Name: Club Car XRT 800
Brand: Club Car
Rating: 4 (1 reviews)

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MANUAL NUMBER

103209106

EDITION CODE 0907D0808C

XRT 800, 810 and 850

GASOLINE/ELECTRIC

2007-2008

MAINTENANCE

SERVICE

MANUAL

Club Car, Inc.

P.O. Box 204658

Augusta, GA 30917-4658

USA

Web www.clubcar.com

Phone 1.706.863.3000

1.800.ClubCar

Int’l +1 706.863.3000

Fax 1.706.863.5808

Default Chapter5
- Table of Contents5
Section 1 - Safety17
- General Warning17
Section 2 - Vehicle Specifications21
- 800 And 810 Specifications21
- Specifications21
Section 3 - General Information25
- Serial Number Identification25
- Storage - Gasoline Vehicle26
  - Preparing the Gasoline Vehicle for Extended Storage26
  - Returning the Stored Gasoline Vehicle to Service28
- Storage - Electric Vehicle28
  - Preparing the Electric Vehicle for Extended Storage29
  - Returning the Stored Electric Vehicle to Service29
Section 4 - Body and Trim31
- Cleaning the Vehicle31
  - Seat Cleaning31
- Front and Rear Body Repair32
- Front Body - 800 and 81033
- Front Body - 85035
- Cargo Bed - 800 and 81038
- Seat Back Support Brackets - 800 and 81041
  - Seat Back Support Bracket Removal41
  - Seat Back Support Bracket Installation42
- Rear Body and Fenders - 800 and 81042
- Rear Body - 85045
  - Rear Body Removal45
  - Rear Body Installation49
- Floor Mat49
  - Floor Mat Removal49
  - Floor Mat Installation49
Section 5 - Accelerator and Brake Pedal Group51
- Brake Pedal and Park Brake51
- Accelerator Pedal - Gasoline Vehicles55
  - Accelerator Pedal Removal55
  - Accelerator Pedal Installation57
- Accelerator Pedal - Electric Vehicles58
  - Accelerator Pedal Removal58
  - Accelerator Pedal Installation60
- Pedal Group Adjustment - Gasoline Vehicle61
- Pedal Group Adjustment - Electric Vehicles66
Section 6 - Wheel Brake Assemblies71
- Brake Shoe Removal71
- Brake Assembly Cleaning75
- Brake Shoe Installation76
- Brake Adjustment78
- Brake Cluster Removal and Installation78
  - Brake Cluster Installation79
- Brake Cable Removal and Installation80
Section 7 - Steering and Front Suspension83
- General Information83
- Steering Wheel83
  - Steering Wheel Removal83
  - Steering Wheel Installation84
- Steering Column84
- Steering Adjustment88
- Rack and Pinion89
- Tie Rod and Drag Link94
  - Tie Rod and Drag Link Removal94
  - Tie Rod and Drag Link Installation94
- Front Suspension95
  - Lubrication95
  - Wheel Alignment95
- Front Suspension Components97
- Front Wheel Bearings and Hubs101
Section 8 - Wheels and Tires103
- General Information103
- Wheels103
  - Wheel Removal103
  - Wheel Installation103
- Tires103
Section 9 - Rear Suspension107
- General Information107
- Shock Absorbers107
  - Shock Absorber Removal and Inspection107
  - Shock Absorber Installation107
- Leaf Springs108
Section 10 - Periodic Maintenance115
- General Information115
- Periodic Service Schedules115
- Periodic Lubrication Schedules118
- Engine Oil - Gasoline Vehicles120
Section 11 - Troubleshooting and Electrical System: 800 and 810 Gas125
- General Information125
- Troubleshooting Guide125
- Electrical System129
- Lockout Cam129
- Wiring Diagrams130
- Test Procedures132
  - Index of Test Procedures132
Section 12 - Troubleshooting and Electrical System: 850 Gas163
- General Information163
- Troubleshooting Guide163
- Wiring Diagram168
- Electrical System170
- Test Procedures170
  - Index of Test Procedures170
Section 13 - Electrical Components: 800 and 810 Gasoline Vehicles200
- Starter/Generator201
- Belt Tension Adjustment208
- Voltage Regulator209
- Diode210
- Key Switch212
