Club Car XRT 950 2009 Manual

2009-2012 XRT 950 Maintenance
and Service Manual
XRT 950 4x2, XRT 950 4x4, XRT 950 EX 4x4
Manual Number 103472727
E d i t i o n C o d e 1 2 0 8 H 0 1 1 G1

FOREWORD
ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper
maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.
ThismanualprovidesdetailedinformationforthemaintenanceandrepairoftheClubCarXRT950vehicles,and
shouldbethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedmustbeproperlyimplemented,
andtheDANGER,WARNING,andCAUTIONstatementsmustbeheeded.
Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland
mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe
vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed
byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.
ItisthepolicyofClubCartoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledgeand
facilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,
vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications
alsorepresentClubCar’scontinuingcommitmenttocustomersupport.
ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout
ourproducts.Formoreinformation,contactyourlocaldealerorClubCar’sTechnicalServicesdepartmentfora
listofupcomingclasses.
Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga
vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized
ClubCardealerordistributorforassistance.Youmayalsowritetousat:ClubCar,LLC,P .O.Box204658;Augusta,
GA30917-4658USA,Attention:TechnicalServices.
WARNING
•ReadSafetyonpage1-1beforeattemptinganyserviceonthevehicle.
•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe
relevanttotheserviceorrepairtobeperformed.
NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCariscontinuallyworking
tofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicingprocedures.
Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoallClubCar
dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.
ClubCarreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithoutthe
obligationofmakingchangestounitspreviouslysold.
Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle
Owner’sManual.
Copyright©2008,2009,2010,2011ClubCar,LLC
ClubCar,Carryall,andArmorFlex
areregisteredtrademarksofClubCar,LLC
ThismanualeffectiveApril4,2008
2009-2012XRT950MaintenanceandServiceManualPagei

CONTENTS
SECTION1–SAFETY......................................................................................................................................1-1
SafetyDetails................................................................................................................................................1-1
PersonalSafety.........................................................................................................................................1-1
MachineSafety..........................................................................................................................................1-1
Information................................................................................................................................................1-1
GeneralWarning...........................................................................................................................................1-2
DisablingtheVehicle..................................................................................................................................1-3
DisconnectingtheBattery–GasolineVehicles............................................................................................1-4
ConnectingtheBattery–GasolineVehicles................................................................................................1-4
SECTION2–VEHICLESPECIFICATIONS........................................................................................................2-1
SECTION3–GENERALINFORMATION...........................................................................................................3-1
ModelIdentication........................................................................................................................................3-1
SerialNumber...........................................................................................................................................3-1
Storage.........................................................................................................................................................3-2
PreparingtheVehicleforExtendedStorage................................................................................................3-3
ReturningtheStoredVehicletoService......................................................................................................3-4
LiftingTheVehicle.........................................................................................................................................3-4
LiftingOnlyTheFront................................................................................................................................3-4
LiftingOnlyTheRear.................................................................................................................................3-5
LiftingTheEntireVehicle............................................................................................................................3-6
UsingaBoosterBattery(JumpStarting)..........................................................................................................3-6
................................................................................................................................................................3-6
SECTION4–BODYANDTRIM.........................................................................................................................4-1
CleaningtheVehicle......................................................................................................................................4-1
FrontBodyRepair.........................................................................................................................................4-2
StressLinesorStreaks..............................................................................................................................4-2
MinorImpactDamage/Deformations...........................................................................................................4-2
MinorScratchesandSurfaceBlemishes.....................................................................................................4-2
SmallScratchesThatCannotBeBuffedOut...............................................................................................4-3
Touch-UpPaintColorChart........................................................................................................................4-3
Gouges,Punctures,Tears,LargeScratches,andAbrasions.........................................................................4-3
FrontBody....................................................................................................................................................4-4
FrontFasciaRemoval................................................................................................................................4-4
FrontFasciaInstallation.............................................................................................................................4-6
FrontCowlRemoval..................................................................................................................................4-6
FrontCowlInstallation................................................................................................................................4-9
InstrumentPanelRemoval.........................................................................................................................4-9
InstrumentPanelInstallation....................................................................................................................4-10
FrontFenderRemoval.............................................................................................................................4-10
FrontFenderInstallation...........................................................................................................................4-11
UnderPedalCloseoutPanelRemoval.......................................................................................................4-11
UnderPedalCloseoutPanelInstallation....................................................................................................4-12
UnderSeatCloseoutPanels........................................................................................................................4-12
UnderSeatCloseoutPanelRemoval........................................................................................................4-12
UnderSeatCloseoutPanelInstallation.....................................................................................................4-13
