Club Car CARRYALL 272 User Manual

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TURF 272 AND CARRYALL 272

GASOLINE VEHICLES

MANUAL NUMBER 102190010

EDITION CODE 0802A00000

MAINTENANCE

SERVICE

2001-2002

Table of Contents

Default Chapter5
- Table of Contents5
Section 1 - Safety21
- General Warning21
Section 2 - Vehicle Specifications25
- General Information25
Section 3 - General Information27
- General Information27
- Engine and Transaxle Identification27
- Serial Number Identification28
- Storage28
  - Returning the Stored Vehicle to Service30
Section 4 - Body and Trim33
- Cleaning the Vehicle34
- Front Body Repair35
- Tube Bumper35
  - Tube Bumper Removal35
  - Tube Bumper Installation35
- Front Body Components35
- Seat38
  - Seat Removal40
  - Seat Installation40
- Seat Support40
- Cargo Bed41
- Rear Fender43
  - Rear Fender Removal43
  - Rear Fender Installation44
- Tailskirt44
  - Tailskirt Removal44
  - Tailskirt Installation46
- Trailer Hitch46
  - Trailer Hitch Removal46
  - Trailer Hitch Installation46
- Floor Mat47
  - Floor Mat Removal47
  - Floor Mat Installation47
Section 5 - Accelerator and Brake Pedal Assemblies51
- Brake Pedal52
  - Brake Pedal Removal52
  - Brake Pedal Installation53
- Accelerator Pedal54
  - Accelerator Pedal Removal54
  - Accelerator Pedal Installation55
- Brake Pedal Adjustment56
- Accelerator Pedal Adjustment57
Section 6A - Mc012C-As00 Transaxle: Hydraulic and Park Brake Sys61
Tems62
- General Information62
- Transaxle Identification62
- Brake System Inspection63
- Brake System Troubleshooting66
- Brake Drum Removal69
  - Front Wheel Brake Drum Removal69
  - Rear Wheel Brake Drum Removal70
- Brake Shoe Removal71
  - Front Brake Shoe Removal71
  - Rear Brake Shoe Removal71
- Brake Cluster Inspection and Cleaning72
- Brake Shoe Installation74
  - Front Brake Shoe Installation74
  - Rear Brake Shoe Installation76
- Brake Drum Installation77
  - Front Wheel Brake Drum Installation77
  - Rear Wheel Brake Drum Installation79
- Brake Cluster Assembly Replacement80
- Wheel Cylinder Replacement83
- Brake Shoe Adjuster Replacement86
- Hydraulic Line and Hose Replacement87
- Master Cylinder and Bell Crank Replacement91
- Bleeding the Hydraulic Brake System93
  - Purging the Hydraulic System95
  - Filling the Hydraulic System96
- Park Brake System97
Section 6B - Mc010C-Bs00 Transaxle: Hydraulic and Park Brake Sys103
Tems104
- General Information104
- Transaxle Identification104
- Brake System Inspection105
- Brake System Troubleshooting108
- Brake Drum Removal111
  - Front Wheel Brake Drum Removal111
  - Rear Wheel Brake Drum Removal112
- Brake Shoe Removal113
  - Front Brake Shoe Removal113
  - Rear Brake Shoe Removal113
- Brake Cluster Inspection and Cleaning114
- Brake Shoe Installation116
  - Front Brake Shoe Installation116
  - Rear Brake Shoe Installation118
- Brake Drum Installation119
  - Front Wheel Brake Drum Installation119
  - Rear Wheel Brake Drum Installation121
- Brake Cluster Assembly Replacement122
- Wheel Cylinder Replacement125
- Brake Shoe Adjuster Replacement127
- Hydraulic Line and Hose Replacement129
- Master Cylinder and Bell Crank Replacement133
- Bleeding the Hydraulic Brake System135
  - Purging the Hydraulic System137
  - Filling the Hydraulic System138
- Park Brake System138
Section 7 - Steering and Front Suspension143
- General Information144
- Steering Wheel144
  - Steering Wheel Removal144
  - Steering Wheel Installation146
- Steering Column147
- Rack and Pinion149
- Front Suspension156
  - Lubrication156
  - Wheel Alignment156
- Front Suspension Components158
- Front Wheel Bearings and Hubs163
Section 8 - Wheels and Tires165
- General Information166
- Wheels166
  - Wheel Removal166
  - Wheel Installation167
- Tires167
