Club Car TURF 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

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Club Car TURF 272 Specifications

General

Brand	Club Car
Model	TURF 272
Category	Utility Vehicle
Language	English

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