 338 18. Loosen, but do not remove, the governor arm retaining bolt (1) (Figure 19-31, Page 19-12). Remove the governor arm from the shaft. Do not disconnect cables. Figure 19-30 Driven Clutch Figure 19-31 Governor Arm Page 19-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 339 (Figure 19-34, Page 19-13). 21.2. Remove two middle transaxle mounting nuts from the engine block studs. 22. Remove leaf springs, wheels and brake assemblies from the transaxle. Figure 19-34 Transaxle Mounting 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-13...
  • Page 340 Tighten the mounting bolt to 14 ft-lb (19.0 N·m) (Figure 19-37, Page 19-15). 11. Install the drive belt. See Drive Belt Installation, Section 20, Page 20-3. Page 19-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 341 15. Adjust the vehicle height with the floor jack to position the leaf springs for mounting in the shackles. Install the mounting bolts, and lock nuts (Figure 19-40, Page 19-15). Figure 19-39 Leaf Springs Figure 19-40 Leaf Springs and Shackles 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-15...
  • Page 342 30 in-lb (3.4 N·m) (Figure 19-44, Page 19-16). Figure 19-43 Oil Level Sensor Jumper wire Figure 19-44 Starter/Generator 1. Yellow Wire 2. White Wire 3. Ground Wire at A2 Terminal Page 19-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 343 26. Connect the impulse line to the fuel pump and secure it with the hose clamp (Figure 19-49, Page 19-18). 27. Connect air intake hose to carburetor and secure hose clamp (Figure 19-50, Page 19-18). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-17...
  • Page 344 • If wires are removed or replaced make sure wiring and wiring harness is properly routed and secured to vehicle frame. Failure to properly route and secure wiring could result in vehicle malfunction, property damage or personal injury. Page 19-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 345 7. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m) (Figure 1-1, Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro- sion. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-19...
  • Page 346 UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE Forward/Reverse Shifter Cable Figure 19-52 Forward/Reverse Shifter Cable Page 19-20 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 347 NEUTRAL position (Figure 19-53, Page 19-21). Tighten nuts at the transaxle to 22 ft-lb (29.8 N·m). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 19-21...

  • Page 349: Troubleshooting

    RPM before the drive belt reaches the top of the driven clutch, there is a torque con- verter problem. If the torque converter is not operating properly: 1. Check the governor and throttle settings. See Governor Cable on page 16-9. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 20-1...

  • Page 350: Drive Belt

    This will keep the vehicle’s maximum ground speed correct. See Section 2 – Vehicle Specifications. DRIVE BELT REMOVAL 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning on page 1-2. Page 20-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 351: Drive Belt Installation

    3. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m). See Figure 1-1, Page 1-3. Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. 4. Connect the spark plug wire to the plug. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 20-3...

  • Page 352: Drive Clutch Removal

    THREE BOSSES IN GRAY DRIVE CLUTCH PULLER (CCI P/N 1014496) Figure 20-3 Loosen Retaining Bolt Figure 20-4 Drive Clutch Removal Page 20-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 353: Drive Clutch Cleaning And Inspection

    2. Inspect the belt contact surfaces of the clutch sheaves for wear. If any area of a sheave contact surface has wear of 0.060 inch (1.52 mm) or more, the clutch should be replaced. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 20-5...
  • Page 354 TORQUE CONVERTER: GASOLINE VEHICLE Drive Clutch TYPICAL 3 PLACES Figure 20-5 Drive Clutch Assembly Page 20-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 355: Drive Clutch Disassembly

    4. Remove the drive buttons (Figure 20-8, Page 20-8). 4.1. Remove the screws, flat washers, drive button take-up springs, and drive buttons as shown (Figure 20-8, Page 20-8). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 20-7...
  • Page 356 Retain all parts. SECONDARY WEIGHT WAVE WASHER PRIMARY WEIGHT SMALL PIN Figure 20-10 Install Pin and Washer Figure 20-11 Install Secondary Weight Page 20-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 357: Inspection Of Drive Clutch Parts

    5. Inspect the primary weights (2) and the hub casting for wear. If the primary weights show signs they are touching the casting, the tips of the weights have worn beyond specification and they must be replaced. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 20-9...

  • Page 358: Drive Clutch Assembly

    (Figure 20-14, Page 20-10). WHITE WASHER Figure 20-14 Install White Washers Page 20-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 359 18. Replace the three plastic plugs (22) into the hole protectors (Figure 20-5, Page 20-6). DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED Figure 20-15 Correct Orientation of Drive Button Take-up Springs 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 20-11...

