Club Car XRT 1200 Manuals

Manuals and User Guides for Club Car XRT 1200. We have 1 Club Car XRT 1200 manual available for free PDF download: Maintenance And Service Manual

Club Car XRT 1200 Maintenance And Service Manual (312 pages)

Brand: Club Car | Category: Utility Vehicle | Size: 18 MB

Table of Contents
5
Section 1 - Safety

15
- General Warning
  15
  - Disabling the Vehicle
    17
  - Disconnecting the Battery
    17
  - Connecting the Battery
    17
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
  26
  - Abrasions and Haze
    26
  - Light Scratches
    26
  - Large Scratches and Abrasions
    26
- Tube Bumper/Brush Guard
  26
  - Tube Bumper/Brush Guard Removal
    26
  - Tube Bumper/Brush Guard Installation
    26
- Front Body Components
  27
  - Dashboard Removal
    27
  - Dashboard Installation
    27
  - Front Body Removal
    29
  - Front Fender Removal
    29
  - Front Fender Installation
    29
  - Front Body Installation
    29
- Seat
  29
  - Seat Adjustment
    31
- Front Seat Support
  31
  - Front Seat Support Removal
    31
  - Front Seat Support Installation
    31
- Rear Seat Support
  33
  - Rear Seat Support Removal (Carryall 472/XRT 1200 SE)
    33
  - Rear Seat Support Installation (Carryall 472/XRT 1200 SE)
    33
- Cargo Bed
  35
  - Cargo Bed Removal
    35
  - Cargo Bed Installation
    35
  - Bed Stop Bumper Adjustment
    37
- Rear Fender
  38
  - Rear Fender Removal
    38
  - Rear Fender Installation
    38
- Tailskirt
  38
  - Tailskirt Removal
    38
  - Tailskirt Installation
    38
- Trailer Hitch
  39
  - Trailer Hitch Removal
    39
  - Trailer Hitch Installation
    39
- Receiver Hitch
  39
  - Receiver Hitch Removal
    39
  - Receiver Hitch Installation
    39
- Floor Mat
  42
  - Floor Mat Removal
    42
  - Floor Mat Installation
    42
Section 5 - Accelerator and Brake Pedal Assemblies

43
- Brake Pedal
  43
  - Brake Pedal Removal
    43
  - Brake Pedal Installation
    43
- Brake Pedal Adjustment
  45
- Accelerator Pedal
  47
  - Accelerator Pedal Removal
    47
  - Accelerator Pedal Installation
    47
- Accelerator Pedal Adjustment
  48
Section 6 - Mc012C-Bs00 Transaxle: Hydraulic and Park Brake Systems

53
Section 7 - Steering and Front Suspension

91
- Steering Wheel
  91
  - Steering Wheel Removal
    91
  - Steering Wheel Installation
    93
- Steering Column
  93
  - Steering Column Removal
    93
  - Steering Column Disassembly
    93
  - Steering Column Assembly
    94
  - Steering Column Installation
    95
- Rack and Pinion
  96
  - Rack and Pinion Inspection
    96
  - Rack and Pinion Removal
    96
  - Rack and Pinion Disassembly
    97
  - Rack and Pinion Assembly
    101
  - Rack and Pinion Installation
    102
- Front Suspension
  103
  - Lubrication
    103
  - Wheel Alignment
    103
- Front Suspension Components
  104
  - Kingpin and Steering Spindle Removal
    104
  - Kingpin and Steering Spindle Installation
    105
  - A-Arm Removal
    106
  - A-Arm Installation
    106
  - Shock Absorber Removal
    108
  - Shock Absorber Installation
    108
- Front Wheel Bearings and Hubs
  109
Section 8 - Wheels and Tires

111
- General Information
  111
Section 9 - Rear Suspension

113
- Shock Absorbers
  113
  - Shock Absorber Removal and Inspection
    113
  - Shock Absorber Installation
    113
- Multi-Leaf Springs
  113
  - Multi-Leaf Spring Removal
    113
  - Multi-Leaf Spring Installation
    115
- Snubber
  116
  - Snubber Removal
    116
  - Snubber Installation
    116
Section 10 - Periodic Maintenance

117
- Periodic Service Schedule
  117
- Periodic Lubrication Schedule
  119
- Master Cylinder
  120
  - Brake Fluid
    120
- Engine Oil
  120
  - Engine Oil Level Check
    120
  - Engine Oil and Filter Change
    121
  - Oil Viscosity
    124
- Fueling Instructions
  124
- Battery
  126
Section 11 - Troubleshooting and Electrical System: Fe400, Key-Start Engine

129
- Troubleshooting Guide
  129
- Electrical System
  133
- Lockout Cam
  133
- Circuit Testing
  133
- Wiring Diagrams
  134
- Test Procedures
  138
  - Index of Test Procedures
    138
Section 12 - Electrical Components: Fe400, Key-Start Engine

