Club Car Carryall 295, 295 SE, XRT 1550, XRT 1550 SE. Gasoline, Diesel, IntelliTach, & Homologated Complete Workshop Service Rep
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2008-2012 All-Wheel Drive
Maintenance and Service
Manual
Carryall 295/295 SE, XRT 1550/1550 SE and IntelliTach
Gasoline and Diesel Vehicles
Manual Number 103373117
Edition Code 1007F0811E
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation.
This manual provides detailed information for the maintenance and repair of Carryall 295, Carryall 295 SE, XRT
1550, XRT 1550 SE and IntelliTach vehicles, and should be thoroughly reviewed prior to servicing the vehicles. The
procedures provided must be properly implemented, and the DANGER, WARNING, and CAUTION statements
must be heeded.
This manual was written for the trained technician who already possesses knowledge and skills in electrical and
mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to the
vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be performed
by an authorized Club Car distributor/dealer representative or by a Club Car factorytrained technician.
It is the policy of Club Car, LLC to assist its distributors and dealers in continually updating their service knowledge
and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical representatives,
periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s
continuing commitment to customer support.
Club Car offers a full line of training and continuing education classes for technicians who want to learn more about
our products. For more information, contact your local dealer or Club Car’s Technical Services department for a
list of upcoming classes.
This manual covers all aspects of typical vehicle service; however, unique situations sometimes occur when servicing a
vehicle. If it appears that a service question is not answered in this manual, please contact your nearest authorized
Club Car dealer or distributor for assistance. You may also write to us at: Club Car, LLC; P.O. Box 204658; Augusta,
GA 30917-4658 USA, Attention: Technical Services.
Copyright © 2007, 2008, 2009, 2010, 2011 Club Car, LLC
Club Car, Carryall, and ArmorFlex
are registered trademarks of Club Car, LLC
This manual effective April 4, 2008
2008-2012 All-Wheel Drive Maintenance and Service Manual Page i
FOREWORD
WARNING
• Read See Section 1 – Safety. before attempting any service on this vehicle.
• Before servicing vehicle, read complete section(s) and any referenced information that may be
relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. The manufacturer is continually
working to further improve its vehicles and other products. These improvements may affect servicing
procedures. Any modification and/or significant change in specifications or procedures will be forwarded to all
dealers and will, when applicable, appear in future editions of this manual.
Damage to a vehicle or component thereof not resulting from a defect or that occurs due to unreasonable
or unintended use, overloading, abuse, or neglect (including failure to provide reasonable or necessary
maintenance as instructed in the vehicle owner’s manual), accident or alteration, including increasing vehicle
speed beyond factory specifications or modifications that affect the stability of the vehicle or the operation
thereof, will void the warranty.
The manufacturer reserves the right to change specifications and designs at any time without notice and
without incurring any obligation or liability whatsoever.
There are no warranties expressed or implied in this manual. See the limited warranty found in the vehicle
owner’s manual or write to Club Car, LLC, P.O. Box 204658, Augusta, GA 30917 -4658 USA, Attention:
Warranty Department.
