Club Car XRT 1200 User Manual (English)

Questions and Answers:

S
smithstephanieAug 17, 2025
Why does the brake pedal go to the floor on my Club Car Utility Vehicle?
- C
  christophermooreAug 17, 2025
  If the brake pedal on your Club Car Utility Vehicle goes to the floor, it could be due to several reasons: excessive clearance between the drums and shoe linings, automatic adjusters not working, bent or distorted brake shoes, a leak in the hydraulic system, or air in the hydraulic system. Check the master cylinder, brake lines, and hoses for leaks and replace any damaged parts. If the automatic adjusters aren't working, try making several forward and reverse brake stops. If the pedal still doesn't come up, replace the automatic adjusters.
J
Jonathan CraneAug 19, 2025
Why does my Club Car Utility Vehicle require excessive brake pedal pressure to stop?
- C
  Christina AllenAug 19, 2025
  Excessive pedal pressure required to stop your Club Car Utility Vehicle can be caused by several factors. These include brake fade, grease or brake fluid on the brake shoe linings, glazed, damaged, or distorted brake shoes, scored or barrel-shaped brake drums, clogged master cylinder lines or hoses, or a frozen master cylinder piston. If there is grease or brake fluid on the brake shoe linings, replace the hub or axle seal and the brake shoes. If the master cylinder lines or hoses are clogged, replace them as required. If the master cylinder piston is frozen, replace the master cylinder.
F
Frank TylerAug 22, 2025
Why does the brake pedal on my Club Car Utility Vehicle feel spongy?
- T
  Tony DavenportAug 22, 2025
  A soft, springy, or spongy brake pedal on your Club Car Utility Vehicle can be caused by bent or distorted brake shoes, cracked or thin drums, poor quality brake fluid (low boiling point), weak (bulging) brake hoses, or air in the hydraulic system. Check the master cylinder, brake lines, and hoses for leaks or bulges, and replace any damaged parts. If the brake fluid is of poor quality, purge the hydraulic fluid and fill with approved DOT 5 (silicone) brake fluid.
T
thomas61Aug 25, 2025
How to fix squealing brakes on my Club Car Utility Vehicle?
- T
  Teresa NortonAug 26, 2025
  Squealing, clicking, or scraping sounds when applying the brakes on your Club Car Utility Vehicle may be due to bent, damaged, or incorrect brake shoes, worn-out brake shoes, foreign material embedded in the brake shoe linings, broken brake shoe return springs or hold-down springs, rough, grooved, or dry brake shoe edges or backing plate bosses, or cracked or scored brake drums. Replace damaged parts. Lubricate the bosses of the brake cluster backing plate, and/or replace the brake shoes.
R
Richard ArnoldAug 28, 2025
What to do if my Club Car Utility Vehicle has over-aggressive braking?
- M
  Michael WatsonAug 28, 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.
A
amy78Aug 31, 2025
Why does my Club Car Utility Vehicle pull to one side when braking?
- T
  Tammy GarciaAug 31, 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.
J
Jennifer SandersSep 2, 2025
What causes a pulsating brake pedal on my Club Car Utility Vehicle?
- J
  Jerry HoffmanSep 2, 2025
  A pulsating brake pedal in your Club Car Utility Vehicle can be caused by warped brake drums or a bent axle. Replace the brake drums if they are warped.
T
tromeroSep 5, 2025
Why is one brake dragging on my Club Car Utility Vehicle?
- S
  Scott SullivanSep 5, 2025
  One brake dragging on your Club Car Utility Vehicle can be caused by weak or broken brake shoe return springs, improper brake shoe adjustment, sticking wheel cylinder pistons, swollen wheel cylinder cups, bent or distorted brake shoes, or a damaged brake line or hydraulic line. Replace the return springs if they are weak or broken. Adjust the shoes and repair the brake shoe adjusters if necessary due to improper brake shoe adjustment. Replace the wheel cylinder if the pistons are sticking or the cups are swollen. Replace brake lines or tubes as required if they are damaged.
M
Monica RodriguezSep 8, 2025
What causes decreasing brake pedal travel in my Club Car Utility Vehicle?
- M
  Mary RyanSep 8, 2025
  Decreasing brake pedal travel in your Club Car Utility Vehicle can be caused by weak or broken brake shoe return springs, a sticking wheel cylinder piston, overly adjusted brake adjusters, or an improperly adjusted park brake. Replace the return springs if they are weak or broken. Replace the wheel cylinder if the piston is sticking. Adjust the brake adjusters if they are overly adjusted. Adjust the park brake if it is improperly adjusted.
R
Richard GallowaySep 12, 2025
Why are all the brakes dragging on my Club Car Utility Vehicle?
- M
  Mrs. Amy Ellis MDSep 12, 2025
  All brakes dragging on your Club Car Utility Vehicle may be due to a binding brake pedal or soft or swollen rubber parts caused by incorrect or contaminated brake fluid. Lubricate and adjust the brake pedal if it is binding. Replace master cylinder if rubber parts are soft or swollen.

