Club Car 2008 Turf Maintenance And Service Manual
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Club Car 2008 Turf Maintenance And Service Manual

Club Car 2008 Turf Maintenance And Service Manual

Gasoline and electric vehicles
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2008
Turf/Carryall
Maintenance and Service
Manual
Turf 1, Turf 2, Turf 6,
Carryall 1, Carryall 2, Carryall 2 Plus, Carryall 6
Gasoline and Electric Vehicles
Manual Number 103373104
Edition Code 0907C1108B

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  • Page 1 2008 Turf/Carryall Maintenance and Service Manual Turf 1, Turf 2, Turf 6, Carryall 1, Carryall 2, Carryall 2 Plus, Carryall 6 Gasoline and Electric Vehicles Manual Number 103373104 Edition Code 0907C1108B...
  • Page 3 If it appears that a service question is not answered in this manual, you may write to us at: Club Car, Inc., P.O. Box 204658, Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech- nical Service Representative at (706) 863-3000, extension 3580.
  • Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    Tilt Bed – Turf 1, 2, Carryall 1, 2 and 2 Plus ..................Tilt Bed Removal .......................... Tilt Bed Installation ........................Flat Bed – Turf 6 and Carryall 6 ......................Flat Bed Removal ......................... Flat Bed Installation ........................2008 Turf/Carryall Vehicle Maintenance and Service Manual Page iii...
  • Page 6 Accelerator Pedal Removal – Electric Vehicles ................Accelerator Pedal Installation – Electric Vehicles ................ 5-11 Pedal Group Adjustment – Gasoline Vehicles ................. 5-11 Pedal Group Adjustment – Electric Vehicles ..................5-16 Page iv 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 7 Tires ..............................Tire Removal ..........................Tire Repair ............................ Tire Installation ..........................SECTION 8 – REAR SUSPENSION General Information .......................... Shock Absorbers ..........................Shock Absorber Inspection and Removal ..................Shock Absorber Installation ......................2008 Turf/Carryall Vehicle Maintenance and Service Manual Page v...
  • Page 8 Tie Rod and Drag Link ........................9-13 Tie Rod and Drag Link Removal ....................9-13 Tie Rod and Drag Link Installation ....................9-13 Front Suspension ..........................9-14 Lubrication ............................ 9-14 Wheel Alignment .......................... 9-14 Page vi 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 9 Front Wheel Bearings and Hubs - 4-Wheel Brake Vehicles ............. 9-23 Front Wheel Free Play Inspection ....................9-23 Front Wheel Bearings and Hub Removal ..................9-24 Front Wheel Bearings and Hub Installation .................. 9-24 SECTION i – INDEX 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page vii...

  • Page 11: Section 1 - Safety

    SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAU- TION.
  • Page 12 • 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 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 13 Place Tow/Run switch in Remove negative the TOW position before disconnecting or connecting cable first. battery cables. Figure 1-3 Turf 2/Carryall 2 IQ Plus Electric Vehicle Figure 1-4 Carryall 6 IQ Plus System Vehicle 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 1-3...

  • Page 15: Section 2 - Vehicle Specifications

    38.5 in. 38.5 in. 38.5 in. Rear wheel tread (98 cm) (98 cm) (98 cm) 908 lb. 1185 lb. 1286 lb. Weight: Standard electric vehicle (412 kg) (537 kg) (583 kg) 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 2-1...
  • Page 16 (544 kg) (680 kg) Standard seating capacity LIQUID CAPACITIES 22 oz. Transaxle (0.67 liters) TIRE PRESSURE 18-20 psi 30-34 psi 30-34 psi Front and rear (1.24-1.38 Bars) (2.07-2.34 Bars) (2.07-2.34 Bars) Page 2-2 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 17: Vehicle Specifications - Gasoline Vehicles

    (122 cm) (122 cm) (122 cm) 65.5 in. 77.5 in. 77.5 in. 98.5 in. Wheelbase (166 cm) (197 cm) (197 cm) (250 cm) Specifications continued on next page . . . 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 2-3...