CONTENTS
SECTION 1 – SAFETY ...................................................................................................................................... 1-1
Safety Details ................................................................................................................................................ 1-1
Personal Safety ......................................................................................................................................... 1-1
Machine Safety.......................................................................................................................................... 1-1
Information ................................................................................................................................................ 1-2
General Warnings .......................................................................................................................................... 1-2
Disabling the Vehicle.................................................................................................................................. 1-3
Disconnecting the Battery – Gasoline/Diesel Vehicles .................................................................................. 1-3
Connecting the Battery – Gasoline/Diesel Vehicles ...................................................................................... 1-4
Recycling Lead-Acid Batteries .................................................................................................................... 1-4
International safety symbols on batteries ..................................................................................................... 1-5
SECTION 2 – VEHICLE SPECIFICATIONS ........................................................................................................ 2-1
295/295 SE and 1550/1550 SE Specifications ............................................................................................. 2-1
295 Homologated Specifications ................................................................................................................. 2-4
Intellitach Specifications ............................................................................................................................. 2-6
SECTION 3 – GENERAL INFORMATION ........................................................................................................... 3-1
Model Identification – Domestic ...................................................................................................................... 3-2
Identification Numbers ............................................................................................................................... 3-3
Model Identification – Homologated ................................................................................................................ 3-5
Identification Numbers ............................................................................................................................... 3-5
Storage ......................................................................................................................................................... 3-7
Preparing the Vehicle for Extended Storage ................................................................................................ 3-8
Returning the Stored Vehicle to Service ...................................................................................................... 3-8
Lifting The Vehicle ......................................................................................................................................... 3-9
Lifting Only The Front ................................................................................................................................ 3-9
Lifting Only The Rear ................................................................................................................................. 3-9
Lifting The Entire Vehicle.......................................................................................................................... 3-10
Using A Booster Battery (Jump Starting) ........................................................................................................ 3-11
SECTION 4 – BODY AND TRIM......................................................................................................................... 4-1
Cleaning the Vehicle ...................................................................................................................................... 4-1
Seat Cleaning............................................................................................................................................ 4-1
Front Body Repair ......................................................................................................................................... 4-2
Light Scratches.......................................................................................................................................... 4-2
Abrasions and Haze .................................................................................................................................. 4-2
Large Scratches and Abrasions .................................................................................................................. 4-2
Front Body Components ................................................................................................................................ 4-3
Instrument Panel Removal ......................................................................................................................... 4-3
Instrument Panel Installation ...................................................................................................................... 4-3
Front Fascia Removal ................................................................................................................................ 4-4
Front Fascia Installation ............................................................................................................................. 4-4
Hood Removal .......................................................................................................................................... 4-4
Hood Installation........................................................................................................................................ 4-4
Center Cowl Panel Removal ....................................................................................................................... 4-4
Center Cowl Panel Installation .................................................................................................................... 4-5
Side Cowl Panel (Fender) Removal ............................................................................................................ 4-5
Side Cowl Panel (Fender) Installation ......................................................................................................... 4-5
Front Fender Flare Removal ....................................................................................................................... 4-6
Front Fender Flare Installation .................................................................................................................... 4-6
Roll-Over Protective Structure (ROPS) ............................................................................................................ 4-6
ROPS Removal ......................................................................................................................................... 4-6
ROPS Installation ...................................................................................................................................... 4-8
Seat .............................................................................................................................................................. 4-9
Seat Removal............................................................................................................................................ 4-9
2008-2012 All-Wheel Drive Maintenance and Service Manual Page iii
Seat Adjustment ........................................................................................................................................ 4-9
Seat Installation ......................................................................................................................................... 4-9
Seat Support Removal ............................................................................................................................... 4-9
Seat Support Installation .......................................................................................................................... 4-10
Seat Belts ................................................................................................................................................... 4-10
