Club Car XRT 800 Manuals

Manuals and User Guides for Club Car XRT 800. We have 1 Club Car XRT 800 manual available for free PDF download: Maintenance Service Manual

Club Car XRT 800 Maintenance Service Manual (516 pages)

GASOLINE/ELECTRIC

Brand: Club Car | Category: Utility Vehicle | Size: 35 MB

Table of Contents
5
Section 1 - Safety

17
- General Warning
  17
Section 2 - Vehicle Specifications

21
- 800 And 810 Specifications
  21
- Specifications
  21
Section 3 - General Information

25
Section 4 - Body and Trim

31
- Cleaning the Vehicle
  31
  - Seat Cleaning
    31
- Front and Rear Body Repair
  32
- Front Body - 800 and 810
  33
  - Bumper/Brush Guard Removal
    33
  - Bumper/Brush Guard Installation
    33
  - Front Body Removal
    33
  - Molded Dash Removal
    34
  - Molded Dash Installation
    34
  - Front Body Installation
    34
- Front Body - 850
  35
- Cargo Bed - 800 and 810
  38
  - Cargo Bed Removal
    38
  - Cargo Bed Installation
    39
  - Bed Latch Assembly
    39
  - Bed Latch Assembly Installation
    41
- Seat Back Support Brackets - 800 and 810
  41
  - Seat Back Support Bracket Removal
    41
  - Seat Back Support Bracket Installation
    42
- Rear Body and Fenders - 800 and 810
  42
  - Rear Body Removal
    42
  - Rear Fender Removal
    44
  - Rear Fender Installation
    44
  - Rear Body Installation
    45
- Rear Body - 850
  45
  - Rear Body Removal
    45
  - Rear Body Installation
    49
- Floor Mat
  49
  - Floor Mat Removal
    49
  - Floor Mat Installation
    49
Section 5 - Accelerator and Brake Pedal Group

51
Section 6 - Wheel Brake Assemblies

71
- Brake Shoe Removal
  71
- Brake Assembly Cleaning
  75
- Brake Shoe Installation
  76
- Brake Adjustment
  78
- Brake Cluster Removal and Installation
  78
  - Brake Cluster Installation
    79
- Brake Cable Removal and Installation
  80
Section 7 - Steering and Front Suspension

83
- General Information
  83
- Steering Wheel
  83
  - Steering Wheel Removal
    83
  - Steering Wheel Installation
    84
- Steering Column
  84
  - Steering Column Removal
    84
  - Steering Column Disassembly
    86
  - Steering Column Assembly
    86
  - Steering Column Installation
    87
- Steering Adjustment
  88
- Rack and Pinion
  89
  - Rack and Pinion Removal
    89
  - Rack and Pinion Disassembly
    89
  - Rack and Pinion Assembly
    92
  - Rack and Pinion Installation
    94
- Tie Rod and Drag Link
  94
  - Tie Rod and Drag Link Removal
    94
  - Tie Rod and Drag Link Installation
    94
- Front Suspension
  95
  - Lubrication
    95
  - Wheel Alignment
    95
- Front Suspension Components
  97
  - Tapered Leaf Spring Removal
    97
  - Tapered Leaf Spring Installation
    97
  - Kingpin and Steering Spindle Removal
    98
  - Kingpin and Steering Spindle Installation
    98
  - Delta A-Plate Removal
    98
  - Delta A-Plate Installation
    101
  - Shock Absorber Removal
    101
  - Shock Absorber Installation
    101
- Front Wheel Bearings and Hubs
  101
  - Front Wheel Free Play Inspection
    101
  - Front Hub Removal
    101
  - Front Hub Installation
    102
Section 8 - Wheels and Tires

103
- General Information
  103
- Wheels
  103
  - Wheel Removal
    103
  - Wheel Installation
    103
- Tires
  103
  - Tire Removal
    103
  - Tire Repair
    104
  - Tire Installation
    105
Section 9 - Rear Suspension

107
- General Information
  107
- Shock Absorbers
  107
  - Shock Absorber Removal and Inspection
    107
  - Shock Absorber Installation
    107
- Leaf Springs
  108
  - Leaf Spring Removal
    108
  - Leaf Spring Installation - All Vehicles
    110
  - Stabilizer Bar Removal
    113
  - Stabilizer Bar Installation
    113
Section 10 - Periodic Maintenance