  • Page 360: Drive Clutch Installation

    Page 20-14). 3. Remove the spring (5) (Figure 20-18, Page 20-14). 4. Retain the key (3). 5. Slide the moveable face (7) off the fixed face shaft (8). Page 20-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 361: Driven Clutch Inspection

    3. Place the end of the spring (5) into the hole in the moveable face assembly. 4. Install the key (3) into the keyway of the fixed face assembly (8) shaft. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 20-13...
  • Page 362 TORQUE CONVERTER: GASOLINE VEHICLE Driven Clutch TYPICAL 3 PLACES Figure 20-18 Driven Clutch Assembly Page 20-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 363 (2), and the hub guide (4). NOTE: It is very important that the bolt, washers, and thrust bearing assembly be assembled in the order described and shown. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 20-15...

  • Page 364: Driven Clutch Installation

    4. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m). See Figure 1-1, Page 1-3. Coat terminals with Battery Terminal Protector Spray (CCI P/N 14305) to min- imize corrosion. Page 20-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 365: Section 21 - Electrical System And Testing: Electric Vehicle

    • Regenerative Braking: When motor braking is activated, the vehicle motor acts as a generator, slow- ing the vehicle as it creates energy that is used to charge the batteries. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-1...

  • Page 366: Wiring Diagram

    : TO ACCELERATOR LIMIT SWITCH (PIN 4) GRN/WHT : TO S. O. C (PIN 5) LT BLUE : TO OBC "CONTROLLER LOCKOUT" Figure 21-1 Wiring Diagram for Electric Vehicles Page 21-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 367: Xrt 800, 810 And 850 Maintenance And Service Manual

    COMPUTER 18_LHT_BLU(W10) 6_BLK(W55) 3 PIN 6_GRN(W64) 6_GRN(W64) CONNECTOR 18_BLK_WHT(W09) 18_BLK_WHT(W09) 18_LT_GREEN(W02) 18_LT_GREEN(W02) 18_RED(W19) 18_RED(W19) 18_GRN_WHT(W30) 18_GRN_WHT(W30) 10_BLK(W49) 10_BLK(W49) 6_BLK(W55) 6_BLK(W55) NSOR Figure 21-2 Wiring Diagram for Electric Vehicles 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-3...

  • Page 368: Troubleshooting

    In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1, the techni- cian should proceed to Troubleshooting Guide 2. If a diagnostic handset is unavailable, the technician should proceed to Troubleshooting Guide 2. Page 21-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 369: Troubleshooting Guide 1

    Test Procedure 15 – Forward/Reverse Failed Forward/Reverse rocker switch Rocker Switch on page 21-30 Troubleshooting Guide continued on next page... 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-5...
  • Page 370 Solenoid coil has failed in an open Replace solenoid. See Solenoid condition Removal on page 23-10. Diagnostic Menu – MAIN DROPOUT fault code Troubleshooting Guide continued on next page... Page 21-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 371 (Model EJ4-4001) Replace the speed controller. See Speed Failure of the FET’s that control armature Controller Removal, Section 23, current Page 23-13. Troubleshooting Guide continued on next page... 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-7...