Bench Seat Belt Removal – 2008 Models .................................................................................................. 4-10
Bench Seat Belt Installation – 2008 Models ................................................................................................ 4-11
Bench Seat Belt Removal – 2009 and Newer Models .................................................................................. 4-11
Bench Seat Belt Installation – 2009 and Newer Models .............................................................................. 4-12
Seat Belt Removal – Homologated Models ................................................................................................ 4-12
Seat Belt Installation – Homologated Models ............................................................................................. 4-13
Cargo Bed – Electric Lift............................................................................................................................... 4-13
Testing the Bed Lift Motor ......................................................................................................................... 4-13
Bed Lift Motor Removal ............................................................................................................................ 4-13
Bed Lift Motor Installation ......................................................................................................................... 4-14
Cargo Bed Removal ................................................................................................................................ 4-14
Cargo Bed Installation .............................................................................................................................. 4-14
Cargo Bed – Manual Lift............................................................................................................................... 4-15
Cargo Bed Removal ................................................................................................................................ 4-15
Cargo Bed Installation .............................................................................................................................. 4-15
Rear Fender ................................................................................................................................................ 4-17
Rear Fender Removal .............................................................................................................................. 4-17
Rear Fender Installation ........................................................................................................................... 4-17
SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES................................................................... 5-1
Accelerator Pedal – Through Early 2010 Model Year........................................................................................ 5-1
Accelerator Pedal Removal – Through Early 2010 Model Year ..................................................................... 5-1
Accelerator Pedal Installation – Through Early 2010 Model Year ................................................................... 5-2
Accelerator Pedal and RPM Adjustment – Through Early 2010 Model Year ................................................... 5-2
Accelerator Pedal – From Late 2010 Model Year ............................................................................................. 5-3
Accelerator Pedal Removal – From Late 2010 Model Year ........................................................................... 5-3
Accelerator Pedal Installation – From Late 2010 Model Year ........................................................................ 5-3
Brake Pedal .................................................................................................................................................. 5-5
Brake Pedal Removal ................................................................................................................................ 5-5
Brake Pedal Installation ............................................................................................................................. 5-5
Brake Pedal Adjustment ............................................................................................................................. 5-5
Park Brake Pedal........................................................................................................................................... 5-6
Park Brake Pedal Assembly Removal – Bell Crank System .......................................................................... 5-6
Park Brake Pedal Assembly Installation – Bell Crank System ....................................................................... 5-6
Park Brake Pedal Assembly Removal – Cable Only System ......................................................................... 5-6
Park Brake Pedal Assembly Installation – Cable Only System ...................................................................... 5-7
SECTION 6 – HYDRAULIC AND PARK BRAKE SYSTEMS ................................................................................ 6-1
Brake System Inspection................................................................................................................................ 6-1
Brake Pedal Inspection .............................................................................................................................. 6-1
Master Cylinder Inspection ......................................................................................................................... 6-2
Brake Line Inspection ................................................................................................................................ 6-3
Park Brake Inspection ................................................................................................................................ 6-3
Brake Disc and Pad Inspection ................................................................................................................... 6-3
Brake System Troubleshooting ....................................................................................................................... 6-4
Brake Pads and Caliper – 2008-2011 Models .................................................................................................. 6-6
Front Brake Pad and Caliper Removal ........................................................................................................ 6-6
Front Brake Pad and Caliper Installation ..................................................................................................... 6-7
Rear Brake Pad and Caliper Removal ......................................................................................................... 6-8
Rear Brake Pad and Caliper Installation ...................................................................................................... 6-9
Brake Disc and Hub – 2008-2011 Models ...................................................................................................... 6-10
Front Wheel Disc and Hub Removal ......................................................................................................... 6-10
Front Wheel Disc and Hub Installation....................................................................................................... 6-14
Rear Wheel Disc Removal ....................................................................................................................... 6-15
Rear Wheel Disc Installation..................................................................................................................... 6-16
Brake Pads and Caliper – Starting 2012 Model Year ...................................................................................... 6-17
Brake Pad and Caliper Removal ............................................................................................................... 6-17
Page iv 2008-2012 All-Wheel Drive Maintenance and Service Manual
Brake Pad and Caliper Installation ............................................................................................................ 6-18
Brake Discs – Starting 2012 Model Year........................................................................................................ 6-19
Disc Removal .......................................................................................................................................... 6-19
Disc Installation ....................................................................................................................................... 6-20
Hydraulic Line Replacement ......................................................................................................................... 6-20
Front Brake Line Removal ........................................................................................................................ 6-20
