2007 Club Car Turf Carryall 2 252 2 Plus XRT 900 Illustrated Parts List

Manual Number 103209004 Edition Code 0107L0112K Turf/Carryall 2, 252, 2 Plus, and XRT 900 Gasoline and Electric Vehicles 2007 Turf/Carryall 2, 252, 2 Plus, and XRT 900 Illustrated Parts List

P. O. Box 204658 Augusta, Georgia 30917-4658 USA Telephone 706-863-3000 Service Parts Fax 706-855-7413 www.clubcar.com USING THE ILLUSTRATED PARTS LIST ý WARNING • This manual is to be used only for identification and ordering of service parts. Be sure to read and use the maintenance and service manual before attempting any vehicle repairs. This manual covers all Turf/Carryall 2, 252, 2 Plus and XRT 900 vehicles built during the 2007 model year. The manual is divided into sections. Note that there are two or three flags on the outside edge of each page. The first flag contains the section number of which that page is a part. The other flag (or flags) contains the letter G or E, signifying that the page pertains to the electric or gasoline vehicles only. Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table of Contents lists section numbers, and under them, the individual page titles and numbers to be found in that section. The index can be used to find specific parts and assemblies. The index is divided into numerical and alphabetical listings with the page numbers in italic text. There is a two-page spread for each individual page title in the Table of Contents. On the left-hand page is an illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon. The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding to the numbers on the illustration), part descriptions, and quantity of parts used. Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indented to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level 2 part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the part quantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. A part that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion of the vehicle illustrated on that particular spread. HOW TO ORDER PARTS Replacement parts and accessories can be obtained from our network of authorized dealers and distributors. You can obtain the name and phone number of your closest authorized Club Car dealer or distributor by visiting our web site at www.clubcar.com and clicking on the “Distributor Search” link or by calling our toll-free Service Parts and Technical Assistance hotline at (800) 872-2246 or (706) 863-3000, extension 3887.

2007 Turf/Carryall 2, 252, 2 Plus, and XRT 900 Gasoline and Electric Vehicle Illustrated Parts List NOTE: This illustrated parts list represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect the parts used to service the vehicle. Any modification and/or significant change in specifications will be for- warded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of this illustrated parts list. Club Car, Inc. reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold. Copyright © 2007 Club Car, Inc. Club Car and ArmorFlex are registered trademarks of Club Car, Inc. This manual effective July 31, 2006.

2007 Turf/Carryall 2, 252, 2 Plus, and XRT 900 Gasoline and Electric Vehicle Illustrated Parts List Page 1 CONTENTS SECTION 1 – BODY AND TRIM Front Body and Trim – Turf/Carryall 2 and Carryall 2 Plus ............................................................................................... 1-3 Front Body and Trim – Turf/Carryall 252 and XRT 900 ...................................................................................................... 1-5 Dash Pockets and Floormat ........................................................................................................................................................ 1-7 Beverage Holder ............................................................................................................................................................................. 1-9 Seat Bottom ...................................................................................................................................................................................... 1-11 Seat Back Assembly ....................................................................................................................................................................... 1-13 Hip Restraints and Seat Back Mounting ................................................................................................................................. 1-15 Tilt Bed, Hinge, and Latch – Turf/Carryall 2, 252, 2 XRT, and Carryall 2 Plus ............................................................. 1-17 Latch Plate ........................................................................................................................................................................................ 1-19 Prop Rod ............................................................................................................................................................................................ 1-21 Cargo Box (Aluminum) ................................................................................................................................................................. 1-23 Cargo Box Mounting ..................................................................................................................................................................... 1-25 Cargo Box (Steel) ............................................................................................................................................................................ 1-27 Trailer Hitch ...................................................................................................................................................................................... 1-29 Receiver Hitch – XRT 900 ............................................................................................................................................................. 1-31 Rear Body Trim – Turf/Carryall 2, and Carryall 2 Plus ........................................................................................................ 1-33 Rear Body Trim – Turf/Carryall 252 and XRT 900 ................................................................................................................ 1-35 SECTION 2 – WHEELS AND TIRES Wheels and Tires – Turf/Carryall 2 ............................................................................................................................................ 2-3 Wheels and Tires, Off-Road Tread – Turf/Carryall 252 and XRT 900 ............................................................................ 2-5 Wheels and Tires, Turf Tread – Turf/Carryall 252 and XRT 900 ...................................................................................... 2-7 SECTION 3 – DECALS Decals – Turf/Carryall 2 IQ Plus Vehicles ................................................................................................................................ 3-3 Decals – Turf/Carryall 2 IQ Plus Vehicles, Continued ......................................................................................................... 3-5 Decals – Turf/Carryall 252 and XRT 900 IQ Plus Vehicles ................................................................................................. 3-7 Decals – Turf/Carryall 252 and XRT 900 IQ Plus Vehicles, Continued .......................................................................... 3-9 Decals – Turf/Carryall 2 Gasoline Vehicles ............................................................................................................................ 3-11 Decals – Turf/Carryall 2 Gasoline Vehicles, Continued ..................................................................................................... 3-13 Decals – Carryall 2 Plus Gasoline Vehicles ............................................................................................................................. 3-15 Decals – Carryall 2 Plus Gasoline Vehicles, Continued ..................................................................................................... 3-17 Decals – Turf/Carryall 252 Gasoline Vehicles ....................................................................................................................... 3-19 Decals – Turf/Carryall 252 Gasoline Vehicles, Continued ................................................................................................ 3-21 Decals – XRT 900 Gasoline Vehicles ......................................................................................................................................... 3-23 Decals – XRT 900 Gasoline Vehicles, Continued ................................................................................................................. 3-25 Decals, Logo – Turf/Carryall 2, and Carryall 2 Plus ............................................................................................................. 3-27