  • Page 372: Troubleshooting Guide 2

    Test Procedure 6 – Tow/Run Switch on Failed Tow/Run switch page 21-15 Replace speed controller. See Speed Speed controller failure Controller Removal, Section 23, Page 23-13. Troubleshooting Guide continued on next page... Page 21-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 373 Battery charger connections – loose wires Check wire connections and tighten if at receptacle or batteries necessary. Refer to the appropriate battery charger Battery charger maintenance and service manual 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-9...
  • Page 374 The battery voltage can be displayed with the Diagnostic Handset. If a handset is not available, proceed to Batteries / Voltage Check without the Diagnostic Handset on page 21-11. Page 21-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 375 If reading is 48-50 volts, check the wire terminal connectors inside six-pin con- nector at OBC six-pin connector. Make sure pins are properly aligned inside housing. Make sure wire col- ors match and are connected to the correct terminals. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-11...
  • Page 376 The accelerator position, which is proportional to the MCOR voltage, can be displayed with the diagnostic handset. If a handset is not available, proceed to MCOR Voltage Test without the Diagnostic Handset on page 21-13. Page 21-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 377 As the pedal is pressed, the reading should increase until it reaches 4.65 volts when the pedal is fully pressed. 7. If reading does not increase as the pedal is pressed, replace the MCOR. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-13...
  • Page 378 4.3. Check continuity on A1 and A2 motor terminal posts and continuity of the F1 and F2 motor terminal posts. Also, check continuity of all motor wires. See Section 26 – Motor (Model 5BC59JBS6390) or Section 27 – Motor (Model EJ4-4001). Page 21-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 379 5. A reading of 32 volts or less will not activate discharge machine. If the voltage of the batteries is below 32 volts, the batteries are deeply discharged or have failed. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-15...
  • Page 380 6.3. Check the continuity of the key switch wires and the MCOR limit switch wires. 7. If the problem was not found, proceed to the following procedure, Key Switch and MCOR Limit Switch Circuit Test without the Diagnostic Handset on page 21-17. Page 21-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 381 5.4.5. If the reading is zero volts, test the continuity of the MCOR limit switch and the green wire. If the limit switch does not pass the continuity test, replace the MCOR. See MCOR Removal on page 23-8. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-17...
  • Page 382 Test Procedure 13 – Motor Speed Sensor on page 21-29 Pin 15 – Red (18-gauge) Pin 16 – Blue (18-gauge) Test Procedure 9E – Pins 8 and 16 on page 21-23 Page 21-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 383 10. If any other reading is observed, check the continuity of the wires in the wire harness. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20k ohm SETTING (READING WITH SPEED CONTROLLER PEDAL UNDEPRESSED) Figure 21-5 Pins 1, 2, and 3 Test 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-19...
  • Page 384 10. The multimeter should indicate zero volts DC while the charger is connected to the vehicle.\ 11. While observing the multimeter, disconnect the DC plug from the vehicle charger receptacle. Page 21-20 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 385 Tighten battery terminals to 110 in-lb (12.4 N·m). 6. Place the Tow/Run switch in the RUN position, key switch in the ON position, and Forward/Reverse switch in the FORWARD position. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-21...
  • Page 386 • Reverse buzzer for proper operation. See Test Procedure 16 – Reverse Buzzer on page 21-31. • Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 21-15. Page 21-22 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 387 9. Insert the red (+) probe of the multimeter into pin 16 (blue wire) of the 16-pin connector. Leave the black (–) probe (alligator clip) connected to the B– terminal of the speed controller. See previous CAUTION. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-23...
  • Page 388 See WARNING “Lift only one end...” in General Warning on page 1-1. Page 21-24 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 389 • Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 21-15. SPEED CONTROLLER WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV SETTING (READING WITH TOW/RUN SWITCH IN RUN) Figure 21-10 Pin 9 Test 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-25...
  • Page 390 • Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 21-15. • Key switch for proper operation. See Test Procedure 8 – Key Switch and MCOR Limit Switch Cir- cuit on page 21-16. Page 21-26 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 391 • Key switch for proper operation. See Test Procedure 8 – Key Switch and MCOR Limit Switch Cir- cuit on page 21-16. • Solenoid for proper operation. See Test Procedure 14 – Solenoid Continuity on page 21-30. SPEED CONTROLLER Figure 21-12 Pin 12 Test 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-27...
  • Page 392 10-gauge wire. The reading should be 48-50 volts (full battery voltage). 2. If the reading is zero volts, check the continuity of the 10-gauge red wire from the positive post of battery no. 1 to the receptacle socket. Page 21-28 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 393 5.3. If reading is below 3.50 volts, check the continuity of the wires and plug and replace the speed con- troller if necessary. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-29...
  • Page 394 3.1. Access the Test menu and select FORWARD INPUT by using the SCROLL DISPLAY buttons. The handset should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or REVERSE position. Page 21-30 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 395 6. Set a multimeter to 200 volts DC. Place the black (–) probe on battery no. 4 negative post and place the red (+) probe on the red wire terminal end that was disconnected from the reverse buzzer. The reading should be approximately 48 volts (full battery voltage). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-31...
  • Page 396 3. Disconnect the six-pin connector at the OBC. 4. Remove the wedge lock from the six-pin connector housing that is connected to the vehicle wire harness. Remove the brown/white wire from the connector plug. Page 21-32 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 397: Communication Display Module (Cdm)

    • F3 – Total accumulated energy units removed since initial vehicle start-up: This information is most useful in making sure that all vehicles in a fleet receive equal usage over long periods of time. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-33...