Front Brake Line Installation ..................................................................................................................... 6-21
Rear Brake Line Removal ........................................................................................................................ 6-22
Rear Brake Line Installation...................................................................................................................... 6-22
Master Cylinder and Reservoir ..................................................................................................................... 6-23
Filling the Hydraulic System ..................................................................................................................... 6-23
Master Cylinder Removal ......................................................................................................................... 6-23
Master Cylinder Installation ...................................................................................................................... 6-24
Bleeding the Hydraulic Brake System ........................................................................................................... 6-24
Bleeding Brakes on a DOT 5 Fluid Filled System ....................................................................................... 6-25
Purging the Hydraulic System................................................................................................................... 6-26
Park Brake System ...................................................................................................................................... 6-27
Park Brake Adjustment – At Rear Calipers ................................................................................................ 6-27
Front Park Brake Cable Adjustment – Bell Crank System ........................................................................... 6-27
Front Park Brake Cable Adjustment – Cable Only System .......................................................................... 6-28
Park Brake Wheel Cables ........................................................................................................................ 6-28
Front Park Brake Cable Removal – Bell Crank System .............................................................................. 6-30
Front Park Brake Cable Installation – Bell Crank System............................................................................ 6-31
Front Park Brake Cable Removal – Cable Only System ............................................................................. 6-31
Front Park Brake Cable Installation – Cable Only System........................................................................... 6-32
Park Brake Equalizer Removal – Bell Crank System .................................................................................. 6-32
Park Brake Equalizer Installation – Bell Crank System ............................................................................... 6-32
Park Brake Equalizer Removal – Cable Only System ................................................................................. 6-33
Park Brake Equalizer Installation – Cable Only System .............................................................................. 6-33
SECTION 7 – STEERING AND FRONT SUSPENSION ....................................................................................... 7-1
Steering Wheel .............................................................................................................................................. 7-1
Steering Wheel Removal ............................................................................................................................ 7-1
Steering Wheel Installation ......................................................................................................................... 7-2
Steering Column............................................................................................................................................ 7-2
Steering Column Removal .......................................................................................................................... 7-2
Steering Column Installation ....................................................................................................................... 7-3
Rack and Pinion ............................................................................................................................................ 7-3
Rack and Pinion Inspection ........................................................................................................................ 7-4
Rack and Pinion Removal .......................................................................................................................... 7-4
Rack and Pinion Installation ....................................................................................................................... 7-4
Rack and Pinion Disassembly .................................................................................................................... 7-5
Rack and Pinion Assembly ......................................................................................................................... 7-9
Front Suspension ........................................................................................................................................ 7-10
Wheel Alignment ..................................................................................................................................... 7-10
Front Suspension Components..................................................................................................................... 7-12
Steering Upright Removal ........................................................................................................................ 7-12
Upper A-Arm Removal ............................................................................................................................. 7-14
Upper A-Arm Installation .......................................................................................................................... 7-15
Lower A-Arm Removal ............................................................................................................................. 7-15
Lower A-Arm Installation .......................................................................................................................... 7-16
Front Coil-Over Shock Absorber Removal ................................................................................................. 7-17
Front Coil-Over Shock Absorber Installation .............................................................................................. 7-18
Steering Upright Installation...................................................................................................................... 7-18
SECTION 8 – WHEELS AND TIRES .................................................................................................................. 8-1
General Information ....................................................................................................................................... 8-1
Wheels ......................................................................................................................................................... 8-2
Wheel Removal ......................................................................................................................................... 8-2
Wheel Installation ...................................................................................................................................... 8-2
Tires ............................................................................................................................................................. 8-2
Tire Removal ............................................................................................................................................. 8-2
2008-2012 All-Wheel Drive Maintenance and Service Manual Page v
Tire Installation .......................................................................................................................................... 8-3
SECTION 9 – REAR SUSPENSION ................................................................................................................... 9-1
Rear Coil-Over Shock Absorber – 2008-2011 Models....................................................................................... 9-1
Rear Shock Absorber Removal................................................................................................................... 9-1
Rear Shock Absorber Installation ................................................................................................................ 9-2
Swing Arms – 2008-2011 Models.................................................................................................................... 9-3