ROPS(RollOverProtectiveStructure)..........................................................................................................4-14
ROPSRemoval.......................................................................................................................................4-14
ROPSInstallation....................................................................................................................................4-16
SidePanel..................................................................................................................................................4-17
SidePanelRemoval................................................................................................................................4-17
SidePanelInstallation..............................................................................................................................4-18
UnderSeatCenterPanel.............................................................................................................................4-18
UnderseatCenterPanelRemoval............................................................................................................4-18
2009-2012XRT950MaintenanceandServiceManualPageiii

UnderseatCenterPanelInstallation.........................................................................................................4-19
RearFender................................................................................................................................................4-19
RearFenderRemoval..............................................................................................................................4-19
RearFenderInstallation...........................................................................................................................4-20
CargoBed...................................................................................................................................................4-20
CargoBedRemoval................................................................................................................................4-20
CargoBedInstallation..............................................................................................................................4-20
SECTION5–ACCELERATORANDBRAKEPEDALGROUP............................................................................5-1
AcceleratorPedalRemoval–ThroughEarly-2012ModelYear.........................................................................5-1
AcceleratorPedalInstallation–ThroughEarly-2012ModelYear.......................................................................5-4
AcceleratorCableRemoval–ThroughEarly-2012ModelYear.........................................................................5-5
AcceleratorCableInstallation–ThroughEarly-2012ModelYear......................................................................5-6
AcceleratorCableAdjustment–ThroughEarly-2012ModelYear......................................................................5-7
AcceleratorPedalRemoval–FromEarly-2012ModelYear..............................................................................5-9
AcceleratorPedalInstallation–FromEarly-2012ModelYear.........................................................................5-10
AcceleratorCableRemoval–FromEarly-2012ModelYear.............................................................................5-11
AcceleratorCableInstallation–FromEarly-2012ModelYear.........................................................................5-12
AcceleratorCableAdjustment–FromEarly-2012ModelYear........................................................................5-12
BrakePedalRemoval..................................................................................................................................5-14
BrakePedalInstallation...............................................................................................................................5-14
BrakePedalAdjustment...............................................................................................................................5-15
SECTION6–BRAKES.....................................................................................................................................6-1
GeneralInformation.......................................................................................................................................6-1
Troubleshooting.............................................................................................................................................6-1
BrakeSystemTroubleshooting...................................................................................................................6-1
BrakeSystemInspection............................................................................................................................6-4
HydraulicandMechanicalComponents...........................................................................................................6-6
BrakeFluidReservoir................................................................................................................................6-7
BrakeHoseReplacement...........................................................................................................................6-7
BrakePadsandCaliper...........................................................................................................................6-12
BrakeDiscs.............................................................................................................................................6-14
MasterCylinderReplacement...................................................................................................................6-15
BleedingtheHydraulicBrakeSystem...........................................................................................................6-16
VacuumBleedingofBrakesonaDOT5FluidFilledSystem......................................................................6-16
ManualBleedingofBrakesonaDOT5FluidFilledSystem.......................................................................6-17
RellingtheHydraulicSystem..................................................................................................................6-18
ParkBrakeSystem......................................................................................................................................6-19
ParkBrakeCableRemoval......................................................................................................................6-19
ParkBrakeCableInstallation....................................................................................................................6-22
ParkBrakeHandleRemoval....................................................................................................................6-24
ParkBrakeHandleInstallation..................................................................................................................6-24
ParkBrakeAdjustment............................................................................................................................6-25
SECTION7–STEERINGANDFRONTSUSPENSION.......................................................................................7-1
SteeringWheel..............................................................................................................................................7-1
SteeringWheelRemoval............................................................................................................................7-1
SteeringWheelInstallation.........................................................................................................................7-2
SteeringColumn............................................................................................................................................7-2
SteeringColumnRemoval..........................................................................................................................7-2
SteeringColumnInstallation.......................................................................................................................7-4
RackandPinion............................................................................................................................................7-5
RackandPinionInspection........................................................................................................................7-5
RackandPinionRemoval..........................................................................................................................7-5
RackandPinionInstallation.......................................................................................................................7-6
FrontSuspension..........................................................................................................................................7-6