  • Page 398: Using The Cdm To Retrieve Data From The Onboard Computer

    • To view F4, press and hold the button on the CDM until “Func 4” appears in the display window. Release the button. The value for F4 will be displayed. NOTE: The values of all four functions can be recalled by pressing and releasing the CDM button. Page 21-34 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 399: Cdm Troubleshooting Guide

    WARNING on connecting charger page 11-1. DC plug Recharge Batteries After a short time, replace the lead and restart the OBC. Figure 21-14 Flow Chart – CDM Troubleshooting Guide 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 21-35...
  • Page 401 5. Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack. Figure 22-1 IQDM Jack On F&R Switch Housing Figure 22-2 IQDM Jack Under Instrument Panel 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 22-1...

  • Page 402: Menu Navigation

    22-6. Each fault is listed at the bottom of the monitor menu. The right hand column lists the number of occurrances for each fault. The number of occurrances is reset to zero each time the fault history is cleared. Page 22-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 403 The programmer setup menu allows the user to set the LCD contrast, display the fault history of the program- mer as well as various other information pertaining to the handset such as model number, serial number, OEM information, etc. See Programmer Setup on page 22-14. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 22-3...

  • Page 404: Monitor Menu

    Forward/Reverse switch in the NEUTRAL position, and the vehicle at rest, the handset should should indicate that speed pulses are off. When the vehicle is gently pushed a short distance, the handset should indicate that speed pulses are on. Page 22-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 405 This menu is reserved for possible future use and has no application at this time. 20+ Speed This menu is reserved for possible future use and has no application at this time. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 22-5...

  • Page 406: Faults Menu

    • E. Gradually reduce the armature current limit • F. Quickly reduce the armature current until speed sensor pulses occur • G. Reduce field current and beep reverse buzzer at a fast rate Page 22-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 407 UNDERVOLTAGE THERMAL CUTBACK MOTOR STALL MAIN DROPOUT A, C OPEN ARMATURE MAX PASSWORD TRIES (no action taken) INCORRECT PASSWORD (no action taken) HIGH SPEED WALKAWAY KEY SWITCH SRO 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 22-7...
  • Page 408 The armature drive FET’s (field effect transistors) regulate the armature current. If the speed controller detects a failure of the armature drive FET’s or circuitry, a hardware failsafe fault is detected. Page 22-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 409 If the key switch is turned off while going downhill at high speed, a High Speed WalkAway fault is detected. Overvoltage If the speed controller detects that the battery voltage is too high (68.4 to 75.6 volts DC), the overvoltage fault is detected. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 22-9...
  • Page 410 22-15. All of the occurrance numbers located in the lower section of the monitor menu will be reset to zero each time the fault history is cleared except for the High Speed WalkAway occurrance numbers. Page 22-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 411: Functions Menu

    IQ System vehicle or group of IQ System vehicles. See Speed Controller Cloning – Transferring Settings from the Handset to the Vehicle on page 22-12. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 22-11...

  • Page 412: Write Settings To Controller

    4.4. Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack (Figure 22-4, Page 22-12 or Figure 22-5, Page 22-12). 5. Scroll to the functions menu and select. Page 22-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 413: Reset All Settings

    This function is similar to the “undo” command on a PC and will work correctly only when the handset has not been unplugged and power to the speed controller has not been interrupted. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 22-13...

  • Page 414: Model Number

    FAULTS This menu selection displays faults that have been detected within the handset. This faults menu does not pertain to any faults detected in the speed controller. Page 22-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 415 This menu selection displays information pertaining to the handset. The information provided in this menu selection includes model number, serial number, the date the handset was manufactured, the handset soft- ware version, etc. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 22-15...

  • Page 416: Iqdm And Iqdm-P Handset Troubleshooting

    Intermittent handset cord adaptor failure on page 22-18 Test Procedure 3 – IQDM Jacks on Loose vehicle wire harness connections page 22-18 Troubleshooting Guide continued on next page... Page 22-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 417 4. Repeat the procedure three more times, each time with the red (+) probe inserted into a different terminal on the end of the cord with the square plug. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 22-17...
  • Page 418 3.3. If no problem is found, connect the four-pin connectors and install the F&R switch housing. 3.4. Install the three self-tapping screws that hold the F&R rocker switch housing (2) to the body. Tighten IQDM Jack. Page 22-18 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 419 2. Place the Tow/Run switch in the TOW position, disconnect the batteries, negative (–) cable first, and wait 90 seconds for the speed controller capacitors to discharge. See General Warning on page 1-1. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 22-19...
  • Page 420 3. Check the IQDM jack on the speed controller. 3.1. Remove the two screws securing the rear body access panel and remove the access panel. 3.2. Remove the two screws (5) securing the controller cover (1) to the component mounting plate (Figure 22-10, Page 22-20).