Swing Arm Removal .................................................................................................................................. 9-3
Swing Arm Installation................................................................................................................................ 9-3
Rear Coil-Over Shock Absorber – Starting 2012 Model Year ............................................................................ 9-4
Rear Shock Absorber Removal................................................................................................................... 9-4
Rear Shock Installation .............................................................................................................................. 9-5
Trailing Arms and Lateral Links – Starting 2012 Model Year ............................................................................. 9-6
Lateral Link Removal ................................................................................................................................. 9-6
Lateral Link Installation .............................................................................................................................. 9-6
Trailing Arm Removal ................................................................................................................................. 9-8
Trailing Arm Installation .............................................................................................................................. 9-8
SECTION 10 – PERIODIC MAINTENANCE ...................................................................................................... 10-1
Periodic Service Schedule............................................................................................................................ 10-1
Periodic Lubrication Schedule ...................................................................................................................... 10-4
Periodic Lubrication Schedule – Intellitach..................................................................................................... 10-6
Lubricating the Attachment Arm and Interface ............................................................................................... 10-7
Brake Fluid Reservoir .................................................................................................................................. 10-8
Brake Fluid.............................................................................................................................................. 10-8
Engine Oil ................................................................................................................................................... 10-8
Oil Pressure – Gasoline Engine ................................................................................................................ 10-9
Engine Oil Level Check ............................................................................................................................ 10-9
Engine Oil and Filter Change .................................................................................................................... 10-9
Oil Viscosity ........................................................................................................................................... 10-12
Spark Plugs................................................................................................................................................ 10-13
Spark Plug Cleaning And Inspection ........................................................................................................ 10-13
Spark Plug Gap Inspection ...................................................................................................................... 10-13
Gearcase Lubrication .................................................................................................................................. 10-13
Lubrication Level Check for Front Differential, Transmission, and Rear Differential ...................................... 10-13
Lubrication Change for Front Differential, Transmission, and Rear Differential ............................................ 10-14
Hydraulic System – Intellitach Vehicle .......................................................................................................... 10-15
Engine Coolant – Diesel Vehicles ................................................................................................................ 10-16
Engine Coolant Level Check ................................................................................................................... 10-16
Fueling Instructions..................................................................................................................................... 10-16
Biodiesel Fuel (Diesel Vehicles Only) ................................................................................................... 10-17
Draining Water from Fuel Filter ................................................................................................................ 10-18
Battery ....................................................................................................................................................... 10-19
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES ............................. 11-1
Troubleshooting Guide .................................................................................................................................. 11-1
Wiring Diagram............................................................................................................................................. 11-8
Test Procedures ......................................................................................................................................... 11-10
SECTION 12 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES ................................. 12-1
Troubleshooting Guide ................................................................................................................................. 12-1
Wiring Diagram............................................................................................................................................ 12-8
Test Procedures ......................................................................................................................................... 12-12
SECTION 13 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES............................................................. 13-1
Starter and Starter Solenoid ......................................................................................................................... 13-1
Relays ........................................................................................................................................................ 13-1
Testing the Relay ..................................................................................................................................... 13-1
Relay Removal ........................................................................................................................................ 13-2
Page vi 2008-2012 All-Wheel Drive Maintenance and Service Manual
Relay Installation ..................................................................................................................................... 13-2
Neutral Switch ............................................................................................................................................. 13-2
Testing the Neutral Switch ........................................................................................................................ 13-2
Neutral Switch Removal ........................................................................................................................... 13-2
Neutral Switch Installation ........................................................................................................................ 13-2
Carburetor Solenoid..................................................................................................................................... 13-3
Testing the Carburetor Solenoid................................................................................................................ 13-3
Carburetor Solenoid Removal ................................................................................................................... 13-3
Carburetor Solenoid Installation ................................................................................................................ 13-3
Carburetor Heater ........................................................................................................................................ 13-4
Carburetor Heater Removal...................................................................................................................... 13-4
