Club Car CARRYALL 472 2004 Manuals

Manuals and User Guides for Club Car CARRYALL 472 2004. We have 1 Club Car CARRYALL 472 2004 manual available for free PDF download: Maintenance Service Manual

Club Car CARRYALL 472 2004 Maintenance Service Manual (376 pages)

GASOLINE VEHICLES

Brand: Club Car | Category: Utility Vehicle | Size: 15 MB

Table of Contents
5
Section 1 - Safety
15
General Warning
15
Section 2 - Vehicle Specifications
19
General Information
19
Section 3 - General Information
21
General Information
21
Engine Identification
21
Serial Number Identification
21
Storage
22
Preparing the Vehicle for Extended Storage
22
To Return Vehicle to Service
23
Section 4 - Body and Trim
25
Cleaning the Vehicle
25
Front Body Repair
25
Abrasions and Haze
25
Light Scratches
26
Large Scratches and Abrasions
26
Tube Bumper
26
Tube Bumper Removal
26
Tube Bumper Installation
26
Front Body Components
26
Dashboard Removal
26
Dashboard Installation
27
Front Body Removal
28
Front Fender Removal
28
Front Fender Installation
28
Front Body Installation
28
Seat
28
Seat Adjustment
30
Front Seat Support
30
Front Seat Support Removal
30
Front Seat Support Installation
30
Rear Seat Support
32
Rear Seat Support Removal
32
Rear Seat Support Installation
33
Cargo Bed
33
Cargo Bed Removal
33
Cargo Bed Installation
35
Bed Stop Bumper Adjustment
36
Rear Fender
36
Rear Fender Removal
36
Rear Fender Installation
36
Tailskirt
36
Tailskirt Removal
36
Tailskirt Installation
37
Trailer Hitch
37
Trailer Hitch Removal
37
Trailer Hitch Installation
37
Receiver Hitch
37
Receiver Hitch Removal
37
Receiver Hitch Installation
37
Floor Mat
40
Floor Mat Removal
40
Floor Mat Installation
40
Section 5 - Accelerator and Brake Pedal Assemblies
41
Brake Pedal
41
Brake Pedal Removal
41
Brake Pedal Installation
41
Brake Pedal Adjustment
43
Accelerator Pedal
45
Accelerator Pedal Removal
45
Accelerator Pedal Installation
45
Accelerator Pedal Adjustment
46
Section 6 - Mc012C-As00 Transaxle: Hydraulic and Park Brake Systems
51
Brake System Inspection
51
Brake System Troubleshooting
53
Brake Drum Removal
56
Front Wheel Brake Drum Removal
56
Rear Wheel Brake Drum Removal
58
Brake Shoe Removal
58
Front Brake Shoe Removal
58
Rear Brake Shoe Removal
58
Brake Cluster Inspection and Cleaning
60
Brake Shoe Installation
61
Front Brake Shoe Installation
62
Rear Brake Shoe Installation
62
Brake Drum Installation
64
Front Wheel Brake Drum Installation
64
Rear Wheel Brake Drum Installation
66
Brake Cluster Assembly Replacement
67
Front Brake Cluster Assembly Removal
67
Front Brake Cluster Assembly Installation
67
Rear Brake Cluster Assembly Removal
68
Rear Brake Cluster Assembly Installation
69
Wheel Cylinder Replacement
69
Front Wheel Cylinder Removal
69
Front Wheel Cylinder Installation
70
Rear Wheel Cylinder Removal
70
Rear Wheel Cylinder Installation
70
Brake Shoe Adjuster Replacement
71
Front Brake Shoe Adjuster Removal
72
Front Brake Shoe Adjuster Installation
72
Rear Brake Shoe Adjuster Removal
72
Rear Brake Shoe Adjuster Installation
72
Hydraulic Line and Hose Replacement
73
Front Brake Line Removal
73
Front Brake Line Installation
73
Front Brake Hose Assembly Removal
74
Front Brake Hose Assembly Installation
74
Rear Brake Line Removal
74