WheelAlignment.......................................................................................................................................7-7
StrutRemovalandInspection.....................................................................................................................7-8
StrutInstallation.........................................................................................................................................7-9
SteeringKnuckleRemoval.........................................................................................................................7-9
Pageiv2009-2012XRT950MaintenanceandServiceManual

SteeringKnuckleInstallation....................................................................................................................7-10
A-ArmRemoval........................................................................................................................................7-11
A-ArmInstallation.....................................................................................................................................7-11
BallJointRemoval....................................................................................................................................7-11
BallJointInstallation................................................................................................................................7-12
FrontWheelBearingsandHubs...................................................................................................................7-12
FrontWheelFreePlayInspection.............................................................................................................7-12
FrontWheelBearingsandHubRemoval...................................................................................................7-12
FrontWheelBearingsandHubInstallation................................................................................................7-13
SECTION8–WHEELSANDTIRES..................................................................................................................8-1
GeneralInformation.......................................................................................................................................8-1
Wheels.........................................................................................................................................................8-2
WheelRemoval.........................................................................................................................................8-2
WheelInstallation......................................................................................................................................8-2
Tires.............................................................................................................................................................8-2
TireRepair................................................................................................................................................8-2
TireRemoval.............................................................................................................................................8-3
TireInstallation..........................................................................................................................................8-3
SECTION9–REARSUSPENSION...................................................................................................................9-1
RearShockRemoval.....................................................................................................................................9-1
RearShockInstallation..................................................................................................................................9-2
LateralLinkRemoval.....................................................................................................................................9-2
LateralLinkInstallation..................................................................................................................................9-2
TrailingArmRemoval.....................................................................................................................................9-3
TrailingArmInstallation..................................................................................................................................9-4
RearWheelBearingsandHubs......................................................................................................................9-5
RearWheelFreePlayInspection................................................................................................................9-5
RearWheelBearingsandHubRemoval.....................................................................................................9-5
RearWheelBearingsandHubInstallation..................................................................................................9-6
WheelAlignment...........................................................................................................................................9-7
SECTION10–PERIODICMAINTENANCE......................................................................................................10-1
GeneralInformation.....................................................................................................................................10-1
Pre-OperationandDailySafetyChecklist......................................................................................................10-2
PerformanceInspection...........................................................................................................................10-3
PeriodicServiceSchedule............................................................................................................................10-3
PeriodicLubricationSchedule......................................................................................................................10-6
BrakeFluidReservoir..................................................................................................................................10-7
EngineOil...................................................................................................................................................10-7
EngineOilLevelCheck............................................................................................................................10-7
EngineOilandFilterChange....................................................................................................................10-8
OilViscosity...........................................................................................................................................10-10
SparkPlugs................................................................................................................................................10-11
SparkPlugCleaningAndInspection........................................................................................................10-11
SparkPlugGapInspection......................................................................................................................10-11
GearcaseLubrication..................................................................................................................................10-11
LubricationLevelCheck–FrontDifferentialandRearTransaxle................................................................10-11
LubricationChange–FrontDifferentialandRearTransaxle......................................................................10-12
AirIntakeSystem.......................................................................................................................................10-13
AirFilterReplacement.............................................................................................................................10-13
FuelingInstructions.....................................................................................................................................10-14
Battery.......................................................................................................................................................10-15
SECTION11–TROUBLESHOOTINGANDELECTRICALSYSTEM..................................................................11-1
GeneralInformation......................................................................................................................................11-1
ElectricalSystem..........................................................................................................................................11-1
WiringDiagram.............................................................................................................................................11-2
TroubleshootingGuide..................................................................................................................................11-8
2009-2012XRT950MaintenanceandServiceManualPagev

