2007-2008 Club Car XRT 800 810 and 850 Service & Repair Manual
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MANUAL NUMBER 103209106
EDITION CODE 0907D0808C
XRT 800, 810 and 850
GASOLINE/ELECTRIC
2007-2008
MAINTENANCE
SERVICE
MANUAL
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page i
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 the Club Car XRT 800, 810 and
850 series vehicles, and should be thoroughly reviewed prior to servicing the vehicle. The procedures pro-
vided 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 factory-
trained technician.
It is the policy of Club Car 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 repre-
sentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other
service publications also represent Club Car’s continuing commitment to customer support.
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, you may write to us at:
Club Car, Inc., P.O. Box 204658; Augusta, GA 30917-4658 USA, Attention: Technical Services, or contact a
Club Car Technical Service Representative at (706) 863-3000, ext. 3580.
Copyright © 2007, 2008 Club Car, Inc.
Club Car and Carryall are registered
trademarks of Club Car, Inc
This manual effective August 1, 2006.
Page ii 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
ý WARNING
• Read Section 1 – Safety before attempting any service on the 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. Club Car is contin-
ually 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 Club Car dealers and will, when applicable, appear in future editions of this
manual.
Club Car reserves the right to change specifications and designs at any time without notice and
without the obligation of making changes to units previously sold.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle Owner’s Manual.
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ............................................................................................................................... 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
800 and 810 Specifications ........................................................................................................... 2-1
850 Specifications ......................................................................................................................... 2-3
SECTION 3 – GENERAL INFORMATION
Serial Number Identification .............................................................................................................. 3-1
Storage – Gasoline Vehicle .............................................................................................................. 3-2
Preparing the Gasoline Vehicle for Extended Storage ................................................................. 3-2
Returning the Stored Gasoline Vehicle to Service ........................................................................ 3-4
Storage – Electric Vehicle ................................................................................................................. 3-4
Preparing the Electric Vehicle for Extended Storage .................................................................... 3-5
Returning the Stored Electric Vehicle to Service .......................................................................... 3-5
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 4-1
Seat Cleaning ............................................................................................................................... 4-1
Front and Rear Body Repair ............................................................................................................. 4-2
Minor Scratches and Surface Blemishes ...................................................................................... 4-2
Small Scratches That Cannot Be Buffed Out ............................................................................... 4-2
Gouges, Punctures, Tears, Large Scratches, and Abrasions ....................................................... 4-2
Front Body – 800 and 810 ................................................................................................................ 4-3
Bumper/Brush Guard Removal ..................................................................................................... 4-3
Bumper/Brush Guard Installation .................................................................................................. 4-3
Front Body Removal ..................................................................................................................... 4-3
Molded Dash Removal ................................................................................................................. 4-4
Molded Dash Installation .............................................................................................................. 4-4
Front Body Installation .................................................................................................................. 4-4
Page iv 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Front Body – 850 .............................................................................................................................. 4-5
Bumper/Brush Guard (Standard) Removal .................................................................................. 4-5
Bumper/Brush Guard (Standard) Installation ............................................................................... 4-6
Bumper/Brush Guard (Heavy Duty) Removal .............................................................................. 4-7
Bumper/Brush Guard (Heavy Duty) Installation ........................................................................... 4-7
Front Removal .............................................................................................................................. 4-7
Front Body Installation .................................................................................................................. 4-7
Cargo Bed – 800 and 810 ................................................................................................................ 4-8
Cargo Bed Removal ..................................................................................................................... 4-8
Cargo Bed Installation .................................................................................................................. 4-9
Bed Latch Assembly ..................................................................................................................... 4-9
Bed Latch Assembly Installation .................................................................................................. 4-11
Seat Back Support Brackets – 800 and 810 .................................................................................... 4-11
Seat Back Support Bracket Removal ........................................................................................... 4-11
Seat Back Support Bracket Installation ........................................................................................ 4-12
Rear Body and Fenders – 800 and 810 ........................................................................................... 4-12
Rear Body Removal ..................................................................................................................... 4-12
Rear Fender Removal .................................................................................................................. 4-14
Rear Fender Installation ............................................................................................................... 4-14
Rear Body Installation .................................................................................................................. 4-15
Rear Body – 850 .............................................................................................................................. 4-15
Rear Body Removal ..................................................................................................................... 4-15
Rear Body Installation .................................................................................................................. 4-19
Floor Mat .......................................................................................................................................... 4-19
Floor Mat Removal ....................................................................................................................... 4-19
Floor Mat Installation .................................................................................................................... 4-19
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Brake Pedal and Park Brake ............................................................................................................ 5-1
Brake Pedal Removal ................................................................................................................... 5-1
Brake Pedal Installation ................................................................................................................ 5-2
Park Brake Removal .................................................................................................................... 5-3
Park Brake Installation ................................................................................................................. 5-4
Accelerator Pedal – Gasoline Vehicles ............................................................................................ 5-5
Accelerator Pedal Removal .......................................................................................................... 5-5
Accelerator Pedal Installation ....................................................................................................... 5-7
Accelerator Pedal – Electric Vehicles .............................................................................................. 5-8
Accelerator Pedal Removal .......................................................................................................... 5-8
Accelerator Pedal Installation ....................................................................................................... 5-10
Pedal Group Adjustment – Gasoline Vehicle ................................................................................... 5-11
Pedal Group Adjustment – Electric Vehicles .................................................................................... 5-16