Club Car XRT 1200 Specifications

General

Brand	Club Car
Model	XRT 1200
Category	Utility Vehicle
Language	English

Summary

Section 1: Safety

General Warning

General safety precautions for operating, repairing, or servicing Club Car vehicles.

Section 2: Vehicle Specifications

Section 5: Accelerator and Brake Pedal Assemblies

Brake Pedal

Information on removing, installing, and adjusting the brake pedal assembly.

Brake Pedal Adjustment

Detailed steps for adjusting the brake pedal height and ensuring proper free play.

Accelerator Pedal

Information on removing, installing, and adjusting the accelerator pedal assembly.

Accelerator Pedal Adjustment

Steps to adjust the accelerator pedal height and ensure correct linkage operation.

Section 6: MC012C-BS00 Unitized Transaxle: Hydraulic and Park Brake Systems

Brake System Inspection

Procedures for inspecting the hydraulic and park brake systems for proper function and wear.

Brake System Troubleshooting

Guide to diagnose and resolve common brake system issues.

Front Wheel Brake Drum Removal

Step-by-step instructions for removing the front wheel brake drum.

Rear Wheel Brake Drum Removal

Procedure for removing the brake drum from the rear wheels.

Brake Shoe Removal

Steps for removing the front and rear brake shoes from the brake cluster.

Brake Cluster Inspection and Cleaning

Guide to inspect and clean brake cluster components for proper function.

Brake Shoe Installation

Procedures for installing brake shoes into the front and rear brake clusters.

Front Wheel Brake Drum Installation

Steps for installing the front wheel brake drum onto the spindle.

Rear Wheel Brake Drum Installation

Steps for installing the rear wheel brake drum onto the axle.

Front Brake Cluster Assembly Removal

Procedure to remove the front brake cluster assembly from the spindle plate.

Front Brake Cluster Assembly Installation

Procedure to install the front brake cluster assembly onto the spindle plate.

Rear Brake Cluster Assembly Removal

Procedure to remove the rear brake cluster assembly from the axle tube flange.

Rear Brake Cluster Assembly Installation

Procedure to install the rear brake cluster assembly onto the axle tube flange.

Wheel Cylinder Replacement

Procedures for removing and installing the front and rear wheel cylinders.

Brake Shoe Adjuster Replacement

Procedures for replacing brake shoe adjusters in the front and rear brake clusters.

Hydraulic Line and Hose Replacement

General warning about opening the hydraulic system and procedures for replacing brake lines and hoses.

Front Brake Line Removal

Steps to remove the front brake line from the master cylinder and T-manifold block.

Front Brake Line Installation

Steps to install the front brake line to the master cylinder and T-manifold block.

Front Brake Hose Assembly Removal

Procedure to remove the front brake hose assembly from the wheel cylinder and T-manifold block.

Front Brake Hose Assembly Installation

Procedure to install the front brake hose assembly to the wheel cylinder and T-manifold block.

Rear Brake Line Removal

Steps to remove the rear brake lines from the master cylinder and brake hoses.

Master Cylinder and Bell Crank Replacement

Master Cylinder Installation

Bleeding the Hydraulic Brake System

Detailed procedure for bleeding air from the hydraulic brake system.

Park Brake System

Information on inspecting and adjusting the park brake system.

Park Brake Cable Installation

Equalizer Cable Installation

Wheel Brake Cable Installation

Park Brake Handle Removal

Park Brake Handle Installation

Park Brake Adjustment

Step-by-step guide to adjust the park brake system for proper operation.