TestProcedures.........................................................................................................................................11-12
SECTION12–ELECTRICALCOMPONENTS..................................................................................................12-1
StarterandStarterSolenoid.........................................................................................................................12-1
NeutralSwitch.............................................................................................................................................12-1
NeutralSwitchRemoval...........................................................................................................................12-1
NeutralSwitchInstallation........................................................................................................................12-2
CarburetorSolenoid.....................................................................................................................................12-2
CarburetorSolenoidRemoval...................................................................................................................12-2
CarburetorSolenoidInstallation................................................................................................................12-3
VoltageRegulator........................................................................................................................................12-3
VoltageRegulatorRemoval......................................................................................................................12-3
VoltageRegulatorInstallation...................................................................................................................12-4
WarningLights............................................................................................................................................12-5
WarningLightRemoval............................................................................................................................12-5
WarningLightInstallation.........................................................................................................................12-5
FuelGauge/HourMeter...............................................................................................................................12-6
FuelGauge/HourMeterRemoval.............................................................................................................12-6
FuelGauge/HourMeterInstallation...........................................................................................................12-6
KeySwitch..................................................................................................................................................12-7
KeySwitchRemoval................................................................................................................................12-7
KeySwitchInstallation.............................................................................................................................12-7
LightSwitch.................................................................................................................................................12-7
LightSwitchRemoval..............................................................................................................................12-7
LightSwitchInstallation............................................................................................................................12-8
FrontDifferentialDisableSwitch(Optional)....................................................................................................12-8
FrontDifferentialDisableSwitchRemoval.................................................................................................12-8
FrontDifferentialDisableSwitchInstallation..............................................................................................12-8
FrontDifferentialLimitSwitch.......................................................................................................................12-8
FrontDifferentialLimitSwitchRemoval.....................................................................................................12-9
FrontDifferentialLimitSwitchInstallation..................................................................................................12-9
Fuse...........................................................................................................................................................12-9
FuseRemoval.........................................................................................................................................12-9
FuseInstallation......................................................................................................................................12-9
FuelLevelSendingUnit..............................................................................................................................12-10
FuelLevelSendingUnitRemoval............................................................................................................12-10
FuelLevelSendingUnitInstallation.........................................................................................................12-10
IgnitionCoilAndChargeCoil.......................................................................................................................12-10
IgnitionCoilAnd/orChargeCoilRemoval.................................................................................................12-10
OilPressureSensor....................................................................................................................................12-11
Headlights..................................................................................................................................................12-11
HeadlightBulbRemoval..........................................................................................................................12-11
HeadlightBulbInstallation.......................................................................................................................12-11
WireHarnessDiodes..................................................................................................................................12-12
DiodeRemoval.......................................................................................................................................12-12
DiodeInstallation....................................................................................................................................12-12
Battery.......................................................................................................................................................12-12
GeneralInformation................................................................................................................................12-13
SECTION13–ENGINE...................................................................................................................................13-1
EngineRemoval..........................................................................................................................................13-1
EngineInstallation.......................................................................................................................................13-5
EngineRPMAdjustment–ThroughEarly-2012ModelYear...........................................................................13-5
VehicleCreep..........................................................................................................................................13-5
IdleSpeedAdjustment.............................................................................................................................13-6
HighSpeedAdjustment...........................................................................................................................13-9
EngineRPMAdjustment–FromEarly-2012ModelYear...............................................................................13-11
VehicleCreep.........................................................................................................................................13-11
IdleSpeedAdjustment............................................................................................................................13-11
HighSpeedAdjustment..........................................................................................................................13-14
GovernorLeverResetAdjustment...............................................................................................................13-16
Pagevi2009-2012XRT950MaintenanceandServiceManual

SECTION14–FUELSYSTEM........................................................................................................................14-1