  • Page 18: Specifications

    Fuel tank liters) liters) liters) liters) TIRE PRESSURE 16-18 psi (1.10- 30-34 psi (2.07- 30-34 psi (2.07- 30-34 psi (2.07- Front and rear 1.24 Bars) 2.34 Bars) 2.34 Bars) 2.34 Bars) Page 2-4 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 19: Section 3 - General Information

    • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION Important features unique to the different models covered in this manual are highlighted. Club Car, Inc. rec- ommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).

  • Page 20: Storage - Gasoline Vehicle

    Do not allow this solution to enter the batteries. Be sure terminals are tight. Let the terminals dry and then coat them with Battery Terminal Protector Spray (CCI P/N 1014305). Page 3-2 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 21 9. Thoroughly clean front body, rear body, seats, cargo bed, engine compartment, and underside of vehicle. 10. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 3-3...

  • Page 22: Returning The Stored Gasoline Vehicle To Service

    Place Tow/Run switch in TOW position. • Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery. Frozen batteries can explode. Page 3-4 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 23: Preparing The Electric Vehicle For Extended Storage

    2. Fully charge batteries. See Section 13 – Batteries in the appropriate maintenance and service sup- plement. 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. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 3-5...

  • Page 25: Section 4 - Body And Trim

    (no. 00) steel wool. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.

  • Page 26: Front Body Repair

    • Be careful not to sand completely through the finish to the body material. If the finish is sanded through and the thermo plastic olefin (TPO) body material is exposed, refer to Gouges, Punctures, Tears, Large Scratches, and Abrasions on page 4-3. Page 4-2 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 27: Touch-Up Paint Color Chart

    BODY AND TRIM Front Body 3. Using the brush provided with the touch-up paint (available from Club Car Service Parts, see following color chart), apply paint to the scratch. Multiple layers of paint may be required to fill the scratch.

  • Page 28: Front Body Installation

    Use the body trim (13) as a guide for drilling the holes. 3. Tighten screws (18) holding front body trim against front body to 17 in-lb (1.9 N·m). 4. Vehicles equipped with headlights: Reconnect the light wiring harness to the headlight assemblies. Page 4-4 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 29: Tilt Bed - Turf 1, 2, Carryall 1, 2 And 2 Plus

    6. Turf 2, Carryall 2, and 2 Plus only: Lift bed and place the prop rod (17) in bed mounting hole. Install a 3/8-inch flat washer (22) and a new cotter pin (23) on prop rod (Figure 4-2, Page 4-6). 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 4-5...
  • Page 30 BODY AND TRIM Tilt Bed – Turf 1, 2, Carryall 1, 2 and 2 Plus TYPICAL 2 PLACES Figure 4-2 Tilt Bed – Turf 1, 2, Carryall 1, 2, and 2 Plus Page 4-6 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 31: Flat Bed - Turf 6 And Carryall 6

    5. Remove two bolts (7) and lock nuts (8) from the bracket (10) on driver-side trim strip (1). Remove bracket from bed. 6. Remove remaining hardware securing driver-side trim strip and remove trim strip from bed. 7. Repeat steps 5 and 6 to remove passenger side trim strip and brackets. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 4-7...

  • Page 32: Flat Bed Trim Installation

    3. Install bolts, flat washers, and lock nuts that secure bed to vehicle frame. Tighten bolts to 75 in-lb (8 N·m). TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 4-3 Flat Bed – Turf 6 and Carryall 6 Page 4-8 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 33 PLACES PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES AT BODY TYPICAL 2 PLACES AT DOOR Figure 4-4 Flat Bed Trim, Access Door, and Side Door – Turf 6 and Carryall 6 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 4-9...

  • Page 34: Access Door - Turf 6 And Carryall 6

    Turf 6, Carryall 6 and other vehicles with taillights: 1. Remove taillight assembly. 1.1. Remove the two screws (14) that secure taillight (15) to the rear fender (Figure 4-6, Page 4-12). 1.2. Disconnect the three taillight wires. Page 4-10 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 35 5. Remove fender (6) from vehicle (Figure 4-5, Page 4-11 or Figure 4-6, Page 4-12). TYPICAL 2 PLACES Figure 4-5 Rear Fender, Trailer Hitch, and Tailskirt – Turf 1, 2, Carryall 1, 2, and 2 Plus 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 4-11...