- Solenoid213
- Fuse214
- Lockout Cam Limit Switch215
- Lockout Cam216
- Reverse Warning Buzzer217
- Reverse Buzzer Limit Switch218
- Oil Warning Light218
- Fuel Gauge/Hour Meter219
- Fuel Level Sending Unit220
- RPM Limiter221
- Ignition Coil222
- Oil Level Sensor225
- Headlights225
- Voltage Limiter226
- Light Switch227
- Battery228
- General Information228
  - Charging the Battery231
  - Battery Installation231
- Battery Storage231
- Ground Cables232
Section 14 - Electrical Components: 850 Gasoline Vehicle234
- Starter/Generator234
- Voltage Regulator243
- Key Switch244
- Solenoid246
- Fuse246
- Kill Limit Switch247
- Neutral Lockout Limit Switch248
- Reverse Warning Buzzer250
- Reverse Buzzer Limit Switch251
- Low Oil Warning Light252
- Fuel Gauge/Hour Meter253
- Fuel Level Sending Unit254
- RPM Limiter254
- Ignition Coil255
- Oil Level Sensor258
- Headlights258
- Voltage Limiter260
- Headlight Switch261
- Battery262
- Ground Cables266
Section 15 - Engine267
- General Information267
- Cylinder Head269
  - General Information269
  - Breather Valve (Reed Valve)269
- Crankcase269
- Ignition Coil and Flywheel272
- Flywheel Installation274
- Engine Installation275
  - Torque Specifications276
  - Adjustments and Settings276
Section 16 - Fuel System: Gasoline Vehicle277
- General Information277
- Carburetor277
  - Main Jet Elevation/Size Chart279
  - Changing the Main Jet279
- Engine Control Linkage282
- Choke and Air Intake System288
- Fuel Filters293
  - Fuel Filter Removal293
  - Fuel Filter Installation293
- Fuel Pump295
- Fuel Tank297
- Fuel Lines301
- Fuel Shut-Off Valve301
- Fueling Instructions302
- Drive Clutch316
- Troubleshooting349
- Drive Belt350
Section 21 - Electrical System and Testing: Electric Vehicle365
- General Information365
- Wiring Diagram366
- Xrt 800, 810 and 850 Maintenance and Service Manual367
- Troubleshooting368
- Communication Display Module (CDM)397
  - Using the CDM to Retrieve Data from the Onboard Computer398
  - CDM Troubleshooting Guide399
Section 22 - Iq Display Module (Iqdm) and Iqdm-P Diagnostics402
- Menu Navigation402
- Introductory Display402
- Monitor Menu404
- Faults Menu406
- Functions Menu411
- Iqdm and Iqdm-P Handset Troubleshooting416
Section 23 - Electrical Components: Electric Vehicle421
- Key Switch – 800 and421
- Forward/Reverse Switch – 800 and424
- Tow/Run Switch427
- Motor Controller Output Regulator (Mcor)428
- Reverse Buzzer429
- Onboard Computer (Obc)431
- Solid State Speed Controller433
- Charger Receptacle435
- Battery Warning Light437
Section 24 – Batteries: Electric Vehicles439
- Battery Troubleshooting Chart440
- Battery Testing441
  - Battery Troubleshooting Examples445
- Battery Replacement446
- Battery Care447
  - Electrolyte Level448
- Battery Charger450
- Charging a Battery Pack that Has Low Voltage454
  - Field Windings Inspection462
  - Motor Components462
- Motor Speed Sensor471
- Armature Inspection and Testing478
- Motor Frame and Field Windings Inspection479
- Motor Brush, Spring, and Terminal Insulator Inspection480
Section 28 - Transaxle (Type G): Electric Vehicle489
- Transaxle Identification489
- Axle Bearing and Shaft489
  - Transaxle Removal493
- Transaxle Disassembly, Inspection, and Assembly495
  - Transaxle Disassembly and Inspection495
  - Transaxle Assembly497
- Transaxle Installation498
- Program Menu502

Brand	Club Car
Model	XRT 800
Category	Utility Vehicle
Language	English

Club Car XRT 800 User Manual

Table of Contents

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Club Car XRT 800 Specifications

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