Club car Turf 272 Guide

TURF 272 AND CARRYALL 272

GASOLINE VEHICLES

MANUAL NUMBER 102190010

EDITION CODE 0802A00000

MAINTENANCE

SERVICE

2001-2002

2001/2002 Turf/Carryall 272 Gasoline Vehicle 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 Turf/Carryall 272 vehicle, and

should be thoroughly reviewed prior to servicing the vehicle.The procedures provided must be properly imple-

mented, 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, Inc. to assist its distributors and dealers in continually updating their service knowl-

edge and facilities so they can provide prompt and efﬁcient service for vehicle owners. Regional technical rep-

resentatives, 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; unique situations, however, do 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; Attention: Technical Services, or contact a Club

Car Technical Service Representative at (706) 863-3000, ext. 3580.

Club Car

and

Carryall

are registered trademarks of Club Car, Inc.

This manual effective July 23, 2001

Page ii 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual

∆

WARNING

• Read 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. Club Car, Inc., is

continually working to further improve our vehicles and other products. These improvements may

affect servicing procedures. Any modiﬁcation and/or signiﬁcant change in speciﬁcations or proce-

dures will be forwarded to all Club Car dealers and will, when applicable, appear in future editions

of this manual.

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.

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, Inc., P.O. Box 204658, Augusta, GA 30917-4658 USA,

Attention: Warranty Department.

2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page iii

CONTENTS

SECTION 1 – SAFETY

General Warning ............................................................................................................................... 1-1

SECTION 2 – VEHICLE SPECIFICATIONS

General Information .......................................................................................................................... 2-1

SECTION 3 – GENERAL INFORMATION

General Information .......................................................................................................................... 3-1

Engine and Transaxle Identification ................................................................................................. 3-1

Serial Number Identification .............................................................................................................. 3-2

Storage ............................................................................................................................................. 3-2

Returning The Stored Vehicle To Service .................................................................................... 3-4

SECTION 4 – BODY AND TRIM

Cleaning the Vehicle ......................................................................................................................... 4-2

Front Body Repair ............................................................................................................................. 4-3

Abrasions and Haze ..................................................................................................................... 4-3

Light Scratches ............................................................................................................................. 4-3

Large Scratches and Abrasions .................................................................................................... 4-3

Tube Bumper .................................................................................................................................... 4-3

Tube Bumper Removal ................................................................................................................. 4-3

Tube Bumper Installation .............................................................................................................. 4-3

Front Body Components ................................................................................................................... 4-3

Dashboard Removal ..................................................................................................................... 4-3

Dashboard Installation .................................................................................................................. 4-4

Front Body Removal ..................................................................................................................... 4-4

Front Fender Removal .................................................................................................................. 4-6

Front Fender Installation ............................................................................................................... 4-6

Front Body Installation .................................................................................................................. 4-6

Seat .................................................................................................................................................. 4-6

Seat Removal ............................................................................................................................... 4-8

Seat Installation ............................................................................................................................ 4-8

Page iv 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual

Seat Support .................................................................................................................................... 4-8

Seat Support Removal ................................................................................................................. 4-8

Seat Support Installation .............................................................................................................. 4-9

Armrest Removal ......................................................................................................................... 4-9

Armrest Installation ...................................................................................................................... 4-9

Cargo Bed ........................................................................................................................................ 4-9

Cargo Bed Removal ..................................................................................................................... 4-9

Cargo Bed Installation .................................................................................................................. 4-11

Bed Stop Bumper Adjustment ...................................................................................................... 4-11

Rear Fender ..................................................................................................................................... 4-11

Rear Fender Removal .................................................................................................................. 4-11

Rear Fender Installation ............................................................................................................... 4-12

Tailskirt ............................................................................................................................................. 4-12

Tailskirt Removal .......................................................................................................................... 4-12

Tailskirt Installation ....................................................................................................................... 4-14

Trailer Hitch ...................................................................................................................................... 4-14

Trailer Hitch Removal ................................................................................................................... 4-14

Trailer Hitch Installation ................................................................................................................ 4-14

Floor Mat .......................................................................................................................................... 4-15

Floor Mat Removal ....................................................................................................................... 4-15

Floor Mat Installation .................................................................................................................... 4-15

SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES

Brake Pedal ...................................................................................................................................... 5-2

Brake Pedal Removal .................................................................................................................. 5-2

Brake Pedal Installation ............................................................................................................... 5-3

Accelerator Pedal ............................................................................................................................. 5-4

Accelerator Pedal Removal .......................................................................................................... 5-4

Accelerator Pedal Installation ....................................................................................................... 5-5

Brake Pedal Adjustment ................................................................................................................... 5-6

Accelerator Pedal Adjustment .......................................................................................................... 5-7

SECTION 6A – MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYS-

TEMS

General Information ......................................................................................................................... 6a-2

Transaxle Identification .................................................................................................................... 6a-2

Brake System Inspection ................................................................................................................. 6a-3

Brake System Troubleshooting ........................................................................................................ 6a-6