  • Page 36: Rear Fender Installation

    Figure 4-6 Rear Fender and Tailskirt – Turf 6 and Carryall 6 REAR FENDER INSTALLATION 1. Install rear fender in the reverse order of removal. Tighten bolts (2) to 35 in-lb (4.0 N·m). Page 4-12 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 37: Trailer Hitch (Optional On Some Models)

    1. Remove the brake and accelerator pedals. See Section 5 – Accelerator and Brake Pedal Group. 2. Remove horn switch if so equipped. 3. Remove the top edge of the floor mat from the overlapping flange under the dash. 4. Lift the mat from the vehicle. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 4-13...

  • Page 38: Front Floor Mat Installation

    (8) (Figure 4-6, Page 4-12). 2. Lift bumper from vehicle. BUMPER INSTALLATION 1. Install the rear bumper in the reverse order of removal. Tighten nuts to 65 in-lb (7.3 N·m) (Figure 4-6, Page 4-12). Page 4-14 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 39: Section 5 - Accelerator And Brake Pedal Group

    3.3. Remove the nut (25) and brake stop bumper (24) (Figure 5-1, Page 5-2 or Figure 5-2, Page 5-3). 3.4. Lift the pedal assembly (10) through the floorboard (Figure 5-3, Page 5-4). 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-1...
  • Page 40 Brake Pedal and Park Brake TYPICAL 4 PLACES TYPICAL 2 PLACES TURF 1 AND CARRYALL 1 VEHICLES ONLY Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting – Two-Wheel Brake Vehicles Page 5-2 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 41 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake TYPICAL 2 PLACES Figure 5-2 Brake and Park Brake Pedal Assembly and Mounting – Four-Wheel Brake Vehicles 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-3...

  • Page 42: Brake Pedal Installation

    • For gasoline vehicles, see Pedal Group Adjustment – Gasoline Vehicles on page 5-11. • For electric vehicles, see Pedal Group Adjustment – Electric Vehicles on page 5-16. Figure 5-3 Brake Pedal Weldment Through Floor Figure 5-4 Park Brake Assembly Page 5-4 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 43: Park Brake Removal

    7. Adjust the pedal group. Refer to the appropriate adjustment procedure: • For gasoline vehicles, see Pedal Group Adjustment – Gasoline Vehicles on page 5-11. • For electric vehicles, see Pedal Group Adjustment – Electric Vehicles on page 5-16. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-5...

  • Page 44: Accelerator Pedal - Gasoline Vehicles

    8. Use a marker to mark the position of the park brake ratchet (23) on the accelerator pivot rod (6). See fol- lowing NOTE. NOTE: Failure to mark position of the ratchet could cause it to be reinstalled improperly, resulting in improper adjustment and possible failure of the park brake. Page 5-6 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 45 13. Remove the accelerator pedal (1) from the vehicle. 14. Inspect all parts for wear and damage. Replace as necessary. Figure 5-6 Accelerator Pedal – Gasoline Vehicles 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-7...

  • Page 46: Accelerator Pedal Installation - Gasoline Vehicles

    Page 5-7). 12. Install the accelerator rod assembly (17, 25, and 24) (Figure 5-6, Page 5-7). 13. Adjust the pedal group. See Pedal Group Adjustment – Gasoline Vehicles on page 5-11. Page 5-8 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 47: Accelerator Pedal - Electric Vehicles

    (15) to make installation of the pivot rod easier. 13. Remove the accelerator pedal (1) from the vehicle (Figure 5-8, Page 5-10). 14. Inspect all parts for wear and damage. Replace as necessary. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-9...
  • Page 48 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles Figure 5-8 Accelerator Pedal – Electric Vehicle Page 5-10 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 49: Accelerator Pedal Installation - Electric Vehicles

