Club Car XRT 950 4x4 2009 Manuals

Manuals and User Guides for Club Car XRT 950 4x4 2009. We have 1 Club Car XRT 950 4x4 2009 manual available for free PDF download: Maintenance And Service Manual

Club Car XRT 950 4x4 2009 Maintenance And Service Manual (256 pages)

Brand: Club Car | Category: Golf Cars | Size: 17.56 MB

Table of Contents
5
Section 1 - Safety
11
Safety Details
11
Personal Safety
11
Machine Safety
11
Information
11
General Warning
12
Disabling the Vehicle
13
Disconnecting the Battery - Gasoline Vehicles
14
Connecting the Battery - Gasoline Vehicles
14
Section 2 - Vehicle Specifications
15
Section 3 - General Information
17
Model Identification
17
Serial Number
17
Storage
18
Preparing the Vehicle for Extended Storage
19
Returning the Stored Vehicle to Service
20
Lifting the Vehicle
20
Lifting Only the Front
20
Lifting Only the Rear
21
Lifting the Entire Vehicle
22
Using a Booster Battery (Jump Starting)
22
Section 4 - Body and Trim
25
Cleaning the Vehicle
25
Front Body Repair
26
Stress Lines or Streaks
26
Minor Impact Damage/Deformations
26
Minor Scratches and Surface Blemishes
26
Small Scratches that Cannot be Buffed out
27
Touch-Up Paint Color Chart
27
Gouges, Punctures, Tears, Large Scratches, and Abrasions
27
Front Body
28
Front Fascia Removal
28
Front Fascia Installation
30
Front Cowl Removal
30
Front Cowl Installation
33
Instrument Panel Removal
33
Instrument Panel Installation
34
Front Fender Removal
34
Front Fender Installation
35
Under Pedal Closeout Panel Removal
35
Under Pedal Closeout Panel Installation
36
Under Seat Closeout Panels
36
Under Seat Closeout Panel Removal
36
Under Seat Closeout Panel Installation
37
ROPS (Roll over Protective Structure)
38
ROPS Removal
38
ROPS Installation
40
Side Panel
41
Side Panel Removal
41
Side Panel Installation
42
Under Seat Center Panel
42
Under Seat Center Panel Removal
42
Under Seat Center Panel Installation
43
Rear Fender
43
Rear Fender Removal
43
Rear Fender Installation
44
Cargo Bed
44
Cargo Bed Removal
44
Cargo Bed Installation
44
Section 5 - Accelerator and Brake Pedal Group
45
Accelerator Pedal Removal - through Early-2012 Model Year
45
Accelerator Pedal Installation - through Early-2012 Model Year
48
Accelerator Cable Removal - through Early-2012 Model Year
49
Accelerator Cable Installation - through Early-2012 Model Year
50
Accelerator Cable Adjustment - through Early-2012 Model Year
51
Accelerator Pedal Removal - from Early-2012 Model Year
53
Accelerator Pedal Installation - from Early-2012 Model Year
54
Accelerator Cable Removal - from Early-2012 Model Year
55
Accelerator Cable Installation - from Early-2012 Model Year
56
Accelerator Cable Adjustment - from Early-2012 Model Year
56
Brake Pedal Removal
58
Brake Pedal Installation
58
Brake Pedal Adjustment
59
Section 6 - Brakes
61
General Information
61
Troubleshooting
61
Brake System Troubleshooting
61
Brake System Inspection
64
Hydraulic and Mechanical Components
66
Brake Fluid Reservoir
67
Brake Hose Replacement
67
Brake Pads and Caliper
72
Brake Discs
74
Master Cylinder Replacement
75
Bleeding the Hydraulic Brake System
76
Vacuum Bleeding of Brakes on a DOT 5 Fluid Filled System
76
Manual Bleeding of Brakes on a DOT 5 Fluid Filled System
77
Refilling the Hydraulic System
78
Park Brake System
79
Park Brake Cable Removal
79
Park Brake Cable Installation
82
Park Brake Handle Removal
84
Park Brake Handle Installation
84
Park Brake Adjustment
85
Section 7 - Steering and Front Suspension
87
Steering Wheel
87
Steering Wheel Removal
87
Steering Wheel Installation
88
Steering Column
88
Steering Column Removal
88
Steering Column Installation
90
Rack and Pinion
91
Rack and Pinion Inspection
91
Rack and Pinion Removal
91
Rack and Pinion Installation
92
Front Suspension
92
Wheel Alignment
93
Strut Removal and Inspection
94
Strut Installation
95
Steering Knuckle Removal
95
Steering Knuckle Installation
96
A-Arm Removal
97
A-Arm Installation
97
Ball Joint Removal
97
Ball Joint Installation
98
Front Wheel Bearings and Hubs
98
Front Wheel Free Play Inspection
98
Front Wheel Bearings and Hub Removal
98
Front Wheel Bearings and Hub Installation
99
Section 8 - Wheels and Tires
101
General Information
101
Wheels
102
Wheel Removal
102
Wheel Installation
102
Tires
102
Tire Repair
102
Tire Removal
103
Tire Installation
103
Section 9 - Rear Suspension
105
Rear Shock Removal
105
Rear Shock Installation
106
Lateral Link Removal
106
Lateral Link Installation
106
Trailing Arm Removal