Section 7: Steering and Front Suspension

Rack and Pinion

Rack and Pinion Disassembly

Rack and Pinion Assembly

Wheel Alignment

Front Wheel Bearings and Hubs

Section 10: Periodic Maintenance

Periodic Service Schedule

Schedule outlining regular maintenance tasks based on time or operating hours.

Periodic Lubrication Schedule

Schedule detailing lubrication points and recommended lubricants for regular maintenance.

Engine Oil

Information on checking and maintaining the engine oil level.

Engine Oil and Filter Change

Procedures for changing the engine oil and oil filter at recommended intervals.

Fueling Instructions

Safety precautions and steps for fueling the vehicle.

Section 11: Troubleshooting and Electrical System: FE400, Key-Start Engine

Troubleshooting Guide

Guide to identify and resolve common symptoms and their possible causes.

Circuit Testing

General guidance and required tools for testing electrical circuits.

Wiring Diagrams

Electrical wiring diagrams for FE400 Key-Start 272/1200 vehicles.

Test Procedure 1: Battery

Procedures for testing the vehicle battery, including hydrometer and voltage tests.

Test Procedure 2: Fuse

Procedure for testing the main fuse in the electrical component box.

Test Procedure 3: Ground Cables

Procedure for testing the integrity of the starter/generator and engine ground straps.

Test Procedure 4: Key Switch (Starter Circuit)

Procedure to test the key switch for proper operation of the starter circuit.

Test Procedure 6: Solenoid

Procedure to test the solenoid for proper continuity and voltage response.

Test Procedure 7: Lockout Cam Limit Switch

Procedure to test the lockout cam limit switch for correct activation in neutral position.

Test Procedure 8: Starter/Generator (Starter Function)

Procedure to test the starter/generator for proper starter function.

Test Procedure 9: Wire Continuity

Procedure to test wires for continuity using a multimeter.

Test Procedure 10: Diode (Generator Circuit)

Procedure to test the diode in the generator circuit for proper function.

Test Procedure 11: Starter/Generator (Generator Function)

Procedure to test the starter/generator for proper generator function.

Test Procedure 12: Voltage Regulator

Procedure to test the voltage regulator for correct output voltage.

Test Procedure 13: Grounded Kill Wire

Procedure to test the engine kill wire for grounding issues.

Test Procedure 14: Ignition Spark

Procedure to test the ignition system for proper spark.

Test Procedure 15: RPM Limiter

Procedure to test the RPM limiter for correct operation.

Test Procedure 16: Ignition Coil

Procedure to test the ignition coil for resistance and function.

Test Procedure 17: Key Switch (Engine Kill Circuit)

Procedure to test the key switch for the engine kill circuit function.

Test Procedure 18: Engine Kill Wire

Procedure to test the engine kill wire for proper grounding.

Test Procedure 21: Oil Level Sensor

Procedure to test the oil level sensor for correct operation.

Test Procedure 22: Oil Warning Light

Procedure to test the oil warning light for proper illumination.

Test Procedure 23: Lockout Cam

Procedure to check the lockout cam for proper engagement with the limit switch.

Test Procedure 24: Battery Test (Under Load)

Procedure to test the battery's performance under load.

Test Procedure 25: Fuel Level Sending Unit

Procedure to test the fuel level sending unit for correct resistance readings.

Section 12: Electrical Components: FE400, Key-Start Engine

Starter/Generator (Model G425419)

Bearing Cleaning and Inspection

Visual Inspection of Armature

Commutator Cleaning and Inspection

Belt Tension Adjustment

Starter/Generator (Model 114-01-4005)

Brush Inspection and Replacement

Brush Spring Inspection and Replacement

Voltage Regulator

Diode

Key Switch

Solenoid

Lockout Cam Limit Switch

Lockout Cam

Oil Warning Light

RPM Limiter

Ignition Coil

Oil Level Sensor

Battery

Information on battery testing, preventive maintenance, self-discharge, water level, and vibration damage.

Ground Cables

Section 13: FE400 Engine

Spark Plug

Engine Removal

Crankcase Cover Removal

Oil Level Sensor

Ignition Coil and Flywheel

Crankcase Cover Installation

Flywheel Installation

Engine Installation

Torque Specifications

Table of torque specifications for FE400 engine components.

Adjustment and Settings

Table of adjustment and setting specifications for the FE400 engine.