2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page v

Brake Drum Removal ....................................................................................................................... 6a-9

Front Wheel Brake Drum Removal ............................................................................................... 6a-9

Rear Wheel Brake Drum Removal ............................................................................................... 6a-10

Brake Shoe Removal ........................................................................................................................ 6a-11

Front Brake Shoe Removal .......................................................................................................... 6a-11

Rear Brake Shoe Removal ........................................................................................................... 6a-11

Brake Cluster Inspection and Cleaning ............................................................................................ 6a-12

Brake Shoe Installation ..................................................................................................................... 6a-14

Front Brake Shoe Installation ....................................................................................................... 6a-14

Rear Brake Shoe Installation ........................................................................................................ 6a-16

Brake Drum Installation .................................................................................................................... 6a-17

Front Wheel Brake Drum Installation ............................................................................................ 6a-17

Rear Wheel Brake Drum Installation ............................................................................................ 6a-19

Brake Cluster Assembly Replacement ............................................................................................. 6a-20

Front Brake Cluster Assembly Removal ....................................................................................... 6a-20

Front Brake Cluster Assembly Installation .................................................................................... 6a-21

Rear Brake Cluster Assembly Removal ....................................................................................... 6a-21

Rear Brake Cluster Assembly Installation .................................................................................... 6a-22

Wheel Cylinder Replacement ........................................................................................................... 6a-23

Front Wheel Cylinder Removal ..................................................................................................... 6a-23

Front Wheel Cylinder Installation .................................................................................................. 6a-23

Rear Wheel Cylinder Removal ..................................................................................................... 6a-24

Rear Wheel Cylinder Installation .................................................................................................. 6a-24

Brake Shoe Adjuster Replacement .................................................................................................. 6a-26

Front Brake Shoe Adjuster Removal ............................................................................................ 6a-26

Front Brake Shoe Adjuster Installation ......................................................................................... 6a-26

Rear Brake Shoe Adjuster Removal ............................................................................................. 6a-27

Rear Brake Shoe Adjuster Installation .......................................................................................... 6a-27

Hydraulic Line and Hose Replacement ............................................................................................ 6a-27

Front Brake Line Removal ............................................................................................................ 6a-28

Front Brake Line Installation ......................................................................................................... 6a-28

Front Brake Hose Assembly Removal .......................................................................................... 6a-28

Front Brake Hose Assembly Installation ....................................................................................... 6a-30

Rear Brake Line Removal ............................................................................................................. 6a-30

Rear Brake Line Installation .......................................................................................................... 6a-30

Rear Brake Hose Removal ........................................................................................................... 6a-31

Rear Brake Hose Installation ........................................................................................................ 6a-31

Page vi 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual

Master Cylinder and Bell Crank Replacement ................................................................................. 6a-31

Bell Crank Removal ..................................................................................................................... 6a-31

Bell Crank Installation .................................................................................................................. 6a-32

Master Cylinder Removal ............................................................................................................. 6a-32

Master Cylinder Installation .......................................................................................................... 6a-33

Bleeding the Hydraulic Brake System .............................................................................................. 6a-33

Purging the Hydraulic System ...................................................................................................... 6a-35

Filling the Hydraulic System ......................................................................................................... 6a-36

Park Brake System .......................................................................................................................... 6a-37

Park Brake Cable Removal .......................................................................................................... 6a-37

Park Brake Cable Installation ....................................................................................................... 6a-37

Park Brake Handle Removal ........................................................................................................ 6a-39

Park Brake Handle Installation ..................................................................................................... 6a-39

Park Brake Adjustment ................................................................................................................ 6a-39

SECTION 6B – MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYS-

TEMS

General Information ......................................................................................................................... 6b-2

Transaxle Identification .................................................................................................................... 6b-2

Brake System Inspection ................................................................................................................. 6b-3

Brake System Troubleshooting ........................................................................................................ 6b-6

Brake Drum Removal ....................................................................................................................... 6b-9

Front Wheel Brake Drum Removal .............................................................................................. 6b-9

Rear Wheel Brake Drum Removal ............................................................................................... 6b-10

Brake Shoe Removal ....................................................................................................................... 6b-11

Front Brake Shoe Removal .......................................................................................................... 6b-11

Rear Brake Shoe Removal .......................................................................................................... 6b-11

Brake Cluster Inspection and Cleaning ............................................................................................ 6b-12

Brake Shoe Installation .................................................................................................................... 6b-14

Front Brake Shoe Installation ....................................................................................................... 6b-14

Rear Brake Shoe Installation ....................................................................................................... 6b-16

Brake Drum Installation .................................................................................................................... 6b-17

Front Wheel Brake Drum Installation ........................................................................................... 6b-17

Rear Wheel Brake Drum Installation ............................................................................................ 6b-19

Brake Cluster Assembly Replacement ............................................................................................. 6b-20

Front Brake Cluster Assembly Removal ...................................................................................... 6b-20

Front Brake Cluster Assembly Installation ................................................................................... 6b-21