    2.2. To provide slack in the brake cables, loosen the equalizer retaining nuts (2 and 3) on the equalizer rod (1) (Figure 5-9, Page 5-12). 2.3. Four-wheel brake vehicles only: Loosen the front brake equalizer rod (Figure 5-10, Page 5-12). 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-11...
  • Page 50 If the gap becomes larger as the park brake pedal is pressed, move the pivot rod supports slightly forward until gap is consistent. See following NOTE. Page 5-12 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 51 Reconnect ball joint (Figure 5-16, Page 5-14). 3.7. If the accelerator push rod was disconnected from the accelerator pedal, reconnect it. 3.8. Check for proper brake operation prior to driving the vehicle. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-13...
  • Page 52 • To prevent accidentally starting the vehicle, disconnect the battery cables as instructed in WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. This will prevent the possibility of the vehicle running over you when you are adjusting the accelerator rod. Page 5-14 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 53 5.5. If the events above occur as they should, hold the ball joint at each end of the accelerator rod with pliers and tighten the accelerator rod jam nut against it. 5.6. Ensure that the events occur as described in step 5.4 above. See following NOTE. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-15...

  • Page 54: Pedal Group Adjustment - Electric Vehicles

    Proper brake pedal height is 6 inches (15.2 cm) (Figure 5-23, Page 5-17). 2.5. Tighten the jam nut (31) to 8 ft-lb (9.5 N·m) (Figure 5-22, Page 5-17). Page 5-16 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 55 Figure 5-24 Park Brake Ratchet/Pawl Gap Adjustment 3.3. With the park brake unlocked, measure and note the distance from the top of the accelerator pedal to the floorboard, then lock the park brake (Figure 5-25, Page 5-18). 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-17...
  • Page 56 26 ft-lb (35.3 N·m) (Figure 5-29, Page 5-19). 1/2-INCH WRENCH 1/2-INCH SOCKET Figure 5-27 Brake Rod Adjustment Figure 5-28 Accelerator Pedal Height Adjustment Page 5-18 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 57 (CCI P/N 101871001) RUBBER STRAP Figure 5-29 Accelerator Pedal Height Adjustment 5. Adjust the brakes. See Brake Adjustment (Self-Adjusting Brakes), Section 6, Page 6-8 or Brake Adjustment (Manually-Adjusted Brakes), Section 6, Page 6-12. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-19...

  • Page 59: Section 6 - Wheel Brake Assemblies

    OSHA/29 CFR - 1910.1001. GENERAL INFORMATION The Club Car vehicles covered in this manual are equipped with two-wheel self-adjusting brakes or four- wheel manually-adjusted brakes. See Section 2 – Specifications. BRAKE SHOE REMOVAL See General Warning, Section 1, Page 1-1.
  • Page 60 6. Using needle nose pliers, rotate the clip retainer pin (1) 90° to remove the shoe retainer clip (2) on each shoe (Figure 6-4, Page 6-3). See following CAUTION. ý CAUTION • The brake shoes are under spring pressure and can release suddenly when brake shoe retainers are removed. Page 6-2 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 61: Brake Assembly Cleaning (Self-Adjusting Brakes)

    3. Lubricate the slide (1) and slide plate (2) with dry moly lubricant (CCI P/N 1012151) on both sides of the backing plate. After lubricating, work the slide back and forth to ensure it slides smoothly and easily (Figure 6-7, Page 6-3). Reinstall rubber boot onto backing plate. See following WARNING. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-3...
  • Page 62 (Figure 6-10, Page 6-4). See preceding WARNING. 7. Install the adjuster wheel and two washers into the adjuster assembly (Figure 6-10, Page 6-4). Figure 6-10 Lubricate Adjuster Page 6-4 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 63: Brake Shoe Installation (Self-Adjusting Brakes)

    1. Turn the adjusting wheel screw so the shoe slot is vertical, then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly (Figure 6-12, Page 6-6). See following NOTE. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-5...
  • Page 64 SPRING COILS SILVER SPRING Note that the silver spring is mounted with the coils to the side of the adjustment lever spring (A). Figure 6-13 Retainer Clip Figure 6-14 Spring Orientation Page 6-6 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 65 • Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft. ADJUSTING ADJUSTING WHEEL TIPS Figure 6-16 Slide Shoes Figure 6-17 Turn Adjusting Wheel (Self-Adjusting Brakes) 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-7...