115
- General Information
  115
- Periodic Service Schedules
  115
- Periodic Lubrication Schedules
  118
- Engine Oil - Gasoline Vehicles
  120
  - Engine Oil Level Check
    120
  - Engine Oil and Filter Change
    121
  - Oil Viscosity
    123
Section 11 - Troubleshooting and Electrical System: 800 and 810 Gas

125
- General Information
  125
- Troubleshooting Guide
  125
- Electrical System
  129
- Lockout Cam
  129
- Wiring Diagrams
  130
- Test Procedures
  132
  - Index of Test Procedures
    132
Section 12 - Troubleshooting and Electrical System: 850 Gas

163
- General Information
  163
- Troubleshooting Guide
  163
- Wiring Diagram
  168
- Electrical System
  170
- Test Procedures
  170
  - Index of Test Procedures
    170
Section 13 - Electrical Components: 800 and 810 Gasoline Vehicles

200
- Starter/Generator
  201
- Belt Tension Adjustment
  208
- Voltage Regulator
  209
- Diode
  210
- Key Switch
  212
- Solenoid
  213
- Fuse
  214
- Lockout Cam Limit Switch
  215
- Lockout Cam
  216
- Reverse Warning Buzzer
  217
- Reverse Buzzer Limit Switch
  218
- Oil Warning Light
  218
- Fuel Gauge/Hour Meter
  219
- Fuel Level Sending Unit
  220
- RPM Limiter
  221
- Ignition Coil
  222
- Oil Level Sensor
  225
- Headlights
  225
- Voltage Limiter
  226
- Light Switch
  227
- Battery
  228
- General Information
  228
  - Charging the Battery
    231
  - Battery Installation
    231
- Battery Storage
  231
- Ground Cables
  232
Section 14 - Electrical Components: 850 Gasoline Vehicle

234
- Starter/Generator
  234
- Voltage Regulator
  243
- Key Switch
  244
- Solenoid
  246
- Fuse
  246
- Kill Limit Switch
  247
- Neutral Lockout Limit Switch
  248
- Reverse Warning Buzzer
  250
- Reverse Buzzer Limit Switch
  251
- Low Oil Warning Light
  252
- Fuel Gauge/Hour Meter
  253
- Fuel Level Sending Unit
  254
- RPM Limiter
  254
- Ignition Coil
  255
- Oil Level Sensor
  258
- Headlights
  258
- Voltage Limiter
  260
- Headlight Switch
  261
- Battery
  262
- Ground Cables
  266
Section 15 - Engine

267
- General Information
  267
  - Before Servicing
    267
  - Engine Rotation
    267
  - Spark Plug
    267
- Cylinder Head
  269
  - General Information
    269
  - Breather Valve (Reed Valve)
    269
- Crankcase
  269
  - Engine Removal
    269
  - Crankcase Cover Removal
    269
  - Oil Level Sensor
    271
  - Crankcase Cover Installation
    271
- Ignition Coil and Flywheel
  272
- Flywheel Installation
  274
- Engine Installation
  275
  - Torque Specifications
    276
  - Adjustments and Settings
    276
Section 16 - Fuel System: Gasoline Vehicle

277
- General Information
  277
- Carburetor
  277
  - Main Jet Elevation/Size Chart
    279
  - Changing the Main Jet
    279
- Engine Control Linkage
  282
  - General Information
    282
  - Accelerator Rod
    283
  - Governor Cable
    285
  - Accelerator Cable
    286
  - Closed Throttle or Idle Adjustment
    287
  - Engine RPM Adjustment
    288
- Choke and Air Intake System
  288
  - Choke Button Removal
    288
  - Choke Button Installation
    288
  - Air Box Removal
    289
  - Air Box Installation
    289
  - Intake Duct Removal
    289
  - Intake Duct Installation
    290
  - Air Filter
    292
- Fuel Filters
  293
  - Fuel Filter Removal
    293
  - Fuel Filter Installation
    293
- Fuel Pump
  295
  - General Information
    295
  - Fuel Pump Removal
    295
  - Fuel Pump Disassembly
    295
  - Fuel Pump Cleaning and Inspection
    296
  - Fuel Pump Assembly
    296
  - Fuel Pump Installation
    297
- Fuel Tank
  297
  - General Information
    297
  - Fuel Tank Removal
    298
  - Fuel Tank Disposal
    299
  - Fuel Tank Storage
    299
  - Fuel Tank Installation
    299
- Fuel Lines
  301
- Fuel Shut-Off Valve
  301
- Fueling Instructions
  302
- Drive Clutch
  316
- Troubleshooting
  349
- Drive Belt
  350
  - Drive Belt Removal
    350
  - Drive Belt Installation
    351
    
