Club Car XRT 810 User Manual

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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

Table of Contents

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

Questions and Answers:

J
Jennifer NormanSep 9, 2025
Why does the transmission on my Club Car Utility Vehicle not engage or disengage smoothly?
- J
  justinkingSep 10, 2025
  If the transmission in your Club Car Utility Vehicle doesn't engage or disengage smoothly, several factors could be responsible. The transmission shifter linkage might be binding or out of adjustment, so adjust the linkage. If the idle RPM setting is too high, adjust it to the correct level. Also, an insufficient or incorrect type of lubricant in the transmission can cause this issue; check and refill or replace the lubricant. Internal gears that are damaged or worn, or synchronizer rings that are worn, damaged, or jammed can also cause this issue, so inspect and replace them as necessary.
M
Martin WallaceSep 12, 2025
What causes the engine to pre-ignite in a Club Car Utility Vehicle?
- B
  Brian JohnsonSep 12, 2025
  If your Club Car Utility Vehicle engine pre-ignites, it could be due to several reasons. The spark plug heat range might be incorrect, so replace the spark plug with the correct heat range. Also, unsuitable or contaminated fuel can cause pre-ignition, so use appropriate fuel.
J
Jesus HallSep 14, 2025
What causes a Club Car Utility Vehicle carburetor to flood?
- T
  Tammy OliverSep 14, 2025
  If the carburetor in your Club Car Utility Vehicle is flooding, it could be due to several reasons. The inlet valve or seat might be leaking, dirty, worn, or damaged, so inspect and clean or replace the inlet valve or seat. A damaged float filled with gasoline can also cause flooding, so replace the float. Additionally, a clogged carburetor vent or a malfunctioning float needle valve can lead to this issue, so clean the carburetor vent and inspect and replace the float needle valve.

Club Car XRT 810 Specifications

General

Brand	Club Car
Model	XRT 810
Category	Utility Vehicle
Language	English

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