  • Page 66: Brake Adjustment (Self-Adjusting Brakes)

    3.2. Tighten the nut on the equalizer rod so that the brake pedal free play is 1/4 to 1/2 inch (6.35 mm to 12.7 mm). 3.3. Tighten the jam nut (3) while holding the adjustment nut (2) in the correct position. Page 6-8 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 67: Brake Assembly Cleaning (Manually-Adjusted Brakes)

    After lubricating, work slide back and forth to ensure it slides smoothly and easily (Figure 6-19, Page 6-9). Reinstall rubber boot onto backing plate. See following WARNING. BOSSES BOSSES Figure 6-19 Lubricate Slide Figure 6-20 Lubricate Raised Bosses 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-9...

  • Page 68: Brake Shoe Installation (Manually-Adjusted Brakes)

    The front brake assembly is rotated 90° (when compared to the rear brake assembly) so the adjusting bolt on each assembly is oriented to the rear of the vehicle rather than at the top of the assembly (Figure 6-32, Page 6-15). Page 6-10 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 69 1/4 to 3/8 inch (6.3 to 9.5 mm) without binding. Make sure the shoes are positioned vertically so the tips of the shoes are positioned flush with the top surface of the shoe mount- ing blocks as shown (Figure 6-26, Page 6-12). See following CAUTION. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-11...

  • Page 70: Brake Adjustment (Manually-Adjusted Brakes)

    NOTE: All brake cluster components must be clean, lubricated, and in good working condition prior to beginning brake adjustment. All wheels must be installed on the vehicle and lug nuts tightened to 55 ft-lb (74.6 N·m). Page 6-12 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 71: Brake Cluster Adjustment

    Figure 6-30 Rear Brake Adjustment Bolt 4. Use a torque wrench and a 7-mm 8-point socket or Club Car brake adjustment tool (CCI P/N 1013582) to turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft-lb (20.3 N·m) and continue clockwise rotation to the point at which torque is released.
  • Page 72 WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 6-31 Rear Manually-Adjusted Brake Assembly Page 6-14 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 73 WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) Figure 6-32 Front Manually-Adjusted Brake Assembly 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-15...

  • Page 74: Brake Cable Equalization

    13 ft-lb (17.6 N·m) (Figure 6-27, Page 6-13). See following CAUTION. ý CAUTION • If the brake pedal return spring (6) was disconnected while equalizing the brake cables, be sure to reconnect it before proceeding (Figure 6-27, Page 6-13). Page 6-16 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 75: Final Brake Cluster Adjustment

    4. Remove the axle: 4.1. Using 90° snap ring pliers, remove the axle retaining ring (1) (Figure 6-3, Page 6-2). 4.2. Pull the axle shaft (2) from the axle tube (Figure 6-3, Page 6-2). 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-17...

  • Page 76: Rear Brake Cluster Installation

    5. Remove bow-tie pin (17) and clevis pin (16) from brake cable (Figure 6-32, Page 6-15). 6. Remove dust cap (6) on hub and bearing assembly (Figure 6-34, Page 6-19). 7. Remove cotter pin (5) and hex nut (7) from spindle shaft (Figure 6-34, Page 6-19). Page 6-18 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 77: Front Brake Cluster Installation

    (19) to mount brake assembly (Figure 6-32, Page 6-15). 2. Tighten bolts to 30 ft-lb (41 N·m). Adjust brakes as previously described in this section for the appropriate vehicle. Use new bow-tie pins when reconnecting brake cables. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-19...