Rear Brake Line Installation
75
Rear Brake Hose Removal
75
Rear Brake Hose Installation
78
Master Cylinder and Bell Crank Replacement
78
Bell Crank Removal
78
Bell Crank Installation
78
Master Cylinder Removal
78
Master Cylinder Installation
79
Bleeding the Hydraulic Brake System
81
Purging the Hydraulic System
82
Filling the Hydraulic System
82
Park Brake System
83
Park Brake Cable Removal
83
Park Brake Cable Installation
84
Park Brake Handle Removal
85
Park Brake Handle Installation
85
Park Brake Adjustment
85
Section 7 - Steering and Front Suspension
89
Steering Wheel
89
Steering Wheel Removal
89
Steering Wheel Installation
91
Steering Column
91
Steering Column Removal
91
Steering Column Disassembly
91
Steering Column Assembly
92
Steering Column Installation
92
Rack and Pinion
93
Rack and Pinion Removal
93
Rack and Pinion Disassembly
95
Rack and Pinion Assembly
99
Rack and Pinion Installation
100
Front Suspension
101
Lubrication
101
Wheel Alignment
101
Front Suspension Components
102
Kingpin and Steering Spindle Removal
102
Kingpin and Steering Spindle Installation
103
A-Arm Removal
104
A-Arm Installation
104
Shock Absorber Removal
106
Shock Absorber Installation
106
Front Wheel Bearings and Hubs
107
Front Wheel Free Play Inspection
107
Front Wheel Bearings and Hub Removal
107
Front Wheel Bearings and Hub Installation
107
Section 8 - Wheels and Tires
109
General Information
109
Section 9 - Rear Suspension
111
Shock Absorbers
111
Shock Absorber Removal and Inspection
111
Shock Absorber Installation
111
Multi-Leaf Springs
111
Multi-Leaf Spring Removal
111
Multi-Leaf Spring Installation
113
Snubber
114
Snubber Removal
114
Snubber Installation
114
Section 10 - Periodic Maintenance
115
Periodic Service Schedule
115
Periodic Lubrication Schedule
116
Master Cylinder
117
Brake Fluid
118
Engine Oil
118
Engine Oil Level Check
118
Engine Oil and Filter Change
119
Oil Viscosity
121
Fueling Instructions
121
Battery
122
Section 11A - Troubleshooting and Electrical System: Fe400, Key-Start Engine
125
Troubleshooting Guide
125
Electrical System
129
Circuit Testing
129
Wiring Diagram
130
Electrical Circuits
132
Starter Circuit
132
Generator Circuit
132
Engine Ignition Circuit
133
Engine Kill Circuit
133
Reverse Buzzer Circuit
134
Low Oil Warning Circuit
134
Lockout Cam Circuit
135
Fuel Gauge and Sending Unit Circuit
136
Hour Meter Circuit
137
Lighting Circuit
137
Test Procedures
138
Index of Test Procedures
138
Section 11B - Troubleshooting and Electrical System: Fe350, Pedal-Start Engine
167
Troubleshooting Guide
167
Electrical System
171
Circuit Testing
171
Fuel Gauge and Sending Unit Circuit
171
Hour Meter Circuit
171
Lighting Circuit
179
Test Procedures
180
Index of Test Procedures
180
Section 12A - Electrical Components: Fe400, Key-Start Engine
209
Starter/Generator
209
Voltage Regulator
219
Diode
220
Key Switch
222
Solenoid
223
Fuse
224
Lockout Cam Limit Switch
225
Lockout Cam
225
Reverse Warning Buzzer
226
Reverse Buzzer Limit Switch
227
Oil Warning Light
228
Fuel Gauge/Hour Meter
229
Fuel Level Sending Unit
230
RPM Limiter
230
Ignition Coil
231
Oil Level Sensor
234
Headlights
234
Headlight Diode
235
Light Switch
236
Battery
236
Ground Cables
241
Section 12B - Electrical Components: Fe350, Pedal-Start Engine