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page v
SECTION 6 – WHEEL BRAKE ASSEMBLIES
Brake Shoe Removal ........................................................................................................................ 6-1
Brake Assembly Cleaning ................................................................................................................. 6-5
Brake Shoe Installation ..................................................................................................................... 6-6
Brake Adjustment ............................................................................................................................. 6-8
Brake Cluster Removal and Installation ............................................................................................ 6-8
Brake Cluster Installation .............................................................................................................. 6-9
Brake Cable Removal and Installation .............................................................................................. 6-10
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information .......................................................................................................................... 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 Disassembly ...................................................................................................... 7-4
Steering Column Assembly .......................................................................................................... 7-4
Steering Column Installation ......................................................................................................... 7-5
Steering Adjustment ......................................................................................................................... 7-6
Rack and Pinion ................................................................................................................................ 7-7
Rack and Pinion Removal ............................................................................................................ 7-7
Rack and Pinion Disassembly ...................................................................................................... 7-7
Rack and Pinion Assembly ........................................................................................................... 7-10
Rack and Pinion Installation ......................................................................................................... 7-12
Tie Rod and Drag Link ...................................................................................................................... 7-12
Tie Rod and Drag Link Removal ................................................................................................... 7-12
Tie Rod and Drag Link Installation ................................................................................................ 7-12
Front Suspension .............................................................................................................................. 7-13
Lubrication .................................................................................................................................... 7-13
Wheel Alignment ........................................................................................................................... 7-13
Front Suspension Components ........................................................................................................ 7-15
Tapered Leaf Spring Removal ...................................................................................................... 7-15
Tapered Leaf Spring Installation ................................................................................................... 7-15
Kingpin and Steering Spindle Removal ........................................................................................ 7-16
Kingpin and Steering Spindle Installation ..................................................................................... 7-16
Delta A-Plate Removal ................................................................................................................. 7-16
Delta A-Plate Installation .............................................................................................................. 7-19
Shock Absorber Removal ............................................................................................................. 7-19
Shock Absorber Installation .......................................................................................................... 7-19
Page vi 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Front Wheel Bearings and Hubs ...................................................................................................... 7-19
Front Wheel Free Play Inspection ................................................................................................ 7-19
Front Hub Removal ...................................................................................................................... 7-19
Front Hub Installation ................................................................................................................... 7-20
SECTION 8 – WHEELS AND TIRES
General Information ......................................................................................................................... 8-1
Wheels ............................................................................................................................................. 8-1
Wheel Removal ............................................................................................................................ 8-1
Wheel Installation ......................................................................................................................... 8-1
Tires ................................................................................................................................................. 8-1
Tire Removal ................................................................................................................................ 8-1
Tire Repair .................................................................................................................................... 8-2
Tire Installation ............................................................................................................................. 8-3
SECTION 9 – REAR SUSPENSION
General Information ......................................................................................................................... 9-1
Shock Absorbers .............................................................................................................................. 9-1
Shock Absorber Removal and Inspection .................................................................................... 9-1
Shock Absorber Installation .......................................................................................................... 9-1
Leaf Springs ..................................................................................................................................... 9-2
Leaf Spring Removal – 800 and 810 ............................................................................................ 9-2
Leaf Spring Removal – 850 .......................................................................................................... 9-4
Leaf Spring Installation – All Vehicles .......................................................................................... 9-4
Stabilizer Bar Removal ................................................................................................................. 9-7
Stabilizer Bar Installation .............................................................................................................. 9-7
SECTION 10 – PERIODIC MAINTENANCE
General Information ......................................................................................................................... 10-1
Periodic Service Schedules ............................................................................................................. 10-1
Periodic Lubrication Schedules ...................................................................................................... 10-4
Engine Oil – Gasoline Vehicles ........................................................................................................ 10-6
Engine Oil Level Check ................................................................................................................ 10-6
Engine Oil And Filter Change ....................................................................................................... 10-7
Oil Viscosity .................................................................................................................................. 10-9
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: 800 AND 810 GAS
General Information ......................................................................................................................... 11-1
Troubleshooting Guide ..................................................................................................................... 11-1
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page vii
Electrical System .............................................................................................................................. 11-5
Lockout Cam ..................................................................................................................................... 11-5
Wiring Diagrams ............................................................................................................................... 11-6
Test Procedures ............................................................................................................................... 11-8
Index of Test Procedures .............................................................................................................. 11-8
SECTION 12 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: 850 GAS
General Information .......................................................................................................................... 12-1
Troubleshooting Guide ..................................................................................................................... 12-1