FuelLines...................................................................................................................................................14-1
FuelFilter....................................................................................................................................................14-1
FuelPump..................................................................................................................................................14-1
Carburetor...................................................................................................................................................14-2
CarburetorJetting....................................................................................................................................14-2
FuelLevelSendingUnit...............................................................................................................................14-3
FuelLevelSendingUnitRemoval.............................................................................................................14-3
FuelLevelSendingUnitInstallation..........................................................................................................14-5
FuelTank....................................................................................................................................................14-7
FuelTankRemoval..................................................................................................................................14-7
FuelTankStorageorDisposal..................................................................................................................14-8
FuelTankInstallation...............................................................................................................................14-9
CarbonCanister(IfEquipped)......................................................................................................................14-9
CarbonCanisterRemoval.......................................................................................................................14-10
CarbonCanisterInstallation....................................................................................................................14-10
SECTION15–EXHAUSTSYSTEM.................................................................................................................15-1
MuferRemoval..........................................................................................................................................15-1
MuferInstallation........................................................................................................................................15-1
ExhaustPipeRemoval.................................................................................................................................15-2
ExhaustPipeInstallation..............................................................................................................................15-2
SECTION16–FRONTDIFFERENTIALANDHALFSHAFTS............................................................................16-1
FrontDifferentialRemoval............................................................................................................................16-1
FrontDifferentialInstallation.........................................................................................................................16-3
FrontHalfshaftRemoval...............................................................................................................................16-5
FrontHalfshaftInstallation............................................................................................................................16-5
SECTION17–TRANSAXLEANDHALFSHAFTS............................................................................................17-1
GeneralInformation.....................................................................................................................................17-1
Ratios.....................................................................................................................................................17-1
TransaxleRemoval......................................................................................................................................17-1
TransaxleInstallation...................................................................................................................................17-6
RearHalfshaftRemoval...............................................................................................................................17-7
RearHalfshaftInstallation............................................................................................................................17-7
ShifterCableAdjustment..............................................................................................................................17-7
Four-WheelDriveCableAdjustment–ThroughEarly-2012ModelYear..........................................................17-8
DifferentialLockCableAdjustment...............................................................................................................17-9
SECTION18–CLUTCHES..............................................................................................................................18-1
ClutchTroubleshooting................................................................................................................................18-1
OuterClutchCover......................................................................................................................................18-2
OuterClutchCoverRemoval....................................................................................................................18-2
OuterClutchCoverInstallation.................................................................................................................18-3
DriveBelt....................................................................................................................................................18-3
DriveBeltRemoval..................................................................................................................................18-3
DriveBeltInstallation...............................................................................................................................18-5
DriveClutch................................................................................................................................................18-5
DriveClutchRemoval..............................................................................................................................18-5
DriveClutchCleaningandInspection........................................................................................................18-6
DriveClutchDisassembly.........................................................................................................................18-7
DriveClutchComponentInspection..........................................................................................................18-7
DriveClutchAssembly.............................................................................................................................18-7
DriveClutchInstallation...........................................................................................................................18-9
DrivenClutch.............................................................................................................................................18-10
DrivenClutchRemoval...........................................................................................................................18-10
DrivenClutchDisassembly......................................................................................................................18-12
DrivenClutchAssembly..........................................................................................................................18-14
2009-2012XRT950MaintenanceandServiceManualPagevii

DrivenClutchInstallation.........................................................................................................................18-14
InnerClutchCover......................................................................................................................................18-14
InnerClutchCoverRemoval....................................................................................................................18-14
InnerClutchCoverInstallation.................................................................................................................18-15
SECTIONi–INDEX
Pageviii2009-2012XRT950MaintenanceandServiceManual

SECTION1–SAFETY1
SAFETYDETAILS
ToensurethesafetyofthoseservicingClubCarvehicles,andtoprotectthevehiclesfrompossibledamageresulting
fromimproperserviceormaintenance,theproceduresinthismanualmustbefollowed.