  • Page 421: Key Switch – 800 And

    3. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 23-1...
  • Page 422 3.1. Remove the plastic cap (1) covering the mounting screw (2) on each side of the center dash panel (3) (Figure 23-3, Page 23-3). 3.2. Loosen, but do not remove, the screw (2) on each side of the center dash panel (3). Page 23-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 423 (8). Hold the key switch and remove the switch retaining nut (6) from the out- side of the dash panel (Figure 23-4, Page 23-4). Figure 23-3 Dash Removal – 850 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 23-3...

  • Page 424: Forward/Reverse Switch – 800 And

    See Test Procedure 15, Section 21, Page 21-30. Forward/Reverse Switch Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning on page 1-2. Page 23-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 425 • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Figure 23-5 Tow/Run Switch and Forward/Reverse Rocker Switch – 800 and 810 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 23-5...
  • Page 426 REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Page 23-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 427: Tow/Run Switch

    2. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 23-7...

  • Page 428: Motor Controller Output Regulator (Mcor)

    6. Push the drive bar (4) into the hole in the I-beam to disengage it from the accelerator pivot rod (5). Figure 23-7 Motor Controller Output Regulator (MCOR) Mounting Page 23-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 429: Reverse Buzzer

    2. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 23-9...
  • Page 430 Tighten nuts to 77 in-lb (8.7 N·m). See Wiring Diagram on page 21-2. 4. Install the blue/white and light blue wires onto the small terminals of the solenoid (Figure 23-8, Page 23-10). 5. Install rear body access panel. Page 23-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 431: Onboard Computer (Obc)

    10-gauge wire (6) from the accessory mounting terminal (Figure 23-10, Page 23-11). 7. Disconnect the gray wire fuse holder at the charger receptacle. 8. Disconnect the black 10-gauge wire (8) at the charger receptacle. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 23-11...
  • Page 432 13. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. Page 23-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 433: Solid State Speed Controller

    2. Using the wiring diagram, install the multi-pin connectors and all wires as illustrated. See Wiring Dia- gram on page 21-2. Tighten bolts (1) to 9 ft-lb (12.2 N·m) (Figure 23-13, Page 23-14). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 23-13...
  • Page 434 REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Page 23-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 435: Charger Receptacle

    7. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 23-15...
  • Page 436 2. Place the two 10-gauge black wires in their original positions on the fuse link mounting posts. Tighten to 23 in-lb (2.6 N·m). 3. Install nuts (2) on fuse link mounting posts and tighten to 23 in-lb (2.6 N·m) (Figure 23-14, Page 23-16). Page 23-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 437: Battery Warning Light

    2. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 23-17...

  • Page 439: Section 24 – Batteries: Electric Vehicles

    “starting, lighting and ignition” (SLI) battery. They should never be substituted for one another. For gasoline vehicles, see Battery on page 13-30 or Battery on page 14-30. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 24-1...

  • Page 440: Battery Troubleshooting Chart

    If discharge time is 60 minutes or If discharge time is less than 60 minutes, more, problem is not with the batteries. replace all batteries below 6.7 volts. Figure 24-1 Battery Troubleshooting Chart Page 24-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 441: Battery Testing

    3. Squeeze the rubber bulb of the hydrometer and insert into the cell. Slowly release the bulb, drawing elec- trolyte up into the glass tube of the hydrometer. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 24-3...
  • Page 442 Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table: SPECIFIC GRAVITY APPROXIMATE (TEMPERATURE STATE OF CHARGE CORRECTED) 1.250-1.280 100% 1.220-1.240 1.190-1.210 1.160-1.180 Page 24-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 443 2. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (Figure 24-3, Page 24-5). RED PROBE TO BATTERY NO. 1 (+) FRONT OF VEHICLE BLACK PROBE TO BATTERY NO. 4 (–) Figure 24-3 Battery Discharge Test 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 24-5...
  • Page 444 57 Minutes 72 Minutes (21-23 °C) (49-54 °C) 75-79 °F 130-150 °F 60 Minutes 74 Minutes (24-26 °C) (54-66 °C) 80-84 °F 62 Minutes ***** ***** (27-29 °C) Page 24-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 445: Battery Troubleshooting Examples

    7.0 amps after a full charge. After confirming there were no problems with the electrical system, charger or brakes, the on-charge voltage was recorded as follows: BATTERY NO. On-Charge Voltage 15.72 V 14.66* V 15.80 V 15.85 V 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 24-7...

