Club Car XRT 1200 2005 Vehicle Parts Manuals

Manuals and User Guides for Club Car XRT 1200 2005 Vehicle Parts. We have 1 Club Car XRT 1200 2005 Vehicle Parts manual available for free PDF download: Maintenance Service Manual

Club Car XRT 1200 2005 Maintenance Service Manual (292 pages)

Brand: Club Car | Category: Utility Vehicle | Size: 19 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/Brush Guard
26
Tube Bumper/Brush Guard Removal
26
Tube Bumper/Brush Guard 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 (Carryall 472/XRT 1200SE)
32
Rear Seat Support Installation (Carryall 472/XRT 1200SE)
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 11 - Troubleshooting and Electrical System: Fe400, Key-Start Engine
125
Troubleshooting Guide
125
Electrical System
129
Lockout Cam
129
Circuit Testing
129
Wiring Diagrams
130
Test Procedures
134
Index of Test Procedures
134
Starter/Generator
134
12. Voltage Regulator
134

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Club Car XRT 1200 2005 Maintenance Service Manual (292 pages)

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