2007 Turf/Carryall 2, 252, 2 Plus, and XRT 900 Gasoline and Electric Vehicle Illustrated Parts List CONTENTS Decals, Logo – Turf/Carryall 252 ................................................................................................................................................ 3-29 Decals, Logo – XRT 900 ................................................................................................................................................................. 3-31 SECTION 4 – BRAKES, PEDAL, AND CABLE ASSEMBLIES Rear Brake Assembly, Self-Adjusting – Vehicle with 2-Wheel Brakes .......................................................................... 4-3 Rear Brake Assembly, Manually-Adjusted – Vehicles with 4-Wheel Brakes ............................................................... 4-5 Brake Pedal Assembly – Vehicles with Two-Wheel Brakes .............................................................................................. 4-7 Brake Pedal Assembly – IQ Plus Vehicles ............................................................................................................................... 4-9 Front Brake Assembly – Vehicles with Four-Wheel Brakes .............................................................................................. 4-11 Front Brake Cables and Equalizer – Vehicles with Four-Wheel Brakes ........................................................................ 4-13 Front Brake Cable Clips and Hardware – Vehicles with Front-Wheel Brakes ............................................................ 4-15 Brake Cables and Equalizer – Turf/Carryall 2 Vehicles with Two-Wheel Brakes ....................................................... 4-17 Rear Brake Cables and Equalizer – IQ Plus Electric Vehicles ............................................................................................ 4-19 Accelerator Pedal Assembly – Electric Vehicles with MCOR ........................................................................................... 4-21 Accelerator Rod ............................................................................................................................................................................... 4-23 SECTION 5 – STEERING, FRONT AND REAR SUSPENSION Steering Column – All Vehicles Except Turf/Carryall 252 and XRT 900 ....................................................................... 5-3 Steering Column – Turf/Carryall 2 XRT and Turf/Carryall 252 Vehicles ....................................................................... 5-5 Steering Wheel – Turf Vehicles .................................................................................................................................................. 5-7 Steering Wheel – Carryall and XRT Vehicles .......................................................................................................................... 5-9 Steering Gear Assembly ............................................................................................................................................................... 5-11 Front Frame Plates – Turf/Carryall 252 and XRT 900 .......................................................................................................... 5-13 Front Suspension, Upper ............................................................................................................................................................. 5-15 Front Suspension, Lower .............................................................................................................................................................. 5-17 Front Suspension, Upper – Turf/Carryall 252 and XRT 900 .............................................................................................. 5-19 Front Suspension, Lower – Turf/Carryall 252 and XRT 900 .............................................................................................. 5-21 Front Suspension, Upper – Turf/Carryall 2 and 2 Plus with Four-Wheel Brakes ...................................................... 5-23 Front Suspension, Lower – Turf/Carryall 2 and 2 Plus with Four-Wheel Brakes ....................................................... 5-25 Front Spindles and Hubs – Vehicles with Two-Wheel Brakes ......................................................................................... 5-27 Front Spindles and Hubs – Vehicles with Four-Wheel Brakes ........................................................................................ 5-29 Steering Gear Assembly ............................................................................................................................................................... 5-31 Rear Suspension – Gasoline Turf/Carryall 2 and Carryall 2 Plus ..................................................................................... 5-33 Rear Suspension – Gasoline Turf/Carryall 252 and XRT 900 ............................................................................................ 5-35 Rear Suspension – Turf/Carryall 2 IQ Plus Vehicles ............................................................................................................. 5-37 Rear Suspension – Turf/Carryall 252 and XRT 900 IQ Plus Vehicles .............................................................................. 5-39 Stabilizer Bar – Turf/Carryall 2, 6, and Carryall 2 Plus Gasoline Vehicles ..................................................................... 5-41 Stabilizer Bar – Turf/Carryall 2 and Carryall 2 Plus Gasoline Vehicles .......................................................................... 5-43