Carburetor Heater Installation ................................................................................................................... 13-4
Voltage Regulator ........................................................................................................................................ 13-5
Testing the Voltage Regulator ................................................................................................................... 13-5
Voltage Regulator Removal ...................................................................................................................... 13-5
Voltage Regulator Installation ................................................................................................................... 13-5
Warning Lights ............................................................................................................................................ 13-6
Testing the Warning Lights ....................................................................................................................... 13-6
Warning Light Removal ............................................................................................................................ 13-6
Warning Light Installation ......................................................................................................................... 13-6
Fuel Gauge/Hour Meter ............................................................................................................................... 13-7
Testing the Fuel Gauge/Hour Meter .......................................................................................................... 13-7
Fuel Gauge/Hour Meter Removal ............................................................................................................. 13-7
Fuel Gauge/Hour Meter Installation........................................................................................................... 13-8
Key Switch .................................................................................................................................................. 13-8
Testing the Key Switch ............................................................................................................................. 13-8
Key Switch Removal ................................................................................................................................ 13-8
Key Switch Installation ............................................................................................................................. 13-8
12-Volt Accessory Receptacle ...................................................................................................................... 13-9
Testing the 12-Volt Accessory Receptacle ................................................................................................. 13-9
12-Volt Accessory Receptacle Removal .................................................................................................... 13-9
12-Volt Accessory Receptacle Installation ................................................................................................. 13-9
Bed Lift Switch ........................................................................................................................................... 13-10
Testing the Bed Lift Switch ...................................................................................................................... 13-10
Bed Lift Switch Removal ......................................................................................................................... 13-10
Bed Lift Switch Installation....................................................................................................................... 13-10
Bed Lift Circuit Breaker ............................................................................................................................... 13-10
Testing the Bed Lift Circuit Breaker .......................................................................................................... 13-10
Bed Lift Circuit Breaker Removal ............................................................................................................. 13-10
Bed Lift Circuit Breaker Installation .......................................................................................................... 13-11
Light Switch................................................................................................................................................ 13-11
Testing the Light Switch .......................................................................................................................... 13-11
Light Switch Removal ............................................................................................................................. 13-11
Light Switch Installation........................................................................................................................... 13-11
Fuse .......................................................................................................................................................... 13-11
Testing the Fuse ..................................................................................................................................... 13-11
Fuse Removal ........................................................................................................................................ 13-12
Fuse Installation ..................................................................................................................................... 13-12
Reverse Warning Buzzer (If Equipped)......................................................................................................... 13-12
Testing the Reverse Warning Buzzer........................................................................................................ 13-12
Reverse Warning Buzzer Removal .......................................................................................................... 13-12
Reverse Warning Buzzer Installation ........................................................................................................ 13-13
Reverse Warning Buzzer Limit Switch (If Equipped) ...................................................................................... 13-13
Testing the Reverse Warning Buzzer Limit Switch ..................................................................................... 13-13
Reverse Warning Buzzer Limit Switch Removal ........................................................................................ 13-13
Reverse Warning Buzzer Limit Switch Installation ..................................................................................... 13-14
Front Differential Limit Switch ...................................................................................................................... 13-14
Testing the Front Differential Limit Switch ................................................................................................. 13-15
Front Differential Limit Switch Removal .................................................................................................... 13-15
Front Differential Limit Switch Installation ................................................................................................. 13-15
Fuel Level Sending Unit .............................................................................................................................. 13-16
Testing the Fuel Level Sending Unit ......................................................................................................... 13-16
Fuel Level Sending Unit Removal ............................................................................................................ 13-16
Fuel Level Sending Unit Installation ......................................................................................................... 13-16
2008-2012 All-Wheel Drive Maintenance and Service Manual Page vii
Ignition Coil and Charge Coil ....................................................................................................................... 13-16
Testing the Ignition Coil ........................................................................................................................... 13-16
Ignition Coil and/or Charge Coil Removal ................................................................................................. 13-16
Oil Pressure Sensor .................................................................................................................................... 13-17
Headlights .................................................................................................................................................. 13-17
Testing the Headlight Bulb and Socket ..................................................................................................... 13-17