Section 9 - Rear Suspension169
- General Information170
- Shock Absorbers170
  - Shock Absorber Removal and Inspection170
  - Shock Absorber Installation173
- Multi-Leaf Springs173
  - Multi-Leaf Spring Removal173
  - Multi-Leaf Spring Installation174
- Snubber175
  - Snubber Removal175
  - Snubber Installation175
Section 10 - Periodic Maintenance177
- General Information178
- Pre-Operation and Daily Safety Checklist179
  - Performance Inspection179
- Periodic Service Schedule180
- Periodic Lubrication Schedule181
- Master Cylinder182
  - Brake Fluid182
- Engine Oil182
  - Oil Viscosity183
- Fueling Instructions183
- Battery184
Section 11A - Troubleshooting and Electrical System: Fe400, Key-Start Engine185
- General Information186
- Troubleshooting Guide187
- Electrical System191
- Wiring Diagram192
- Electrical Circuits194
- Circuit Testing199
- Test Procedures205
  - Index of Test Procedures205
Section 11B - Troubleshooting and Electrical System: Fe350, Pedal-Start Engine235
- General Information236
- Troubleshooting Guide237
- Electrical System241
Section 12A - Electrical Components: Fe400, Key-Start Engine285
- Starter/Generator286
- Voltage Regulator297
- Diode298
- Key Switch300
- Solenoid301
- Fuse302
- Lockout Cam Limit Switch304
- Lockout Cam305
- Reverse Warning Buzzer306
- Reverse Buzzer Limit Switch307
- Oil Warning Light308
- Fuel Gauge/Hour Meter309
- Fuel Level Sending Unit310
- RPM Limiter310
- Ignition Coil311
- Oil Level Sensor314
- Headlights315
- Headlight Diode316
- Light Switch317
- Battery317
- Ground Cables322
Section 12B - Electrical Components: Fe350, Pedal-Start Engine323
- Starter/Generator324
- Voltage Regulator335
- Key Switch336
- Solenoid337
- Kill Limit Switch340
- Neutral Lockout Limit Switch341
- Neutral Lockout Cam342
- Reverse Warning Buzzer343
- Reverse Buzzer Limit Switch344
- Oil Warning Light345
- Fuel Gauge/Hour Meter346
- RPM Limiter347
- Ignition Coil348
- Oil Level Sensor351
- Headlights352
- Voltage Limiter353
- Light Switch354
- Battery354
  - Charging the Battery357
- Ground Cables359
Section 13 - Fe350 and Fe400 Engines362
- General Information362
- Engine Mounting Plate368
- Cylinder Head368
- Crankcase382
- Piston and Connecting Rod386
- Cylinder Block389
- Ignition Coil and Flywheel391
- Oil Pump393
  - Oil Pressure Relief Valve394
- Crankshaft and Counterbalance396
Section 14 - Fuel System415
- General Information416
- How the Carburetor Works416
- Carburetor419
  - Main Jet Elevation/Size Chart420
  - Changing the Main Jet420
- Engine Control Linkage424
- Choke and Air Intake System430
- Fuel Filters435
- Fuel Pump436
- Fuel Tank440
- Fuel Lines445
- Fuel Shut-Off Valve446
Section 15 - Exhaust System449
- General Information450
- Muffler450
  - Muffler Removal450
  - Muffler Installation451
Section 16A - Mc012C-As00 Unitized Transaxle with Differential Lock455
- Transaxle Models and Identification456
  - Lubrication457
- Axle Shaft459
- Unitized Transaxle Removal463
- Unitized Transaxle Disassembly472
- Component Disassembly474
- Unitized Transaxle Component Inspection482
- Unitized Transaxle Assembly488
- Unitized Transaxle Installation496
- Forward/Reverse Shifter Cable504
- Differential Lock System506
Section 16B - Mc010C-Bs00 Unitized Transaxle with Differential Lock509
- Transaxle Models510
  - Lubrication511
- Axle Shaft513
- Unitized Transaxle Removal517
- Unitized Transaxle Disassembly526
- Component Disassembly529
- Unitized Transaxle Component Inspection536
- Unitized Transaxle Assembly542
- Unitized Transaxle Installation549
- Forward/Reverse Shifter Cable557
- Differential Lock System559
Section 17 - Torque Converter563
- General Information564
- Drive Belt566
  - Drive Belt Removal566
  - Drive Belt Installation567
- Drive Clutch567
- Driven Clutch576