Rear Brake Cluster Assembly Removal ....................................................................................... 6b-21

Rear Brake Cluster Assembly Installation .................................................................................... 6b-22

2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page vii

Wheel Cylinder Replacement ........................................................................................................... 6b-23

Front Wheel Cylinder Removal ..................................................................................................... 6b-23

Front Wheel Cylinder Installation .................................................................................................. 6b-23

Rear Wheel Cylinder Removal ..................................................................................................... 6b-24

Rear Wheel Cylinder Installation .................................................................................................. 6b-24

Brake Shoe Adjuster Replacement .................................................................................................. 6b-25

Front Brake Shoe Adjuster Removal ............................................................................................ 6b-26

Front Brake Shoe Adjuster Installation ......................................................................................... 6b-26

Rear Brake Shoe Adjuster Removal ............................................................................................. 6b-26

Rear Brake Shoe Adjuster Installation .......................................................................................... 6b-27

Hydraulic Line and Hose Replacement ............................................................................................ 6b-27

Front Brake Line Removal ............................................................................................................ 6b-27

Front Brake Line Installation ......................................................................................................... 6b-29

Front Brake Hose Assembly Removal .......................................................................................... 6b-29

Front Brake Hose Assembly Installation ....................................................................................... 6b-29

Rear Brake Line Removal ............................................................................................................. 6b-30

Rear Brake Line Installation .......................................................................................................... 6b-30

Rear Brake Hose Removal ........................................................................................................... 6b-30

Rear Brake Hose Installation ........................................................................................................ 6b-31

Master Cylinder and Bell Crank Replacement .................................................................................. 6b-31

Bell Crank Removal ...................................................................................................................... 6b-31

Bell Crank Installation ................................................................................................................... 6b-31

Master Cylinder Removal ............................................................................................................. 6b-32

Master Cylinder Installation .......................................................................................................... 6b-32

Bleeding the Hydraulic Brake System .............................................................................................. 6b-33

Purging the Hydraulic System ...................................................................................................... 6b-35

Filling the Hydraulic System ......................................................................................................... 6b-36

Park Brake System ........................................................................................................................... 6b-36

Park Brake Cable Removal .......................................................................................................... 6b-36

Park Brake Cable Installation ....................................................................................................... 6b-37

Park Brake Handle Removal ........................................................................................................ 6b-38

Park Brake Handle Installation ..................................................................................................... 6b-39

Park Brake Adjustment ................................................................................................................. 6b-39

SECTION 7 – STEERING AND FRONT SUSPENSION

General Information .......................................................................................................................... 7-2

Steering Wheel ................................................................................................................................. 7-2

Steering Wheel Removal .............................................................................................................. 7-2

Steering Wheel Installation ........................................................................................................... 7-4

Page viii 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual

Steering Column .............................................................................................................................. 7-5

Steering Column Removal ........................................................................................................... 7-5

Steering Column Disassembly ..................................................................................................... 7-6

Steering Column Assembly .......................................................................................................... 7-6

Steering Column Installation ........................................................................................................ 7-7

Rack and Pinion ............................................................................................................................... 7-7

Rack and Pinion Removal ............................................................................................................ 7-7

Rack and Pinion Disassembly ...................................................................................................... 7-8

Rack and Pinion Assembly .......................................................................................................... 7-11

Rack and Pinion Installation ......................................................................................................... 7-12

Front Suspension ............................................................................................................................. 7-14

Lubrication .................................................................................................................................... 7-14

Wheel Alignment .......................................................................................................................... 7-14

Front Suspension Components ........................................................................................................ 7-16

Kingpin and Steering Spindle Removal ........................................................................................ 7-16

Kingpin and Steering Spindle Installation ..................................................................................... 7-16

A-Arm Removal ............................................................................................................................ 7-17

A-Arm Installation ......................................................................................................................... 7-19

Shock Absorber Removal ............................................................................................................ 7-19

Shock Absorber Installation ......................................................................................................... 7-20

Front Wheel Bearings and Hubs ...................................................................................................... 7-21

Front Wheel Free Play Inspection ................................................................................................ 7-21

Front Wheel Bearings and Hub Removal ..................................................................................... 7-21

Front Wheel Bearings and Hub Installation .................................................................................. 7-21

SECTION 8 – WHEELS AND TIRES

General Information ......................................................................................................................... 8-2

Wheels ............................................................................................................................................. 8-2

Wheel Removal ............................................................................................................................ 8-2

Wheel Installation ......................................................................................................................... 8-3

Tires ................................................................................................................................................. 8-3

Tire Repair ................................................................................................................................... 8-3

Tire Removal ................................................................................................................................ 8-3

Tire Installation ............................................................................................................................. 8-3

SECTION 9 – REAR SUSPENSION

General Information ......................................................................................................................... 9-2

Shock Absorbers .............................................................................................................................. 9-2

Shock Absorber Removal and Inspection .................................................................................... 9-2

Shock Absorber Installation ......................................................................................................... 9-5

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