171
- Starter/Generator (Model G425419)
  171
- Starter/Generator (Model 114-01-4005)
  180
- Voltage Regulator
  191
- Diode
  192
- Key Switch
  194
- Solenoid
  195
- Fuse
  196
- Lockout Cam Limit Switch
  197
- Lockout Cam
  198
- Reverse Warning Buzzer
  199
- Reverse Buzzer Limit Switch
  200
- Oil Warning Light
  200
- Fuel Gauge/Hour Meter
  201
- Fuel Level Sending Unit
  202
- RPM Limiter
  203
- Ignition Coil
  204
- Oil Level Sensor
  207
- Headlights
  207
- Headlight Diode
  208
- Light Switch
  209
- Battery
  209
- Ground Cables
  214
Section 13 - Fe400 Engine

215
- General Information
  215
  - Before Servicing
    215
  - Lubrication System
    215
  - Spark Plug
    216
- Cylinder
  217
  - Breather Valve (Reed Valve)
    217
  - Valve Clearance Check and Adjustment
    217
- Crankcase
  217
  - Engine Removal
    217
  - Crankcase Cover Removal
    218
  - Oil Level Sensor
    219
- Ignition Coil and Flywheel
  220
  - Crankcase Cover Installation
    221
- Flywheel Installation
  221
- Engine Installation
  222
  - Torque Specifications
    223
  - Adjustment and Settings
    223
Section 14 - Fuel System

225
- General Information
  225
- Carburetor
  225
  - Main Jet Elevation/Size Chart
    226
  - Changing the Main Jet
    226
- Engine Control Linkage
  230
  - General Information
    230
  - Accelerator Rod
    230
  - Governor Cable
    231
  - Accelerator Cable
    232
  - Closed Throttle or Idle Adjustment
    233
  - Engine RPM Adjustment
    234
- Choke and Air Intake System
  236
  - Choke Cable Removal
    236
  - Choke Cable Installation
    236
  - Air Box Removal
    236
  - Air Box Installation
    236
  - Intake Duct Repair
    237
  - Intake Duct Removal
    237
  - Intake Duct Installation
    241
  - Air Filter
    242
- Fuel Filters
  242
  - Fuel Filter Removal
    242
  - Fuel Filter Installation
    243
- Fuel Pump
  243
  - General Information
    243
  - Fuel Pump Removal
    243
  - Fuel Pump Disassembly (Metal Pump Only)
    244
  - Fuel Pump Cleaning and Inspection (Metal Pump Only)
    245
  - Fuel Pump Assembly (Metal Pump Only)
    245
  - Fuel Pump Installation
    245
- Fuel Tank
  246
  - Fuel Tank Removal
    246
  - Fuel Tank Storage or Disposal
    250
  - Fuel Tank Installation
    250
- Fuel Lines
  251
- Fuel Shut-Off Valve
  252
- Carbon Canister (if Equipped)
  252
  - Carbon Canister Removal
    252
  - Carbon Canister Installation
    253
Section 15 - Exhaust System

255
- Muffler
  255
  - Muffler Removal
    255
  - Muffler Installation
    255
Section 16 - Mc012C-Bs00 Unitized Transaxle with Differential Lock

257
- General Information
  257
  - Lubrication
    258
- Axle Shaft
  259
  - Axle Shaft, Bearing, and Oil Seal Removal
    259
  - Axle Shaft, Bearing, and Oil Seal Installation
    261
- Unitized Transaxle Removal
  262
- Unitized Transaxle Installation
  271
- Forward/Reverse Shifter Cable
  279
- Differential Lock System
  281
Section 17 - Torque Converter

285
- General Information
  285
- Troubleshooting
  285
- Drive Belt
  287
  - Drive Belt Removal
    287
  - Drive Belt Installation
    287
- Drive Clutch
  288
  - Drive Clutch Removal
    288
  - Drive Clutch Cleaning and Inspection
    289
  - Drive Clutch Disassembly
    290
  - Inspection of Drive Clutch Parts
    291
  - Drive Clutch Assembly
    294
  - Drive Clutch Installation
    295
- Driven Clutch
  296
  - Driven Clutch Removal
    296
  - Driven Clutch Disassembly
    296
  - Driven Clutch Inspection
    297
  - Driven Clutch Assembly
    297
  - Driven Clutch Installation
    301

Club Car Categories

Utility Vehicle Golf Cars Offroad Vehicle Electric Vehicles Battery Charger

More Club Car Manuals

Club Car XRT 1200 Manuals

Club Car XRT 1200 Maintenance And Service Manual (312 pages)

Table of Contents

Section 1 - Safety

Section 2 - Vehicle Specifications

Section 3 - General Information

Section 4 - Body and Trim

Section 5 - Accelerator and Brake Pedal Assemblies

Section 6 - Mc012C-Bs00 Transaxle: Hydraulic and Park Brake Systems

Section 7 - Steering and Front Suspension

Section 8 - Wheels and Tires

Section 9 - Rear Suspension

Section 10 - Periodic Maintenance

Section 11 - Troubleshooting and Electrical System: Fe400, Key-Start Engine

Section 12 - Electrical Components: Fe400, Key-Start Engine

Section 13 - Fe400 Engine

Section 14 - Fuel System

Section 15 - Exhaust System

Section 16 - Mc012C-Bs00 Unitized Transaxle with Differential Lock

Section 17 - Torque Converter

Related Products

Club Car Categories