  • Page 78: Front Brake Cables

    4. Remove bolt (4) and nut (6) from brake cable clamp (5) (Figure 6-35, Page 6-20). 5. Remove cable from vehicle. TYPICAL BOTH SIDES OF VEHICLE Figure 6-35 Front Brake Cables Page 6-20 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 79: Front Brake Cable Installation

    7. Install brake cable clevis onto brake lever arm and install clevis pin (3) and a new bow-tie pin (2). 8. Adjust brakes as described in this section for the appropriate vehicle. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-21...

  • Page 80: Rear Brake Cables

    4.1. Remove bow-tie pins (1), clevis pins (2), and E-clips (3) (Figure 6-39, Page 6-23). 4.2. Remove cable (4) from cable support bracket (5). 4.3. Note location of hangers (for installation of cables). Pull cables out of vehicle. Page 6-22 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 81: Rear Brake Cable Installation

    (1) (Figure 6-39, Page 6-23). 3. Place cables in cable support bracket (5) and secure with E-clips. 4. Adjust brakes as described in this section for the appropriate vehicle. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-23...

  • Page 83: Section 7 - Wheels And Tires

    1. Install wheel(s), and use a crisscross pattern to tighten the lug nuts until they are snug. 2. Lower the vehicle, and use a crisscross pattern finish tightening the lug nuts to 55 ft-lb (74.6 N·m). 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 7-1...

  • Page 84: Tires

    3.4. Once the lower bead is started over the rim flange, the tire can be removed from the rim by hand. TIRE TOOL UPPER TIRE BEADS TIRE BEADS POSITIONED IN RIM WELL LOWER FLANGE VALVE STEM SIDE UP TIRE BEADS Figure 7-1 Tire Removal Page 7-2 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 85: Tire Repair

    Over-inflation could cause the tire to explode, possibly resulting in personal injury. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 7-3...
  • Page 86 • 18-20 psi (1.24-1.38 Bars) for Turf 1 and Carryall 1 electric vehicles • 30-34 psi (2.07-2.34 Bars) for all other vehicles. 9. Immerse the wheel and tire assembly in water to make sure there are no leaks. Page 7-4 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 87: Section 8 - Rear Suspension

    3. Remove lower mounting hardware (5, 9 and 10) on shock absorber lower mount (Figure 8-3, Page 8-4 or Figure 8-4, Page 8-5). See also Figure 8-1, Page 8-1. 4. Compress the shock absorber to remove it. Figure 8-1 Shock Absorber Removal 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 8-1...

  • Page 88: Shock Absorber Installation

    LIFTING POSITION FOR TURF 2, CARRYALL 2 AND CARRYALL 2 PLUS Position floor jack under hitch bracket or frame. LIFTING POSITION FOR TURF 6 AND CARRYALL 6 Figure 8-2 Lift Vehicle Page 8-2 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 89: Multi-Leaf Spring Installation

    (12). See following CAUTION. CAUT ION • When placing transaxle on spring, be sure to position locating bolt on the spring in the locating hole in the transaxle saddle (23) (Figure 8-3, Page 8-4). 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 8-3...

  • Page 90: Rear Suspension Turf/Carryall Vehicles

    TYPICAL ON TYPICAL BOTH SIDES BOTH SIDES OF VEHICLE REAR BRAKE CABLE REAR BRAKE CABLE ELECTRIC VEHICLES ONLY TYPICAL 2 PLACES Figure 8-3 Rear Suspension – Turf 1 and Carryall 1 Vehicles Page 8-4 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 91 BOTH SIDES OF VEHICLE REAR BRAKE CABLE ELECTRIC VEHICLES ONLY ELECTRIC VEHICLES ONLY TYPICAL 2 PLACES Figure 8-4 Rear Suspension – All Turf and Carryall Vehicles Except Turf 1 and Carryall 1 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 8-5...

  • Page 92: Snubber

    1. Install in the reverse order of removal. 2. Tighten snubber bracket mounting nuts (1) to 13 ft-lb (17.6 N·m) (Figure 8-5, Page 8-6). SNUBBER MOUNTING BRACKET SNUBBER Figure 8-5 Snubber Brackets Page 8-6 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 93: Stabilizer Bar

    (5). Do not remove the stabilizer bar links from frame (Figure 8-6, Page 8-7). TYPICAL 8 PLACES TYPICAL 8 PLACES REFERENCE REAR SUSPENSION TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 8-6 Stabilizer Bar 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 8-7...