Wiring Diagram ................................................................................................................................. 12-6
Electrical System .............................................................................................................................. 12-8
Test Procedures ............................................................................................................................... 12-8
Index of Test Procedures .............................................................................................................. 12-8
SECTION 13 – ELECTRICAL COMPONENTS: 800 AND 810 GASOLINE VEHICLES
Starter/Generator .............................................................................................................................. 13-1
Voltage Regulator ............................................................................................................................. 13-11
Diode ................................................................................................................................................ 13-12
Key Switch ........................................................................................................................................ 13-14
Solenoid ............................................................................................................................................ 13-15
Fuse .................................................................................................................................................. 13-16
Lockout Cam Limit Switch ................................................................................................................ 13-17
Lockout Cam ..................................................................................................................................... 13-18
Reverse Warning Buzzer .................................................................................................................. 13-19
Reverse Buzzer Limit Switch ............................................................................................................ 13-20
Oil Warning Light .............................................................................................................................. 13-20
Fuel Gauge/Hour Meter .................................................................................................................... 13-21
Fuel Level Sending Unit .................................................................................................................... 13-22
RPM Limiter ...................................................................................................................................... 13-23
Ignition Coil ....................................................................................................................................... 13-24
Oil Level Sensor ............................................................................................................................... 13-27
Headlights ......................................................................................................................................... 13-27
Voltage Limiter .................................................................................................................................. 13-28
Light Switch ...................................................................................................................................... 13-29
Battery .............................................................................................................................................. 13-30
Ground Cables .................................................................................................................................. 13-34
SECTION 14 – ELECTRICAL COMPONENTS: 850 GASOLINE VEHICLE
Starter/Generator .............................................................................................................................. 14-1
Voltage Regulator ............................................................................................................................. 14-11
Page viii 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Key Switch ....................................................................................................................................... 14-12
Solenoid ........................................................................................................................................... 14-14
Fuse ................................................................................................................................................. 14-14
Kill Limit Switch ................................................................................................................................ 14-15
Neutral Lockout Limit Switch ............................................................................................................ 14-16
Reverse Warning Buzzer ................................................................................................................. 14-18
Reverse Buzzer Limit Switch ........................................................................................................... 14-19
Low Oil Warning Light ...................................................................................................................... 14-20
Fuel Gauge/Hour Meter ................................................................................................................... 14-21
Fuel Level Sending Unit ................................................................................................................... 14-22
RPM Limiter ..................................................................................................................................... 14-22
Ignition Coil ...................................................................................................................................... 14-23
Oil Level Sensor ............................................................................................................................... 14-26
Headlights ........................................................................................................................................ 14-26
Voltage Limiter ................................................................................................................................. 14-28
Headlight Switch .............................................................................................................................. 14-29
Battery .............................................................................................................................................. 14-30
Ground Cables ................................................................................................................................. 14-34
SECTION 15 – ENGINE
General Information ......................................................................................................................... 15-1
Before Servicing ........................................................................................................................... 15-1
Engine Rotation ............................................................................................................................ 15-1
Spark Plug .................................................................................................................................... 15-1
Cylinder Head .................................................................................................................................. 15-3
General Information ...................................................................................................................... 15-3
Breather Valve (Reed Valve) ........................................................................................................ 15-3
Crankcase ........................................................................................................................................ 15-3
Engine Removal ........................................................................................................................... 15-3
Crankcase Cover Removal .......................................................................................................... 15-3
Oil Level Sensor ........................................................................................................................... 15-5
Crankcase Cover Installation ....................................................................................................... 15-5
Ignition Coil and Flywheel ................................................................................................................ 15-6
Flywheel Installation ......................................................................................................................... 15-8
Engine Installation ............................................................................................................................ 15-9
Torque Specifications ................................................................................................................... 15-10
Adjustments and Settings ............................................................................................................ 15-10
SECTION 16 – FUEL SYSTEM: GASOLINE VEHICLE
General Information ......................................................................................................................... 16-1
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This service manual for the Club Car 2007-2008 XRT 800, 810, and 850 provides comprehensive information for vehicle maintenance and repair. It covers a wide range of topics including safety guidelines, vehicle specifications, general information, body and trim, accelerator and brake pedal group, wheel brake assemblies, steering and front suspension, wheels and tires, rear suspension, periodic maintenance, troubleshooting, and electrical systems for gas and electric vehicles.
The manual also includes detailed sections on the engine, fuel system, exhaust system, unitized transaxle, torque converter, IQ display module diagnostics, electrical components, batteries, battery charger, motor models, and transaxle types for electric vehicles. It is a valuable resource for both professional mechanics and DIY enthusiasts.
Language: English
Pages: 516
Format: PDF
Platform: Windows and Mac