Other manuals for Club Car CARRYALL 272

Maintenance And Service Manual312 pages

Questions and Answers:

J
Jeanette ConleySep 6, 2025
Why is only one brake dragging on my Club Car Golf Cars?
- D
  dandersonSep 6, 2025
  If one brake is dragging on your Club Car Golf Cars, several issues could be responsible. It may be due to weak or broken brake shoe return springs, requiring their replacement. Improper brake shoe adjustment can also cause this, necessitating adjustment of the shoes and repair of the brake shoe adjusters if needed. Sticking wheel cylinder pistons should be addressed by replacing the wheel cylinder. Swollen wheel cylinder cups also require wheel cylinder replacement and purging of the hydraulic system. Bent or distorted brake shoes should be replaced. Loose or worn front wheel bearings should be adjusted or replaced. Finally, a damaged brake line or hydraulic line should be replaced as required.
L
llindseyAug 23, 2025
What to do if Club Car Golf Cars pulls to one side when braking?
- J
  James BenitezAug 25, 2025
  If you notice your Club Car Golf Cars pulling to one side when braking, several issues could be the cause. It might be due to incorrect or distorted brake shoes, which would need replacement. Grease or brake fluid on the brake shoe linings can also cause this, requiring replacement of the hub, axle seal, or wheel cylinder along with the brake shoes. A loose or distorted brake cluster backing plate should be tightened or replaced. Scored or warped brake drums should also be replaced. If there's water on the brake shoe linings, applying the brakes several times to dry them may resolve the issue. A sticking wheel cylinder piston requires replacement of the wheel cylinder. Lastly, faulty suspension parts can also lead to pulling, so inspect the steering, front, and rear suspension.
B
bjacksonAug 25, 2025
Why is the brake pedal spongy on my Club Car Golf Cars?
- C
  Charles MorrisonAug 26, 2025
  If the brake pedal on your Club Car Golf Cars feels soft, springy, or spongy when you press it, several factors could be responsible. The brake shoes might be bent or distorted, in which case they should be replaced. The brake drums could be cracked or thin, requiring replacement. Using poor quality brake fluid with a low boiling point can also cause this issue; if this is the case, purge the hydraulic fluid and replace it with approved DOT 5 (silicone) brake fluid. Weak brake hoses that expand under pressure can also create this sensation, so inspect the master cylinder, brake lines, and hoses for leaks or bulges and replace any damaged parts. Finally, air in the hydraulic system can lead to a spongy pedal feel, so ensure the system is properly bled.
R
Richard SmithAug 27, 2025
Why is my Club Car Golf Cars braking too aggressively?
- T
  Theresa GarrettAug 27, 2025
  If you're experiencing over-aggressive braking with your Club Car Golf Cars, it could be due to several factors. The brake shoes may be incorrect or distorted, requiring replacement. Grease or brake fluid on the brake shoe linings can also cause this, necessitating replacement of the hub, axle seal, or wheel brake cylinder along with the brake shoes. A loose or distorted brake backing plate should be tightened or replaced. Scored or warped brake drums should be replaced. A corroded master cylinder bore requires replacement of the master cylinder. Lastly, binding brake pedal linkage should be lubricated and adjusted.
W
William JohnsonAug 27, 2025