ItisimportanttonotethatthroughoutthismanualtherearestatementslabeledDANGER,WARNING,orCAUTION.
Thesespecialstatementsrelatetospecicsafetyissues,andmustberead,understood,andheededbefore
proceedingwithprocedures.TherearestatementslabeledNOTE,whichprovideotheressentialserviceor
maintenanceinformation.
PERSONALSAFETY
DANGER
•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.The
colorassociatedwithDangerisRED.
WARNING
•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.
ThecolorassociatedwithWarningisORANGE.
CAUTION
•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin
minorpersonalinjury.ThecolorassociatedwithCautionisYELLOW.
MACHINESAFETY
CAUTION
•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould
resultinpropertydamage.
ACAUTION,withoutthesafetyalertsymbol,isintendedformachineandpropertysafety.Itisusedthroughoutthis
manualfollowedbyspecicinstructionstopreventmachineorpropertydamage.FailuretofollowtheseCAUTION
messagescouldresultinmachineorpropertydamage.
INFORMATION
NOTE:Instructionsthatclarifysteps,procedures,orotherinformationinthismanual.
2009-2012XRT950MaintenanceandServiceManualPage1-1

1GeneralWarningSAFETY
GENERALWARNING
Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Service
techniciansshouldbecomefamiliarwiththesegeneralsafetystatements.Also,otherspecicsafetystatementsappear
throughoutthismanualandonthevehicle.
DANGER
•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice
area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand
rubbergloveswhenworkingonornearbatteries.
•Battery–Poison!Containsacid!Causessevereburns.Avoidcontactwithskin,eyes,orclothing.
Antidotes:
–External:Flushwithwater.Callaphysicianimmediately.
–Internal:Drinklargequantitiesofmilkorwater.Followwithmilkofmagnesiaorvegetable
oil.Callaphysicianimmediately.
–Eyes:Flushwithwaterfor15minutes.Callaphysicianimmediately.
•Gasoline–Flammable!Explosive!Donotsmoke.Keepsparksandamesawayfromthevehicleand
servicearea.Serviceonlyinawell-ventilatedarea.
•Donotoperategasolinevehicleinanenclosedareawithoutproperventilation.Theengineproduces
carbonmonoxide,whichisanodorless,deadlypoison.
WARNING
•Theengineproducescarbonmonoxide,whichisadeadly,odorless,colorlessgasthatcanquickly
accumulateinanenclosedcab.Donotruntheengineinaparkedvehiclewithoutpropercab
ventilation.Movetofreshairifyoufeelnausea,headache,dizziness,drowsiness,orweakness.
•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and
CAUTIONstatementsinthismanualaswellasthoseonthevehicle.
•Onlytrainedtechniciansshouldserviceorrepairthevehicle.Anyonedoingevensimplerepairsor
serviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.Theappropriate
instructionsmustbeusedwhenperformingmaintenance,service,oraccessoryinstallation.
•Priortoservicingthevehicleorleavingthevehicleunattended,turnthekeyswitchOFF,remove
thekey,andplacetheForward/ReversehandleintheNEUTRALposition.Chockthewheelswhen
servicingthevehicle.
•Toavoidunintentionallystartingthevehicledisconnectbatteryandsparkplugwires.See
DisconnectingtheBattery–GasolineVehicleonpage1-4.
•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery
cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or
anyothermetalcomponent.
•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicle.Wearafullfaceshieldand
rubbergloveswhenworkingonornearbatteries.
•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthevehicle.
WARNINGCONTINUEDONNEXTPAGE
Page1-22009-2012XRT950MaintenanceandServiceManual

SAFETYGeneralWarning1
WARNING
•Movingparts!Donotattempttoservicethevehiclewhileitisrunning.
•Ensurebatteryconnectionsarecleanandproperlytightened.SeeBatteryonpage12-12.
•Hot!Donotattempttoservicehotengineorexhaustsystem.Failuretoheedthiswarningcould
resultinsevereburns.
•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto
avoidshortingofcomponentsorwiring.