Headlight Bulb Removal .......................................................................................................................... 13-17
Headlight Bulb Installation ....................................................................................................................... 13-17
Wire Harness Diodes .................................................................................................................................. 13-18
Testing the Wire Harness Diodes ............................................................................................................. 13-18
Wire Harness Diode Removal .................................................................................................................. 13-18
Wire Harness Diode Installation ............................................................................................................... 13-18
Battery ....................................................................................................................................................... 13-19
General Information ................................................................................................................................ 13-19
Testing the Battery .................................................................................................................................. 13-19
Preventive Maintenance .......................................................................................................................... 13-19
Self-Discharge........................................................................................................................................ 13-20
Water Level ............................................................................................................................................ 13-20
Vibration Damage ................................................................................................................................... 13-20
Mineral Content ...................................................................................................................................... 13-20
Battery Removal ..................................................................................................................................... 13-21
Charging the Battery ............................................................................................................................... 13-21
Battery Installation .................................................................................................................................. 13-21
Battery Storage ...................................................................................................................................... 13-22
Charging a Dead Battery ......................................................................................................................... 13-22
SECTION 14 – ELECTRICAL COMPONENTS: DIESEL VEHICLES .................................................................. 14-1
Starter and Starter Solenoid ......................................................................................................................... 14-1
Relays ........................................................................................................................................................ 14-1
Testing the Relay ..................................................................................................................................... 14-1
Relay Removal ........................................................................................................................................ 14-2
Relay Installation ..................................................................................................................................... 14-2
Neutral Switch ............................................................................................................................................. 14-2
Testing the Neutral Switch ........................................................................................................................ 14-2
Neutral Switch Removal ........................................................................................................................... 14-2
Neutral Switch Installation ........................................................................................................................ 14-2
Fuel Solenoid .............................................................................................................................................. 14-3
Testing the Fuel Solenoid ......................................................................................................................... 14-3
Fuel Solenoid Removal ............................................................................................................................ 14-3
Fuel Solenoid Installation ......................................................................................................................... 14-3
60-Amp Fusible Link .................................................................................................................................... 14-4
Testing the 60-Amp Fusible Link ............................................................................................................... 14-4
60-Amp Fusible Link Removal .................................................................................................................. 14-4
60-Amp Fusible Link Installation ............................................................................................................... 14-4
Warning Lights ............................................................................................................................................ 14-5
Testing the Warning Lights ....................................................................................................................... 14-5
Warning Light Removal ............................................................................................................................ 14-5
Warning Light Installation ......................................................................................................................... 14-5
Fuel Gauge/Hour Meter ............................................................................................................................... 14-6
Testing the Fuel Gauge/Hour Meter .......................................................................................................... 14-6
Fuel Gauge/Hour Meter Removal ............................................................................................................. 14-7
Fuel Gauge/Hour Meter Installation........................................................................................................... 14-7
Key Switch .................................................................................................................................................. 14-7
Testing the Key Switch ............................................................................................................................. 14-7
Key Switch Removal ................................................................................................................................ 14-7
Key Switch Installation ............................................................................................................................. 14-7
12-Volt Accessory Receptacle ...................................................................................................................... 14-8
Testing the 12-Volt Accessory Receptacle ................................................................................................. 14-8
12-Volt Accessory Receptacle Removal .................................................................................................... 14-8
12-Volt Accessory Receptacle Installation ................................................................................................. 14-8
Bed Lift Switch ............................................................................................................................................ 14-9
Testing the Bed Lift Switch ....................................................................................................................... 14-9
Bed Lift Switch Removal .......................................................................................................................... 14-9
Page viii 2008-2012 All-Wheel Drive Maintenance and Service Manual
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Get your hands on the complete workshop service repair manual for Club Car Carryall 295, 295 SE, XRT 1550, and XRT 1550 SE. This manual covers gasoline, diesel, IntelliTach, and homologated models from 2007 to 2012.
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