Name: Club Car 2007 Carryall 295
Brand: Club Car
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Manual Number 103209114

Edition Code 1006F1208E

Gasoline, Diesel and IntelliTach, and Homologated Vehicles

2007 Carryall 295/295SE

and XRT 1550/1550SE

Maintenance and Service

Manual

Default Chapter1
- Maintenance and Service1
- Table of Contents5
Section 1 - Safety19
- General Warning19
Section 2A - Vehicle Specifications: Honda Gas & Kubota Diesel Powered23
- 295/295 SE and 1550/1550 SE Specifications23
- Intellitach Specifications25
Section 2B - Vehicle Specifications: Kawasaki Gas & Kubota Diesel Powered27
- 295/295 SE and 1550/1550 SE Specifications27
- 295 Homologated Specifications29
- Intellitach Specifications31
Section 3 - General Information33
- General Information33
  - Model Identification33
- Storage34
  - Preparing the Vehicle for Extended Storage35
  - Returning the Stored Vehicle to Service36
- Using a Booster Battery (Jump Starting)37
Section 4 - Body and Trim39
- Cleaning the Vehicle39
  - Seat Cleaning39
- Front Body Repair40
- Front Body Components41
- Roll-Over Protective Structure (ROPS)44
  - ROPS Removal45
  - ROPS Installation46
- Seat47
- Safety Belts48
  - Safety Belt Removal48
  - Safety Belt Installation49
- Cargo Bed - Electric Lift49
- Cargo Bed - Manual Lift51
  - Cargo Bed Removal51
  - Cargo Bed Installation51
- Rear Fender53
  - Rear Fender Removal53
  - Rear Fender Installation53
- Floor Mat53
  - Floor Mat Removal53
  - Floor Mat Installation53
Section 5 - Accelerator and Brake Pedal Assemblies55
- Accelerator Pedal55
- Brake Pedal57
- Park Brake Pedal58
  - Park Brake Pedal Assembly Removal58
  - Park Brake Pedal Assembly Installation58
Section 6 - Hydraulic and Park Brake Systems61
- Brake System Inspection61
- Brake System Troubleshooting63
- Brake Pads and Caliper65
- Brake Disc and Hub70
- Hydraulic Line Replacement77
- Master Cylinder and Reservoir80
- Bleeding the Hydraulic Brake System82
  - Bleeding Brakes on a DOT 5 Fluid Filled System82
  - Purging the Hydraulic System84
- Park Brake System85
Section 7 - Steering and Front Suspension91
- Steering Wheel91
  - Steering Wheel Removal91
  - Steering Wheel Installation92
- Steering Column92
  - Steering Column Removal92
  - Steering Column Installation93
- Rack and Pinion93
- Front Suspension101
  - Wheel Alignment101
- Front Suspension Components103
Section 8 - Wheels and Tires111
- General Information111
- Wheels112
  - Wheel Removal112
  - Wheel Installation112
- Tires112
  - Tire Removal112
  - Tire Installation113
Section 9 - Rear Suspension115
- Rear Coil-Over Shock Absorber115
- Swing Arms116
  - Swing Arm Removal116
  - Swing Arm Installation117
Section 10A - Periodic Maintenance: Honda Gasoline & Kubota Diesel Powered Vehicles119
- Periodic Service Schedule119
- Periodic Lubrication Schedule122
- Lubricating the Attachment Arm and Interface124
- Brake Fluid Reservoir125
  - Brake Fluid125
- Engine Oil125
- Gearcase Lubrication131
  - Lubrication Level Check for Front Differential, Transmission, and Rear Differential131
  - Lubrication Change for Front Differential, Transmission, and Rear Differential131
- Hydraulic System - Intellitach Vehicle133
- Engine Coolant - Diesel Vehicles134
  - Engine Coolant Level Check134
- Fueling Instructions134
  - Draining Water from Fuel Filter135
- Battery136
Section 10B - Periodic Maintenance: Kawasaki Gasoline & Kubota die137
- Periodic Service Schedule137
- Periodic Lubrication Schedule140
- Lubricating the Attachment Arm and Interface142
- Brake Fluid Reservoir143
  - Brake Fluid143
- Engine Oil143
- Spark Plugs148
  - Spark Plug Cleaning and Inspection148
  - Spark Plug Gap Inspection148
- Gearcase Lubrication149
  - Lubrication Level Check for Front Differential, Transmission, and Rear Differential149
  - Lubrication Change for Front Differential, Transmission, and Rear Differential149
- Hydraulic System - Intellitach Vehicle151
- Engine Coolant - Diesel Vehicles152
  - Engine Coolant Level Check152
- Fueling Instructions152
  - Draining Water from Fuel Filter153
- Battery154
Section 11A - Troubleshooting and Electrical System: Kawasaki Powered Gasoline Vehicles155
- Troubleshooting Guide155
- Wiring Diagram160
- Test Procedures162
- Test Procedures166
  - Index of Test Procedures204
Cles291
Section 12B - Electrical Components: Honda Powered Gasoline Vehi-291
- Starter and Starter Solenoid291
- Neutral Switch292
- Carburetor Heater293
- Voltage Regulator294
- Warning Lights295
- Fuel Gauge/Hour Meter296
- Key Switch297
- Volt Accessory Receptacle298
- Bed Lift Switch299
- Light Switch300
- Reverse Warning Buzzer (if Equipped)301
  - Reverse Warning Buzzer Limit Switch (if Equipped)302
  - Front Differential Limit Switch303
  - Fuel Level Sending Unit304
- Oil Pressure Sensor305
  - Wire Harness Diodes306
  - Battery307
  - Starter and Starter Solenoid311
  - Neutral Switch312
- Voltage Regulator313
  - Warning Lights314
  - Fuel Gauge/Hour Meter315
  - Key Switch316
- Volt Accessory Receptacle317
- Bed Lift Switch318
- Light Switch319
- Reverse Warning Buzzer320
- Reverse Warning Buzzer Limit Switch321
- Fuel Level Sending Unit322
- Charge Coil323
- Wire Harness Diodes324
- Battery325
- Preventive Maintenance326
Section 12C - Electrical Components: Diesel Vehicles329
- Starter and Starter Solenoid329
- Neutral Switch330
- Amp Fusible Link331
- Warning Lights333
- Fuel Gauge/Hour Meter334
- Key Switch335
- Bed Lift Switch336
- Bed Lift Circuit Breaker337
- Fuse338
- Reverse Warning Buzzer Limit Switch (if Equipped)339
- Front Differential Limit Switch341
  - Electric Fuel Pump342
- Oil Pressure Sensor344
- Thermostat Switch345
- Wire Harness Diodes348
- Fuel Level Sending Unit363
- Clutches379
Clutches391
Section 13B - Honda Gasoline Engine, Muffler, Fuel System, and391
- Gasoline Engine391
- Choke and Air Intake System414
Section 13C - Diesel Engine, Muffler, Fuel System, and Clutches431
Section 14 - Drivetrain Components469
- Half Shafts469
  - Half Shaft Installation471
- Front Differential472
  - Front Differential Installation474
  - Front Driveshaft Installation475
- Rear Axle476
  - Rear Axle Installation478
- Rear Driveshaft479
- Cylinders524
- Angle Frame Bushings537
  - Whisk Broom Angle Frame538
- Front Mount539
  - Front Mount Installation540
- Hydraulic Pump Assembly541

Club Car 2007 Carryall 295 User Manual

Table of Contents

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Club Car 2007 Carryall 295 Specifications

Related product manuals

Brand	Club Car
Model	2007 Carryall 295
Category	Utility Vehicle
Language	English