•Checkthevehicleowner’smanualforproperlocationofallvehiclesafetyandoperationdecalsand
makesuretheyareinplaceandareeasytoread.
•Anymodicationorchangetothevehiclethataffectsthestabilityorhandlingofthevehicle,or
increasesmaximumvehiclespeedbeyondfactoryspecications,couldresultinseverepersonal
injuryordeath.
•Thediameterofalltiresonthevehiclemustbeequal;otherwisetheall-wheeldrivesystemwillnot
operateasintendedandcouldresultinseverepersonalinjuryordeath.Neverinstalltiresofdifferent
diametersonthevehicle.
•Liftonlyoneendofthevehicleatatime.Useasuitableliftingdevice(chainhoistorhydraulicoor
jack)with1000lb.(454kg)minimumliftingcapacity.Donotuseliftingdevicetoholdvehicleinraised
position.Useapprovedjackstandsofproperweightcapacitytosupportthevehicleandchock
thewheelsthatremainontheoor.Whennotperformingatestorserviceprocedurethatrequires
movementofthewheels,lockthebrakes.
•Whenservicingthevehiclewithpartofthevehicleonjackstands,donotoperatetheenginewiththe
Forward/ReversehandleineithertheFORWARDorREVERSEposition.Thefour-wheeldrivesystem
mayengageanywheel(s),frontorrear,dependingonthemodeselected(Figure1-2,Page1-4).
•Ifwiresareremovedorreplaced,makesurewiringandwireharnessareproperlyroutedandsecured.
Failuretoproperlyrouteandsecurewiringcouldresultinvehiclemalfunction,propertydamage,
personalinjury,ordeath.
•Forvehicleswithcargobeds,removeallcargobeforeraisingthebedorservicingthevehicle.Ensure
thatthebedlockingpinissecurelyengagedwhilebedisraised.Donotclosebeduntilallpersonsare
clearofcargobedarea.Keephandsclearofallcrushareas.Donotdropcargobed;lowergentlyand
keepentirebodyclear.Failuretoheedthiswarningcouldresultinseverepersonalinjuryordeath.
•Improperuseofthevehicleorfailuretoproperlymaintainitcouldresultindecreasedvehicle
performance,severepersonalinjury,ordeath.
•Donotleavechildrenunattendedonvehicle.
DISABLINGTHEVEHICLE
1.Settheparkbrake.
2.TurnthekeyswitchOFFandremovethekey.
3.PlacetheForward/ReversecontrolintheNEUTRALposition.
4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.
2009-2012XRT950MaintenanceandServiceManualPage1-3

1GeneralWarningSAFETY
DISCONNECTINGTHEBATTERY–GASOLINEVEHICLES
1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.
2.Disconnectthebatterycables,negative(–)cablerst,asshown(Figure1-1).
3.Disconnectthesparkplugwire(s)fromthesparkplug(s).
2
(+)
1
(–)
1.Removenegativebatterycable.
2.Removepositivebatterycable.
Connectbatterycablesinreverseorder.
821
Figure1-1BatteryCableRemoval
795
Figure1-24x4DriveWarning
CONNECTINGTHEBATTERY–GASOLINEVEHICLES
1.Connectthebatterycables,positive(+)cablerst.
2.Tightenbatteryterminalsto80in-lb(9N·m).
3.CoatterminalswithBatteryT erminalProtectorSpray(CCP/N1014305)tominimizecorrosion.
4.Connectthesparkplugwire(s)tothesparkplug(s).