Why does my Club Car Golf Cars have a hard brake pedal?
- K
  Kayla GreenAug 27, 2025
  A hard pedal on your Club Car Golf Cars, requiring excessive pressure to stop, can stem from several causes. Brake fade can lead to this issue, suggesting the brake shoes need replacement. Grease or brake fluid on the brake shoe linings can also cause a hard pedal, necessitating replacement of the hub or axle seal along with the brake shoes. Glazed brake shoe linings are another potential cause, also requiring brake shoe replacement.
C
Christine GonzalezAug 28, 2025
What causes a hard brake pedal on Club Car Golf Cars?
- K
  Kimberly RodriguezAug 28, 2025
  A hard brake pedal on your Club Car Golf Cars can be caused by several issues: damaged or distorted brake shoes (replace the brake shoes), scored or barrel-shaped brake shoe drums (replace the brake drums), clogged master cylinder lines or hoses (replace brake lines or hoses), or a frozen master cylinder piston (replace the master cylinder).
S
sherrybrownSep 12, 2025
What to do if my Club Car Utility Vehicle has over-aggressive braking?
- H
  Heather GilmoreSep 13, 2025
  Over-aggressive braking in your Club Car Utility Vehicle may be due to incorrect or distorted brake shoes, grease or brake fluid on the brake shoe linings, a loose or distorted brake backing plate, scored or warped brake drums, a corroded master cylinder bore, or binding brake pedal linkage. Replace the brake shoes, hub, axle seal, or wheel brake cylinder if there is grease or brake fluid on the linings. Tighten or replace the back plate and/or hardware if it is loose or distorted. Replace the brake drums if they are scored or warped. Replace the master cylinder if the bore is corroded. Lubricate and adjust the brake pedal linkage if it is binding.
D
Dylan AndersonSep 14, 2025
Why does my Club Car Utility Vehicle pull to one side when braking?
- A
  Angela TuckerSep 14, 2025
  Your Club Car Utility Vehicle may pull to one side when braking due to incorrect or distorted brake shoes, grease or brake fluid on the brake shoe linings, a loose or distorted brake cluster backing plate, scored or warped brake drums, water on the brake shoe linings, a sticking wheel cylinder piston, or faulty suspension parts. If there is water on the brake shoe linings, apply the brakes several times to dry them. If the backing plate is loose or distorted, tighten or replace the backing plate and/ or hardware. If the wheel cylinder piston is sticking, replace the wheel cylinder.
C
Corey WarnerSep 5, 2025
What to do if brake pedal travel is decreasing on Club Car Golf Cars?
- P
  Patrick LucasSep 5, 2025
  Decreasing brake pedal travel in your Club Car Golf Cars can be caused by a sticking wheel cylinder piston (replace the wheel cylinder), overly adjusted brake adjusters (adjust brake adjusters), or an improperly adjusted park brake (adjust park brake).
M
Miss Stacy SmithSep 2, 2025
Why are the rear brakes dragging on my Club Car Golf Cars?
- J
  Jennifer WatkinsSep 2, 2025
  If the rear brakes are dragging on your Club Car Golf Cars, it could be due to binding park brake cables, which would require adjustment or replacement, followed by adjustment. Alternatively, improper brake adjustment can cause this issue, requiring adjustment of the shoes and repair of the brake shoe adjusters if necessary.

Club Car CARRYALL 272 Specifications

General

Brand	Club Car
Model	CARRYALL 272
Category	Utility Vehicle
Language	English

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