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Carryall 2 Plus
Club Car Carryall 2 Plus Service Manual
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Manual Number 103897404
Edition Code 121
1A00000
T
urf 1, T
urf 2, T
urf 6, Carryall 1, Carryall 2, Carryall 2 Plus,
Carryall 6 G/E
2012 T
urf/Carryall
Maintenance and Service
Manual
2
Table of Contents
Default Chapter
5
Table of Contents
5
Section 1 - Safety
11
General Warning
11
Disabling the Vehicle
13
Disconnecting the Battery - Gasoline Vehicles
13
Connecting the Battery - Gasoline Vehicles
13
Disconnecting the Batteries - Electric Vehicles
13
Connecting the Batteries - Electric Vehicles
14
Section 2 - Vehicle Specifications
15
Vehicle Specifications - Electric Vehicles
15
Specifications
16
Vehicle Specifications - Gasoline Vehicles
17
Specifications
18
Section 3 - General Information
19
General Information
19
Serial Number Identification
19
Storage - Gasoline Vehicle
20
Preparing the Gasoline Vehicle for Extended Storage
20
Returning the Stored Gasoline Vehicle to Service
22
Storage - Electric Vehicle
22
Preparing the Electric Vehicle for Extended Storage
22
Returning the Stored Electric Vehicle to Service
24
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
26
Touch-Up Paint Color Chart
27
Gouges, Punctures, Tears, Large Scratches, and Abrasions
27
Front Body
28
Front Body Removal
28
Front Body Installation
28
Tilt Bed - Turf 1, 2, Carryall 1, 2 and 2 Plus
30
Tilt Bed Removal
30
Tilt Bed Installation
30
Flat Bed - Turf 6 and Carryall 6
32
Flat Bed Removal - Turf 6 and Carryall 6
32
Flat Bed Installation - Turf 6 and Carryall 6
32
Flat Bed Trim - Turf 6 and Carryall 6
34
Flat Bed Trim Removal - Turf 6 and Carryall 6
34
Flat Bed Trim Installation - Turf 6 and Carryall 6
34
Access Door - Turf 6 and Carryall 6
35
Access Door Removal - Turf 6 and Carryall 6
35
Access Door Installation - Turf 6 and Carryall 6
35
Rear Fender
36
Rear Fender Removal
36
Rear Fender Installation
37
Trailer Hitch - Heavy Duty (Optional on some Models)
39
Trailer Hitch Removal - Heavy Duty
39
Trailer Hitch Installation - Heavy Duty
39
Tailskirt
39
Tailskirt Removal
39
Tailskirt Installation
39
Floor Mat
39
Front Floor Mat Removal
39
Front Floor Mat Installation
40
Rear Floor Mat Removal - Turf 6 and Carryall 6 Only
40
Rear Floor Mat Installation - Turf 6 and Carryall 6 Only
40
Bumper
40
Bumper Removal
40
Bumper Installation
40
Section 5 - Accelerator and Brake Pedal Group
41
Brake Pedal and Park Brake
41
Brake Pedal Removal
41
Brake Pedal Installation
44
Park Brake Removal
45
Park Brake Installation
45
Accelerator Pedal - Gasoline Vehicles
46
Accelerator Pedal Removal - Gasoline Vehicles
46
Accelerator Pedal Installation - Gasoline Vehicles
48
Accelerator Pedal - Electric Vehicles
49
Accelerator Pedal Removal - Electric Vehicles
49
Accelerator Pedal Installation - Electric Vehicles
51
Pedal Group Adjustment - Gasoline Vehicles
51
Pedal Group Adjustment - Electric Vehicles
56
Section 6 - Wheel Brake Assemblies
61
General Information
61
Brake Shoe Removal
61
Brake Assembly Cleaning (Self-Adjusting Brakes)
63
Brake Shoe Installation (Self-Adjusting Brakes)
65
Brake Adjustment (Self-Adjusting Brakes)
68
Brake Assembly Cleaning (Manually-Adjusted Brakes)
69
Brake Shoe Installation (Manually-Adjusted Brakes)
70
Brake Adjustment (Manually-Adjusted Brakes)
72
Brake Cluster Adjustment
73
Brake Cable Equalization
76
Final Brake Cluster Adjustment
77
Test Drive Vehicle
77
Brake Cluster Removal and Installation
77
Rear Brake Cluster Removal
77
Rear Brake Cluster Installation
78
Front Brake Cluster Removal
78
Front Brake Cluster Installation
79
Front Brake Cables
80
Front Brake Cable Removal
80
Front Brake Cable Installation
81
Rear Brake Cables
82
Rear Brake Cable Removal
82
Rear Brake Cable Installation
83
Section 7 - Steering and Front Suspension
85
General Information
85
Steering Wheel
85
Steering Wheel Removal
85
Steering Wheel Installation
86
Steering Column
86
Steering Column Removal
86
Steering Column Disassembly
89
Steering Column Assembly
89
Steering Column Installation
89
Steering Adjustment
91
Rack and Pinion
92
Rack and Pinion Inspection
92
Rack and Pinion Removal
92
Rack and Pinion Disassembly
94
Rack and Pinion Assembly
95
Rack and Pinion Installation
97
Tie Rod and Drag Link
98
Tie Rod and Drag Link Removal - MAINTENANCE-FREE BALL JOINTS
98
Tie Rod and Drag Link Installation - MAINTENANCE-FREE BALL JOINTS
98
Front Suspension
99
Lubrication
99
Wheel Alignment
99
Front Suspension Components
101
Leaf Spring Removal
101
Leaf Spring Installation
101
Kingpin and Steering Spindle Removal
101
Kingpin and Steering Spindle Installation
107
Delta A-Plate Removal
107
Delta A-Plate Installation
107
Shock Absorber Removal
107
Shock Absorber Installation
108
Front Wheel Bearings and Hubs
108
Front Wheel Free Play Inspection
108
Front Wheel Bearings and Hub Removal
109
Front Wheel Bearings and Hub Installation
109
Section 8 - Wheels and Tires
111
General Information
111
Wheels
111
Wheel Removal
111
Wheel Installation
111
Tires
112
Tire Repair
113
Tire Installation
113
Section 9 - Rear Suspension
115
General Information
115
Shock Absorbers
115
Shock Absorber Inspection and Removal
115
Shock Absorber Installation
116
Multi-Leaf Springs
116
Multi-Leaf Spring Removal
116
Multi-Leaf Spring Installation
117
Snubber
120
Snubber Removal
120
Snubber Installation
120
Stabilizer Bar
121
Stabilizer Bar Removal
121
Stabilizer Bar Installation
122
Jounce Bumpers
122
Jounce Bumper Removal
122
Jounce Bumper Installation
122
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Club Car Carryall 2 Plus Specifications
General
Brand
Club Car
Model
Carryall 2 Plus
Category
Utility Vehicle
Language
English
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