    Drive Clutch Removal
    352
    
    Drive Clutch Cleaning and Inspection
    353
    
    Drive Clutch Disassembly
    355
    
    Inspection of Drive Clutch Parts
    357
    
    Drive Clutch Assembly
    358
    
    Drive Clutch Installation
    360
  - Driven Clutch
    360
    
    Driven Clutch Removal
    360
    
    Driven Clutch Disassembly
    360
    
    Driven Clutch Inspection
    361
    
    Driven Clutch Assembly
    361
    
    Driven Clutch Installation
    364
Section 21 - Electrical System and Testing: Electric Vehicle

365
- General Information
  365
- Wiring Diagram
  366
- Xrt 800, 810 and 850 Maintenance and Service Manual
  367
- Troubleshooting
  368
- Communication Display Module (CDM)
  397
  - Using the CDM to Retrieve Data from the Onboard Computer
    398
  - CDM Troubleshooting Guide
    399
Section 22 - Iq Display Module (Iqdm) and Iqdm-P Diagnostics

402
- Menu Navigation
  402
- Introductory Display
  402
- Monitor Menu
  404
- Faults Menu
  406
- Functions Menu
  411
  - Get Settings from Controller
    411
  - Write Settings to Controller
    412
  - Reset All Settings
    413
  - Model Number
    414
- Iqdm and Iqdm-P Handset Troubleshooting
  416
Section 23 - Electrical Components: Electric Vehicle

421
- Key Switch – 800 and
  421
- Forward/Reverse Switch – 800 and
  424
- Tow/Run Switch
  427
- Motor Controller Output Regulator (Mcor)
  428
- Reverse Buzzer
  429
- Onboard Computer (Obc)
  431
- Solid State Speed Controller
  433
- Charger Receptacle
  435
- Battery Warning Light
  437
Section 24 – Batteries: Electric Vehicles

439
- Battery Troubleshooting Chart
  440
- Battery Testing
  441
  - Battery Troubleshooting Examples
    445
- Battery Replacement
  446
- Battery Care
  447
  - Electrolyte Level
    448
- Battery Charger
  450
  - Charging Batteries
    450
  - Plug and Receptacle
    451
  - Charger Shuts off after 16 Hours
    452
  - Early Excessive Discharging
    453
  - Incoming Ac Service
    453
  - Fleet Rotation
    453
  - Numbering Vehicles and Chargers
    453
- Charging a Battery Pack that Has Low Voltage
  454
  - Field Windings Inspection
    462
  - Motor Components
    462
- Motor Speed Sensor
  471
- Armature Inspection and Testing
  478
- Motor Frame and Field Windings Inspection
  479
- Motor Brush, Spring, and Terminal Insulator Inspection
  480
Section 28 - Transaxle (Type G): Electric Vehicle

489
- Transaxle Identification
  489
- Axle Bearing and Shaft
  489
  - Transaxle Removal
    493
- Transaxle Disassembly, Inspection, and Assembly
  495
  - Transaxle Disassembly and Inspection
    495
  - Transaxle Assembly
    497
- Transaxle Installation
  498
- Program Menu
  502
  - Speed Setting
    502
  - Fast Accel
    503
  - Pedal up Mode
    503
  - Speed Cal
    503
  - Code A, Code B, and Code C
    503

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Club Car XRT 800 Manuals

Club Car XRT 800 Maintenance Service Manual (516 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 Group

Section 6 - Wheel Brake Assemblies

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: 800 and 810 Gas

Section 12 - Troubleshooting and Electrical System: 850 Gas

Section 13 - Electrical Components: 800 and 810 Gasoline Vehicles

Section 14 - Electrical Components: 850 Gasoline Vehicle

Section 15 - Engine

Section 16 - Fuel System: Gasoline Vehicle

Section 21 - Electrical System and Testing: Electric Vehicle

Section 22 - Iq Display Module (Iqdm) and Iqdm-P Diagnostics

Section 23 - Electrical Components: Electric Vehicle

Section 24 – Batteries: Electric Vehicles

Section 28 - Transaxle (Type G): Electric Vehicle

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