2007 Turf/Carryall 2, 252, 2 Plus, and XRT 900 Gasoline and Electric Vehicle Illustrated Parts List Page 3 CONTENTS SECTION 6 – ELECTRICAL SYSTEM – GASOLINE VEHICLE Wiring – Turf/Carryall 2 and 252 ............................................................................................................................................... 6-5 Wiring – Carryall 2 Plus ................................................................................................................................................................. 6-9 Wiring – XRT 900 ............................................................................................................................................................................ 6-13 Headlight and Horn Electrical Components ........................................................................................................................ 6-15 Headlights ......................................................................................................................................................................................... 6-17 Electrical Component Box – Turf/Carryall 2, and 252 ........................................................................................................ 6-19 Electrical Component Box – XRT 900 ...................................................................................................................................... 6-21 Electrical Component Box – Carryall 2 Plus .......................................................................................................................... 6-23 Instrument Panel and Electrical Components – XRT 900 and Carryall 2 Plus .......................................................... 6-25 Instrument panel and Electrical Components – Turf/Carryall 2 and 252 ................................................................... 6-27 Horn and Brake Switches ............................................................................................................................................................. 6-29 Starter/Generator Assembly Model G425419 – Gasoline Vehicles .............................................................................. 6-31 FE350 Starter/Generator Mounting – Gasoline Vehicles ................................................................................................. 6-33 Battery – Gasoline Vehicle ........................................................................................................................................................... 6-35 Operation and Maintenance Switch ....................................................................................................................................... 6-37 SECTION 7 – FE350 ENGINE WITH ACR (CARRYALL 2 PLUS) FE350 Engine with ACR (Automatic Compression Release) – Shrouds and Brackets ........................................... 7-3 AS11 FE350 Engine – Ignition Components and Flywheel ............................................................................................. 7-5 FE350 Engine – Oil Circulation .................................................................................................................................................. 7-7 AS11 FE350 Engine – Cylinder Head ....................................................................................................................................... 7-9 FE350 Engine with ACR – Crankcase, Camshaft, and Oil Sensor ................................................................................... 7-11 AS11 FE350 Engine – Crankcase and Crankshaft ................................................................................................................ 7-13 Engine Mounting – Turf/Carryall 252 and XRT 900 ............................................................................................................ 7-15 FE350 Engine Mounting – Turf/Carryall 2 and Carryall 2 Plus ........................................................................................ 7-17 SECTION 8 – FE350 ENGINE WITHOUT ACR (TURF/CA 2, 252 AND XRT 900) AS11 FE350 Engine without ACR (Automatic Compression Release) – Shrouds and Brackets ......................... 8-3 AS11 FE350 Engine – Ignition Components and Flywheel ............................................................................................. 8-5 FE350 Engine – Oil Circulation .................................................................................................................................................. 8-7 AS11 FE350 Engine – Cylinder Head ....................................................................................................................................... 8-9 AS11 FE350 Engine without ACR – Crankcase, Camshaft, and Oil Sensor ................................................................. 8-11 AS11 FE350 Engine – Crankcase and Crankshaft ................................................................................................................ 8-13 Engine Mounting – Turf/Carryall 252 and 2 XRT ................................................................................................................. 8-15 FE350 Engine Mounting .............................................................................................................................................................. 8-17