243
Starter/Generator
243
Voltage Regulator
253
Key Switch
254
Solenoid
255
Fuse
256
Kill Limit Switch
256
Neutral Lockout Limit Switch
258
Neutral Lockout Cam
259
Reverse Warning Buzzer
259
Reverse Buzzer Limit Switch
260
Oil Warning Light
261
Fuel Gauge/Hour Meter
262
Fuel Level Sending Unit
263
RPM Limiter
263
Ignition Coil
264
Oil Level Sensor
267
Headlights
267
Headlight Diode
268
Light Switch
269
Battery
269
Charging the Battery
272
Ground Cables
274
Section 13 - Fe350 and Fe400 Engines
275
General Information
275
Before Servicing
275
Lubrication System
275
Spark Plug
276
Cylinder
277
Breather Valve (Reed Valve)
277
Valve Clearance Check and Adjustment
277
Crankcase
277
Engine Removal
277
Crankcase Cover Removal
278
Oil Level Sensor
279
Ignition Coil and Flywheel
280
Crankcase Cover Installation
281
Flywheel Installation
281
Engine Installation
282
Torque Specifications
283
Adjustment and Settings
283
Section 14 - Fuel System
285
General Information
285
Carburetor
285
Main Jet Elevation/Size Chart
286
Changing the Main Jet
286
Engine Control Linkage
290
General Information
290
Accelerator Rod
290
Governor Cable
292
Accelerator Cable
293
Closed Throttle or Idle Adjustment
294
Engine RPM Adjustment
295
Choke and Air Intake System
297
Choke Cable Removal
297
Choke Cable Installation
297
Air Box Removal
297
Air Box Installation
297
Intake Duct Repair
298
Intake Duct Removal
298
Intake Duct Installation
299
Air Filter
301
Fuel Filters
301
Fuel Filter Removal
301
Fuel Filter Installation
302
Fuel Pump
302
General Information
302
Fuel Pump Removal
302
Fuel Pump Disassembly
303
Fuel Pump Cleaning and Inspection
306
Fuel Pump Assembly
306
Fuel Pump Installation
306
Fuel Tank
307
Fuel Tank Removal
307
Fuel Tank Storage or Disposal
308
Fuel Tank Installation
309
Fuel Lines
312
Fuel Shut-Off Valve
313
Section 15 - Exhaust System
315
Muffler
315
Muffler Removal
315
Muffler Installation
315
Section 16 - Mc012C-As00 Unitized Transaxle with Differential Lock
319
General Information
319
Lubrication
320
Axle Shaft
321
Axle Shaft, Bearing, and Oil Seal Removal
321
Axle Shaft, Bearing, and Oil Seal Installation
323
Unitized Transaxle Removal
324
Unitized Transaxle Installation
333
Forward/Reverse Shifter Cable
341
Forward/Reverse Shifter Cable Removal
341
Forward/Reverse Shifter Cable Installation
342
Forward/Reverse Shifter Cable Adjustment
343
Differential Lock System
343
Differential Lock System Inspection
343
Differential Lock Cable Removal
344
Differential Lock Cable Installation
344
Section 17 - Torque Converter
347
General Information
347
Troubleshooting
349
Drive Belt
349
Drive Belt Removal
349
Drive Belt Installation
350
Drive Clutch
350
Drive Clutch Removal
350
Drive Clutch Cleaning and Inspection
351
Drive Clutch Disassembly
352
Inspection of Drive Clutch Parts
353
Drive Clutch Assembly
356
Drive Clutch Installation
357
Driven Clutch
358
Driven Clutch Removal
358
Driven Clutch Disassembly
359
Driven Clutch Inspection
359
Driven Clutch Assembly
359
Driven Clutch Installation
363

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Club Car CARRYALL 472 2004 Manuals

Club Car CARRYALL 472 2004 Maintenance Service Manual (376 pages)

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