  • Page 446: Battery Replacement

    Spray (CCI P/N 1014305) to minimize future corrosion. 10. Give the batteries a full charge prior to operation. This ensures all the batteries are fully charged and the cells are equalized prior to use. Page 24-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 447: Battery Care

    4. Batteries should be properly charged every day they are used. Check the batteries periodically to see that they are in a full state of charge. See Battery Charger on page 24-12. 5. Keep hold-downs tight. See Vibration Damage on page 24-11. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 24-9...

  • Page 448: Electrolyte Level

    For best results, use a battery watering gun to add water to batteries. Check the electrolyte level more frequently in hot weather or when batteries are old. Page 24-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 449 This may cause leaks which would dry out a cell or cause internal short circuits. See Battery Replacement on page 24-8. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 24-11...

  • Page 450: Battery Charger

    While the charger is plugged in, the vehicle’s control circuit is locked out, preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle. Page 24-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 451: Plug And Receptacle

    See following NOTE. NOTE: If the warning tag has been damaged or removed from the DC cord, have it replaced immediately. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 24-13...

  • Page 452: Charger Shuts Off After 16 Hours

    Placing the bat- teries on charge after each use reduces the depth of discharge and prolongs battery life. Page 24-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 453: Early Excessive Discharging

    2. Batteries that are in vehicles for winter storage should be left disconnected in the vehicles if the batteries are not going to be connected to a charger. 3. Fully charge the batteries prior to storage. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 24-15...

  • Page 454: Charging A Battery Pack That Has Low Voltage

    ON, during off-season storage. The storage charge feature will automatically charge the batteries as needed throughout the storage period. CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See the appropriate battery charger maintenance and service manual. Page 24-16 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 455 SECTION 25 – BATTERY CHARGER: ELECTRIC VEHICLE Refer to the appropriate Battery Charger Maintenance and Service Manual. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 25-1...
  • Page 457 A2 terminal, a grounded wire in the brush area, or a grounded armature/commutator. An incor- rect reading for the F1 or F2 terminal indicates a possible grounded F1 or F2 terminal or field coil. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 26-1...
  • Page 458 Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor. When not performing a test or service procedure that requires movement of the wheels, lock the brakes. Page 26-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 459 Fingers may get pinched when motor disengages. 10. Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 26-3...
  • Page 460 8. To remove brush springs (14) from the rigging, lift the spring extensions out and over the brush mounts and then slide the springs off their mounting tabs (Figure 26-5, Page 26-4). MATCH MARKS ARMATURE Figure 26-4 Motor Disassembly Figure 26-5 Brush Spring Removal Page 26-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 461 1. With a multimeter set to 200 ohms, place one probe on the commutator and the other on the armature core. The multimeter should indicate no continuity (Figure 26-6, Page 26-6). If the reading is incorrect, replace the armature. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 26-5...

  • Page 462: Field Windings Inspection

    See Motor Assembly on page 26-10. When replacing brushes, replace all four brushes. Never replace only two. Install the brushes in the same rigging 180° apart from each other. Page 26-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 463 An arbor with an outside diameter of less than 5/8 inch (16 mm) should be used to press the bear- ing onto the armature. 2. Install the speed sensor magnet. See Speed Sensor Magnet Installation on page 26-9. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 26-7...
  • Page 464 MOTOR (MODEL 5BC59JBS6390) Motor TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 26-9 Motor – Model 5BC59JBS6390 Page 26-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 465 0.016 inch (0.406 0.031 in. (0.8 mm) mm), it should be undercut to 8-16 microinches Machined face of commutator (203.2-406.4 nm) Field coil resistance 1.61 ohms (shunt-wound, 3.20 hp) 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 26-9...
  • Page 466 (Figure 26-5, Page 26-4). PRESS WEDGE ATTACHMENT TOOL (CCI P/N 1012812) BEARING PULLER (CCI P/N 1012811) Figure 26-10 Bearing Removal Page 26-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 467 Make sure the bearing is properly seated in the end shield when assembling the motor. END SHIELD MOUNTING SCREW RIGGING TERMINAL BEARING RETAINER POST MOUNTING Figure 26-11 Brush Installation Figure 26-12 End Shield Installation 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 26-11...
  • Page 468 NOTE: The motor coupling and the new molded bumper must be free of grease and debris. 3.2. Ensure that the installed bumper is seated at the bottom of the coupling. Page 26-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 469 5. If using a chain hoist, lower the vehicle and guide the leaf springs into the shackles. If using a floor jack, raise the transaxle until the leaf springs can be guided into the shackles. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 26-13...
  • Page 470 • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. VIEWED FROM DRIVER SIDE Figure 26-17 Motor Installation Figure 26-18 Motor Mount Page 26-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 471: Motor Speed Sensor