2007 Turf/Carryall 2, 252, 2 Plus, and XRT 900 Gasoline and Electric Vehicle Illustrated Parts List CONTENTS SECTION 9 – EXHAUST SYSTEM Exhaust System – FE350 Engine ................................................................................................................................................ 9-3 SECTION 10 – FUEL, INTAKE, AND GOVERNOR SYSTEMS Splash Guard ..................................................................................................................................................................................... 10-3 Fuel Tank (Non-Clifornia) with Sending Unit ........................................................................................................................ 10-5 Fuel System ....................................................................................................................................................................................... 10-7 Carburetor Assembly – FE350 .................................................................................................................................................... 10-9 Carburetor Installation – FE350 ................................................................................................................................................. 10-11 Governor and Accelerator Cables ............................................................................................................................................. 10-13 Air Box and Intake Hose ................................................................................................................................................................ 10-15 Intake System ................................................................................................................................................................................... 10-17 Fuel Tank (California) with Sending Unit ................................................................................................................................ 10-19 SECTION 11 – TORQUE CONVERTER Drive Clutch – Turf/Carryall 2, and 252 ................................................................................................................................... 11-3 Drive Clutch – XRT 900 .................................................................................................................................................................. 11-5 Drive Clutch – Carryall 2 Plus ...................................................................................................................................................... 11-7 Drive Belt – FE350 ........................................................................................................................................................................... 11-9 Driven Clutch – Turf/Carryall 2, 252 ......................................................................................................................................... 11-11 Driven Clutch – Carryall 2 Plus, and XRT 900 ........................................................................................................................ 11-13 SECTION 12 – UNITIZED TRANSAXLE Unitized Transaxle – Gear Cases and Brackets ..................................................................................................................... 12-3 Transaxle – Gasoline Vehicles, Transmission and Gear Reduction ............................................................................... 12-5 Transaxle – Gasoline Vehicles, Differential and Axles ........................................................................................................ 12-7 Forward/Reverse Shifter ............................................................................................................................................................... 12-9 Forward/Reverse Shifter Cable .................................................................................................................................................. 12-13 SECTION 13 – ELECTRICAL SYSTEM – ELECTRIC VEHICLES Headlight and Horn Electrical Components ......................................................................................................................... 13-3 Wiring – Turf/Carryall 2 ................................................................................................................................................................. 13-7 Headlights ......................................................................................................................................................................................... 13-9 Instrument Panel with Electrical Components – Turf/Carryall 252, and XRT 900 .................................................... 13-11 Horn and Brake Switches ............................................................................................................................................................. 13-13 Motor Controller Output Regulator (MCOR) ......................................................................................................................... 13-15 Instrument Panel and Electrical Components – Turf/Carryall 2 ..................................................................................... 13-17 Battery Charger Receptacle ......................................................................................................................................................... 13-19

2007 Turf/Carryall 2, 252, 2 Plus, and XRT 900 Gasoline and Electric Vehicle Illustrated Parts List Page 5 CONTENTS Electrical Installation ..................................................................................................................................................................... 13-23 Tow/Run Switch .............................................................................................................................................................................. 13-25 Electrical Components ................................................................................................................................................................. 13-29 Hour Meter – Turf 2, 252, Carryall 252, XRT 900 .................................................................................................................. 13-31 Batteries, T-105 ................................................................................................................................................................................ 13-33 Batteries, T-105 ................................................................................................................................................................................ 13-35 SECTION 14 – ELECTRIC MOTOR Motor (Model DA5-4006) – IQ Plus .......................................................................................................................................... 14-3 SECTION 15 – TRANSAXLE – ELECTRIC VEHICLES Transaxle – Electric Vehicles ....................................................................................................................................................... 15-3 SECTION 16 – BATTERY CHARGER IQ Plus Domestic Battery Charger (Model 25730) .............................................................................................................. 16-3 IQ Plus Onboard Battery Charger (Model 25260) ............................................................................................................... 16-5 Onboard Charger (Model 25260) and Reel Mounting ...................................................................................................... 16-7 Onboard Charger (Model 25260) and Reel Mounting – IQ Plus Turf/Carryall 2, Continued ............................... 16-11 IQ Plus Battery Charger (Model 25880), Export and European ...................................................................................... 16-13 IQ Plus Onboard Battery Charger (Model 25660), Export ................................................................................................ 16-15 Onboard Charger (Model 25660) and Reel Mounting ...................................................................................................... 16-17 Onboard Charger (Model 25660) and Reel Mounting – IQ Plus Turf/Carryall 2, Continued ............................... 16-21 SECTION 17 – MAINTENANCE AND SERVICE TOOLS Maintenance and Service Tools ................................................................................................................................................ 17-3 Maintenance and Service Tools, Continued ......................................................................................................................... 17-5 Maintenance and Service Tools, Continued ......................................................................................................................... 17-7 Maintenance and Service Tools, Continued ......................................................................................................................... 17-9 Maintenance and Service Tools, Continued ......................................................................................................................... 17-11 SECTION i – INDEX

2007 Club Car Turf Carryall 2 252 2 Plus XRT 900 Illustrated Parts List

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