107
Trailing Arm Installation
108
Rear Wheel Bearings and Hubs
109
Rear Wheel Free Play Inspection
109
Rear Wheel Bearings and Hub Removal
109
Rear Wheel Bearings and Hub Installation
110
Wheel Alignment
111
Section 10 - Periodic Maintenance
113
General Information
113
Pre-Operation and Daily Safety Checklist
114
Performance Inspection
115
Periodic Service Schedule
115
Periodic Lubrication Schedule
118
Brake Fluid Reservoir
119
Engine Oil
119
Engine Oil Level Check
119
Engine Oil and Filter Change
120
Oil Viscosity
122
Spark Plugs
123
Spark Plug Cleaning and Inspection
123
Spark Plug Gap Inspection
123
Gearcase Lubrication
123
Lubrication Level Check - Front Differential and Rear Transaxle
123
Lubrication Change - Front Differential and Rear Transaxle
124
Air Intake System
125
Air Filter Replacement
125
Fueling Instructions
126
Battery
127
Section 11 - Troubleshooting and Electrical System
129
General Information
129
Electrical System
129
Wiring Diagram
130
Troubleshooting Guide
136
Test Procedures
140
Section 12 - Electrical Components
167
Starter and Starter Solenoid
167
Neutral Switch
167
Neutral Switch Removal
167
Neutral Switch Installation
168
Carburetor Solenoid
168
Carburetor Solenoid Removal
168
Carburetor Solenoid Installation
169
Voltage Regulator
169
Voltage Regulator Removal
169
Voltage Regulator Installation
170
Warning Lights
171
Warning Light Removal
171
Warning Light Installation
171
Fuel Gauge/Hour Meter
172
Fuel Gauge/Hour Meter Removal
172
Fuel Gauge/Hour Meter Installation
172
Key Switch
173
Key Switch Removal
173
Key Switch Installation
173
Light Switch
173
Light Switch Removal
173
Light Switch Installation
174
Front Differential Disable Switch (Optional)
174
Front Differential Disable Switch Removal
174
Front Differential Disable Switch Installation
174
Front Differential Limit Switch
174
Front Differential Limit Switch Removal
175
Front Differential Limit Switch Installation
175
Fuse
175
Fuse Removal
175
Fuse Installation
175
Fuel Level Sending Unit
176
Fuel Level Sending Unit Removal
176
Fuel Level Sending Unit Installation
176
Ignition Coil and Charge Coil
176
Ignition Coil And/Or Charge Coil Removal
176
Oil Pressure Sensor
177
Headlights
177
Headlight Bulb Removal
177
Headlight Bulb Installation
177
Wire Harness Diodes
178
Diode Removal
178
Diode Installation
178
Battery
178
General Information
179
Section 13 - Engine
183
Engine Removal
183
Engine Installation
187
Engine RPM Adjustment - through Early-2012 Model Year
187
Vehicle Creep
187
Idle Speed Adjustment
188
High Speed Adjustment
191
Engine RPM Adjustment - from Early-2012 Model Year
193
Vehicle Creep
193
Idle Speed Adjustment
193
High Speed Adjustment
196
Governor Lever Reset Adjustment
198
Section 14 - Fuel System
201
Fuel Lines
201
Fuel Filter
201
Fuel Pump
201
Carburetor
202
Carburetor Jetting
202
Fuel Level Sending Unit
203
Fuel Level Sending Unit Removal
203
Fuel Level Sending Unit Installation
205
Fuel Tank
207
Fuel Tank Removal
207
Fuel Tank Storage or Disposal
208
Fuel Tank Installation
209
Carbon Canister (if Equipped)
209
Carbon Canister Removal
210
Carbon Canister Installation
210
Section 15 - Exhaust System
211
Muffler Removal
211
Muffler Installation
211
Exhaust Pipe Removal
212
Exhaust Pipe Installation
212
Section 16 - Front Differential and Halfshafts
213
Front Differential Removal
213
Front Differential Installation
215
Front Halfshaft Removal
217
Front Halfshaft Installation
217
Section 17 - Transaxle and Halfshafts
219
General Information
219
Ratios
219
Transaxle Removal
219
Transaxle Installation
224
Rear Halfshaft Removal
225
Rear Halfshaft Installation
225
Shifter Cable Adjustment
225
Four-Wheel Drive Cable Adjustment - through Early-2012 Model Year
226
Differential Lock Cable Adjustment
227
Section 18 - Clutches
229
Clutch Troubleshooting
229
Outer Clutch Cover
230
Outer Clutch Cover Removal
230
Outer Clutch Cover Installation
231
Drive Belt
231
Drive Belt Removal
231
Drive Belt Installation
233
Drive Clutch
233
Drive Clutch Removal
233
Drive Clutch Cleaning and Inspection
234
Drive Clutch Disassembly
235
Drive Clutch Component Inspection
235
Drive Clutch Assembly
235
Drive Clutch Installation
237
Driven Clutch
238
Driven Clutch Removal
238
Driven Clutch Disassembly
240
Driven Clutch Assembly
242

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Club Car XRT 950 4x4 2009 Maintenance And Service Manual (256 pages)

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