    3. Place the Tow/Run switch in the TOW position and connect the batteries, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. Figure 26-19 Motor Speed Sensor 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 26-15...
  • Page 473 A2 terminal, a grounded wire in the brush area, or a grounded armature/commutator. An incor- rect reading for the S1 or S2 terminal indicates a possible grounded S1 or S2 terminal or field coil. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 27-1...
  • Page 474 Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor. When not performing a test or service procedure that requires movement of the wheels, lock the brakes. Page 27-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 475 Fingers may get pinched when motor disengages. 10. Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 27-3...
  • Page 476 5.1. With the end cap bolts loose (about 1/4 inch between the end cap and the head of the bolt), place a socket on the head of the bolt. See following CAUTION. Page 27-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 477 14.1. Remove the retaining ring that secures the bearing in the end cap (Figure 27-11, Page 27-6). 14.2. Use an arbor press to remove the bearing from the end cap. 15. Inspect the bearing for wear and damage. See Bearing Inspection on page 27-9. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 27-5...

  • Page 478: Armature Inspection And Testing

    2. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 27-4. Visual Inspection • Burned, charred or cracked insulation • Improperly cured varnish • Thrown solder • Flared armature windings • Damaged armature core laminations Page 27-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 479: Motor Frame And Field Windings Inspection

    ARMATURE CORE COMMUTATOR Figure 27-12 Armature Test MOTOR FRAME AND FIELD WINDINGS INSPECTION 1. Remove the motor from the vehicle. See Motor Removal, Section 27, Page 27-2. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 27-7...

  • Page 480: Motor Brush, Spring, And Terminal Insulator Inspection

    4. Use dial calipers or a micrometer to measure the brush length. The minimum-allowable brush length is 0.62 inches (16 mm). Replace the set of brushes as required. See preceding NOTE. Page 27-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 481 Figure 27-14 Bearing Inspection Speed Sensor Magnet Inspection Inspect the speed sensor magnet (24) for rust, wear, and cracks (Figure 27-15, Page 27-10). Replace the magnet if necessary. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 27-9...
  • Page 482 Motor Component Testing and Inspection TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 27-15 Motor – Model EJ4-4001 Page 27-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 483 (Figure 27-15, Page 27-10). 2.4. Secure the brush rigging to the end cap with two screws. Tighten the screws to 25 in-lb (2.8 N·m) (Figure 27-10, Page 27-6). 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 27-11...
  • Page 484 7. Install the speed sensor (10) with screws (25). Tighten to 25 in-lb (2.8 N·m). 8. Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem. Page 27-12 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 485 NOTE: The motor coupling and the new molded bumper must be free of grease and debris. 3.2. Ensure that the installed bumper is seated at the bottom of the coupling. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 27-13...
  • Page 486 5. If using a chain hoist, lower the vehicle and guide the leaf springs into the shackles. If using a floor jack, raise the transaxle until the leaf springs can be guided into the shackles. Page 27-14 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 487 Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. VIEWED FROM DRIVER SIDE Figure 27-24 Motor Mount 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 27-15...

  • Page 489: Transaxle Identification

    Place jack stands under the axle tubes to support the vehicle. See WARNING “Lift only one end...” in General Warning on page 1-1. 3. Remove the rear wheel and brake drum. See Brake Shoe Removal on page 6-1. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 28-1...
  • Page 490 (1 or 2) must be replaced. Figure 28-1 Axle Tube Figure 28-2 Axle Seal and Adapter Ring Removal Figure 28-3 Axle Seal and Adapter Ring Figure 28-4 Axle Seal and Adapter Ring Installation Page 28-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 491 TRANSAXLE (TYPE G): ELECTRIC VEHICLE Axle Bearing and Shaft TYPICAL 6 PLACES Figure 28-5 Axles And Tubes 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 28-3...
  • Page 492 Do not remove the axle bearing (5) from a Type G transaxle. If bearing is worn or damaged, the entire axle assembly (1 or 2) must be replaced (Figure 28-5, Page 28-3). Page 28-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 493: Transaxle Removal