  • Page 94: Stabilizer Bar Installation

    1. Grip jounce bumper (19) and pull from bumper mount (20) (Figure 8-3, Page 8-4). JOUNCE BUMPER INSTALLATION 1. Insert jounce bumper (19) into bumper mount (20) (Figure 8-3, Page 8-4). Make sure the entire circum- ference of bumper is seated firmly in mounting hole. Page 8-8 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 95: Section 9 - Steering And Front Suspension

    (Figure 9-2, Page 9-2). 5.4. Using a 1/2-inch drive air impact wrench, tighten the anvil screw (6) until the steering wheel breaks free from the steering shaft. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-1...

  • Page 96: Steering Wheel Installation

    See General Warning, Section 1, Page 1-1. STEERING COLUMN REMOVAL 1. Remove the steering wheel as previously instructed. 2. Remove the front body. See Front Body Removal, Section 4, Page 4-3. Page 9-2 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 97 STEERING AND FRONT SUSPENSION Steering Column TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 9-3 Steering Column 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-3...

  • Page 98: Steering Column Disassembly

    5) (Figure 9-3, Page 9-3). 7. Remove the steering column from the vehicle. STEERING COLUMN DISASSEMBLY 1. Remove bolts (6) and mounts (4 and 5) from steering column. Remove boot (12) (Figure 9-3, Page 9-3). Page 9-4 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 99: Steering Column Assembly

    STEERING COLUMN INSTALLATION 1. Install boot (12). Reinstall mount (4 and 5) onto the end of the steering column. Tighten bolts (6) to 20 ft-lb (27 N·m) (Figure 9-3, Page 9-3). 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-5...
  • Page 100 10. Reinstall center dash panel in reverse order of disassembly. Make sure the key switch terminals do not touch the frame and the center dash panel is properly seated and snapped into place. 11. Install front body and bumper. See Front Body Installation, Section 4, Page 4-4. Page 9-6 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 101: Steering Adjustment

    • urethane bushings (2) (Figure 9-21, Page 9-18 or Figure 9-23, Page 9-20) • leaf springs (6) (Figure 9-22, Page 9-19 or Figure 9-24, Page 9-21) 6. Replace components as necessary. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-7...

  • Page 102: Rack And Pinion

    6. Remove the rack screw lock nut (15), rack guide screw (16), rack guide pressure spring (14), and the rack guide (13) (Figure 9-12, Page 9-10). 7. Remove the universal joint assembly from the pinion (8) by fully removing the bolt and then sliding off the universal joint. Page 9-8 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 103 WOOD BLOCKS Figure 9-11 Secure Rack in Vise 14. Inspect the bushing (5) for excessive wear. If wear is excessive, replace the steering box assembly (CCI P/N 101878302) (Figure 9-12, Page 9-10). 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-9...

  • Page 104: Rack And Pinion Assembly

    (5) and housing (6). Install the stop washer (18) and retaining ring (19) to the end of the rack (Figure 9-12, Page 9-10). TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 9-12 Steering Gear Page 9-10 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 105 15/16-INCH DEEP WELL SOCKET DUST SEAL Figure 9-13 Press In Dust Seal Figure 9-14 Rack and Pinion Adjustment VISE 3/8-INCH 1/4 DRIVE DEEP WELL SOCKET Figure 9-15 Rack and Pinion Resistance 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-11...

  • Page 106: Rack And Pinion Installation

    15 ft-lb (20 N·m). 4. Tighten the steering rack mounting bolts (30) to 22 ft-lb (29.8 N·m) (Figure 9-12, Page 9-10). 5. Adjust the steering. See Steering Adjustment on page 9-7. Page 9-12 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 107: Tie Rod And Drag Link

    (22) (Figure 9-12, Page 9-10). Tighten nut to 18 ft-lb (2.0 N·m). 6. Adjust camber and toe-in. See Camber Adjustment on page 9-14 and Toe-in Adjustment on page 9-15. 7. Adjust steering. See Steering Adjustment on page 9-7. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-13...