Section 14: Fuel System

Carburetor

Fuel Pump

Fuel Pump Cleaning and Inspection (Metal Pump Only)

Fuel Pump Assembly (Metal Pump Only)

Fuel Pump Installation

Fuel Tank

Fuel Tank Installation

Engine Control Linkage

Accelerator Rod

Accelerator Cable

Closed Throttle or Idle Adjustment

Engine RPM Adjustment

Procedure to adjust the engine RPM to the specified governed speed.

Section 15: Exhaust System

Section 16: MC012C-BS00 Unitized Transaxle with Differential Lock

Axle Shaft

Axle Shaft, Bearing, and Oil Seal Removal

Axle Shaft, Bearing, and Oil Seal Installation

Unitized Transaxle Removal

Unitized Transaxle Installation

Differential Lock System

Differential Lock Cable Removal

Differential Lock Cable Installation

Section 17: Torque Converter

Troubleshooting

Troubleshooting steps for issues related to the torque converter, governor, and engine RPM.

Drive Belt

Drive Clutch

Drive Clutch Cleaning and Inspection

Drive Clutch Disassembly

Inspection of Drive Clutch Parts

Drive Clutch Assembly

Driven Clutch

Driven Clutch Inspection

Driven Clutch Assembly

Driven Clutch Installation

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Club Car XRT 1200 User Manual

Table of Contents

Questions and Answers:

Club Car XRT 1200 Specifications

Summary

Section 1: Safety

General Warning

Section 2: Vehicle Specifications

Section 5: Accelerator and Brake Pedal Assemblies

Brake Pedal

Brake Pedal Adjustment

Accelerator Pedal

Accelerator Pedal Adjustment

Section 6: MC012C-BS00 Unitized Transaxle: Hydraulic and Park Brake Systems

Brake System Inspection

Brake System Troubleshooting

Front Wheel Brake Drum Removal

Rear Wheel Brake Drum Removal

Brake Shoe Removal

Brake Cluster Inspection and Cleaning

Brake Shoe Installation

Front Wheel Brake Drum Installation

Rear Wheel Brake Drum Installation

Front Brake Cluster Assembly Removal

Front Brake Cluster Assembly Installation

Rear Brake Cluster Assembly Removal

Rear Brake Cluster Assembly Installation

Wheel Cylinder Replacement

Brake Shoe Adjuster Replacement

Hydraulic Line and Hose Replacement

Front Brake Line Removal

Front Brake Line Installation

Front Brake Hose Assembly Removal

Front Brake Hose Assembly Installation

Rear Brake Line Removal

Master Cylinder and Bell Crank Replacement

Master Cylinder Installation

Bleeding the Hydraulic Brake System

Park Brake System

Park Brake Cable Installation

Equalizer Cable Installation

Wheel Brake Cable Installation

Park Brake Handle Removal

Park Brake Handle Installation

Park Brake Adjustment

Section 7: Steering and Front Suspension

Rack and Pinion

Rack and Pinion Disassembly

Rack and Pinion Assembly

Wheel Alignment

Front Wheel Bearings and Hubs

Section 10: Periodic Maintenance

Periodic Service Schedule

Periodic Lubrication Schedule

Engine Oil

Engine Oil and Filter Change

Fueling Instructions

Section 11: Troubleshooting and Electrical System: FE400, Key-Start Engine

Troubleshooting Guide

Circuit Testing

Wiring Diagrams

Test Procedure 1: Battery

Test Procedure 2: Fuse

Test Procedure 3: Ground Cables

Test Procedure 4: Key Switch (Starter Circuit)

Test Procedure 6: Solenoid

Test Procedure 7: Lockout Cam Limit Switch

Test Procedure 8: Starter/Generator (Starter Function)

Test Procedure 9: Wire Continuity

Test Procedure 10: Diode (Generator Circuit)

Test Procedure 11: Starter/Generator (Generator Function)

Test Procedure 12: Voltage Regulator

Test Procedure 13: Grounded Kill Wire

Test Procedure 14: Ignition Spark

Test Procedure 15: RPM Limiter

Test Procedure 16: Ignition Coil

Test Procedure 17: Key Switch (Engine Kill Circuit)

Test Procedure 18: Engine Kill Wire

Test Procedure 21: Oil Level Sensor

Test Procedure 22: Oil Warning Light