    Figure 28-6 Vehicle Supported on Jack Stands Figure 28-7 Disconnect Brakes Remove bolts, then rotate shackles up and away from spring. Figure 28-8 Disconnect Shocks Figure 28-9 Shackles 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 28-5...
  • Page 494 NOTE: Recycle or dispose of used oil or lubricant in accordance with local, state, and federal regulations. 15. Remove the brake assemblies if required. See Brake Cluster Removal on page 6-8.. Page 28-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 495: Transaxle Disassembly, Inspection, And Assembly

    (Figure 28-5, Page 28-3). See also Figure 28-13, Page 28-8. 7. Press the bearing (18) off the intermediate gear assembly (Figure 28-5, Page 28-3). See also Figure 28-13, Page 28-8. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 28-7...
  • Page 496 9. Inspect parts for wear or damage. Any worn or damaged parts should be replaced. See following NOTE. NOTE: Damaged or worn gears should be replaced as sets. Page 28-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 497: Transaxle Assembly

    8.4. Install axle tube (14 and 35) with bolts (8) (Figure 28-5, Page 28-3). Tighten the bolts to 37 ft-lb (50.2 N·m). 9. Install the brake assemblies as instructed. See Brake Cluster Installation on page 6-9. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 28-9...

  • Page 498: Transaxle Installation

    6. Connect the four motor wires. Tighten the retaining nuts to 65 in-lb (7.3 N·m). Use two wrenches to pre- vent the posts from turning. See following NOTE. Page 28-10 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 499 REVERSE position. The reverse buzzer will sound as a warning when the Forward/ Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 28-11...
  • Page 501 5. Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack. Figure 29-1 IQDM Jack On F&R Switch Housing Figure 29-2 IQDM Jack Under Instrument Panel 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 29-1...

  • Page 502: Program Menu

    14.8 mph (23.8 km/h) Private speed mode 19.6 mph (31.5 km/h) Program Program Monitor Faults SPEED SETTING Functions Information Programmer Setup Figure 29-3 Access Program Menu Figure 29-4 Change Speed Setting Page 29-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...

  • Page 503: Fast Accel

    Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more infor- mation on this feature, contact your local Club Car distributor or dealer. 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 29-3...
  • Page 505 ............24-10 adjustment ............6-8 excessive early discharging ......24-15 cable fleet rotation ...........24-15 installation ...........6-11 hydrometer calibration ........24-4 removal ............6-10 maintenance, preventive ........24-9 see also batteries, electrolyte cleaning assembly ..........6-5 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page i-1...
  • Page 506 (torque converter) troubleshooting ..20-1 disassembly ........... 20-12 clutch, drive see drive clutch inspection ............20-13 clutch, driven installation ............20-16 see driven clutch removal ............20-12 Page i-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 507 ............14-29 testing ............11-35 testing ..........11-36, 12-34 hour meter circuit testing ........12-33 headlights installation ............14-21 see also lighting circuit operation ............13-21 removal ............14-21 testing ..........11-37, 12-35 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page i-3...
  • Page 508 ......26-6, 27-7 kill circuit, engine identification ..........26-1, 27-1 testing ........11-28, 12-19, 12-28 installation ...........26-12, 27-13 kill limit switch motor braking ........... 21-1 installation ............14-16 protection circuit ..........21-4 Page i-4 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 509 .......... 14-14, 23-10 adjustment removal ..........14-14, 23-10 electric (MCOR) ...........5-17 gasoline vehicle ...........5-12 testing ........11-15, 12-15, 21-30 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page i-5...
  • Page 510 ...........13-1, 14-1 rework .............. 14-8 testing ......11-17, 11-20, 12-16, 12-18 test procedures ..........12-8 steering 1 – battery ............12-9 adjustment ............7-6 2 – fuse ............12-12 Page i-6 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 511 ..........11-9, 11-31 see service tools diode ..............11-18 torque converter engine kill circuit ..........11-29 troubleshooting ..........20-1 fuel gauge ............11-33 Tow/Run switch ..........21-4 fuel level sending unit ........11-32 installation ............23-7 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page i-7...
  • Page 512 ..........21-1 WARNING definition of ............1-1 water level see batteries, electrolyte level wheel installation ............8-1 removal .............. 8-1 see also tire wheel, steering see steering wheel Page i-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 513 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 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual...
  • Page 516 Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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