  • Page 108: Front Suspension

    Use 7 mm deep well IMPROPER socket to adjust CAMBER eccentric. Club Car ADJUSTMENT Club Car Club Car UNEQUAL SPACE BETWEEN TIRES AND FRAMING SQUARES Figure 9-16 Check Camber Figure 9-17 Adjust Camber Page 9-14 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 109 6. If adjustment is necessary, loosen the jam nut on each tie rod ball joint and rotate the tie rod to increase or decrease toe-in (Figure 9-19, Page 9-15). See following CAUTION. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-15...

  • Page 110: 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. See Camber Adjustment on page 9-14 and Toe-in Adjustment on page 9-15. Page 9-16 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 111: Kingpin And Steering Spindle Removal

    See following NOTE. NOTE: If the bushings are replaced, ream new bushings to 0.750-0.752 (3/4 inch) (19.05-19.10 mm) in diameter. The reamer should be long enough to ream both bushings from one direction. 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-17...

  • Page 112: Two-Wheel Brake Vehicle Upper Portion

    STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 9-21 Two-Wheel Brake Vehicle – Upper Portion Page 9-18 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 113 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 4 PLACES DRIVER SIDE ONLY PASSENGER SIDE ONLY TYPICAL 4 PLACES Figure 9-22 Two-Wheel Brake Vehicle – Lower Portion 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-19...
  • Page 114 STEERING AND FRONT SUSPENSION Front Suspension Components REFERENCE STEERING GEAR TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 9-23 Four-Wheel Brake Vehicle – Upper Portion Page 9-20 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 115 STEERING GEAR ASSEMBLY TYPICAL 4 PLACES PASSENGER SIDE ONLY TYPICAL 4 PLACES LEAF SPRING APPEARANCE MAY VARY ON DIFFERENT MODELS. TYPICAL 4 PLACES Figure 9-24 Four-Wheel Brake Vehicle – Lower Portion 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-21...

  • Page 116: Kingpin And Steering Spindle Installation

    2. Remove the nut (9) attaching the shock absorber to the A-Plate (Figure 9-21, Page 9-18 or Figure 9-23, Page 9-20). 3. Remove the nut (32) and bolt (8) attaching the shock absorber to the shock and gear support. 4. Remove the shock absorber. Page 9-22 2008 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 117: Shock Absorber Installation

    4. Install a new cotter pin (2). If movement continues, replace the wheel bearings (5) as required (Figure 9-25, Page 9-23). Figure 9-25 Front Wheel Bearings and Hub - Four-Wheel Brake Vehicles 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-23...

  • Page 118: Front Wheel Bearings And Hub Removal

    8. Repeat the procedure for the opposite wheel. 9. Install the wheels and then finger-tighten the lug nuts. 10. Lower the vehicle and finish tightening lug nuts (using a crisscross pattern) to 55 ft-lb (74.6 N·m). Page 9-24 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 119 ............4-14 cluster (rear) adjustment ...........6-13 installation ...........6-18 hitch, trailer removal ............6-17 see trailer hitch pedal height adjustment (electric) ......5-16 height adjustment (gas) .......5-11 lubrication installation .............5-4 removal ............5-1 front suspension ..........9-14 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page i-1...
  • Page 120 ........... 9-12 removal ............9-8 tailskirt steering column installation ............4-13 assembly ............9-5 removal ............4-13 disassembly ............9-4 tie rod and drag link installation ............9-5 installation ............9-13 Page i-2 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 121 ............4-5 removal ..............4-5 tire installation ............7-3 pressure .............7-1 removal ..............7-2 repair ..............7-3 trailer hitch installation ............4-13 removal ............4-13 WARNING definition of ............1-1 wheel see also tire installation ............7-1 removal ..............7-1 2008 Turf/Carryall Vehicle Maintenance and Service Manual Page i-3...
  • Page 122 2008 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 124 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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