Page1-42009-2012XRT950MaintenanceandServiceManual

SECTION2–VEHICLESPECIFICATIONS2
SPECIFICATIONSXRT950
4X2
XRT950
4X4
XRT950EX
4X4
POWERSOURCEGasolineGasolineGasoline
Engine:4-cycleOHV,480cc,14.0maximumHP@3600RPM(perSAEJ1940/1349),
twin-cylinder,air-cooled,withpressurelubricationsystem•••
Fuelsystem:Down-draftcarburetorwithoatbowl,xedjets,fuellters,andimpulsefuelpump•••
Governor:Internaltoengine,centrifugal•••
Ignition:Transistorizedmagneto•••
Transmission:Forwardandreversewithneutral(18.19:1forward,34.37:1reverse)•••
Electricalsystem:12voltstartingbattery:525ccaat0°F(-17.8°C).80-minutereserve
capacity(25-ampat80°F)35amp-hours•••
Torqueconverter:Automatic,variable-speed,drytype•••
STEERING/SUSPENSION/BRAKES
Suspension:
Front:MacPhersonStrut
Rear:Independentwithcoil-overshockabsorbers
•••
Steering:Self-adjustingrackandpinion,Ackerman•••
Brakes:Hydraulicbrakesystem–brakepadsanddiscsoneachwheelwithseparate
hand-operatedparkbrake•••
BODY/CHASSIS
Frame/Chassis:Boxtubesteel•••
Sideandrearbody:Polypropylene•••
Cargobed:Powder-coatedsteel•••
Frontbody:TPO(ThermoPlasticOlen)•••
Tires:AllTerrain:25x9–12frontandrear,tubeless,4-plyratedloadrange
Mud:25x9–12frontandrear;tubeless,4-plyratedloadrange•
Tires:AllTerrain:25x9–12front,25x11–12(Kenda)or25x10–12(OTR)rear,tubeless,
4-plyratedloadrange
Mud:25x9–12front,25x11–12rear;tubeless,4-plyratedloadrange
••
DIMENSIONS/WEIGHT
Overalllength:105in.(266.7cm)
Overallwidth:55.0in.(139.7cm)
Overallheight(withROPS):withall-terraintires73.0in.(185.4cm)
Wheelbase69.5in.(176.5cm)
Groundclearance:undertransaxle9.0in.(22.9cm)
Frontwheeltrackwidth44in.(111.8cm)
Rearwheeltrackwidth45in.(114.3cm)
Weight:withall-terraintiresandwithoutbrushguard1200lb.
(544.3kg)
1210lb.
(548.8kg)
1275lb.(578.3
kg)
TABLECONTINUEDONNEXTPAGE
2009-2012XRT950MaintenanceandServiceManualPage2-1

2GeneralWarningVEHICLESPECIFICATIONS
SPECIFICATIONSXRT950
4X2
XRT950
4X4
XRT950EX
4X4
Forwardspeed25mph(40km/h)
GovernedRPM3950
TurningRadius139in.(354cm)
Loadbedheight32in.(81.3cm)
Loadbedsize(boxbedinsidedimensions)
34x47x10in.
(86.4x119.4x25.4cm)
(9.25cubicfeet)
Maximumpayloadcapacity(levelsurfaceonly)425lb.(193kg)
Vehicleratedcapacity(payload,driver,andpassenger;levelsurfaceonly)925lb.(420kg)
Maximumgrossvehicleweight(fullyloadedvehicle,includingaccessories)2135lb.(968kg)
Standardseatingcapacity2
LIQUIDCAPACITIES
Enginecrankcasewithlter:SAE10W-30,APIclassicationSJ1.5qt.
(1.4L)
Frontdifferential:80W90gearoil5.5oz.(170mL)
Reartransaxle:10W-30SF ,SG,SH1gal.(3.79L)
Brakeuid:DOT5(silicone)brakeuid8oz.(240ml)
Fueltank:unleadedgasoline5.2gallons
(19.7L)
TIREPRESSURE
All-terraintread:
CarlisleAllTrailII25x9–12and25x11–12
Front&
Rear:16psi
(1.1Bars)
Front&
Rear:16psi
(1.1Bars)
Front&Rear:
16psi(1.1Bars)
KendaTerraTracK50225x9–12and25x11–12
Front:13psi
(0.9Bars)
Rear:16psi
(1.1Bars)
Front:13psi
(0.9Bars)
Rear:16psi
(1.1Bars)
Front:13psi
(0.9Bars)
Rear:16psi
(1.1Bars)
OTR350MAGOffRoad25x9–12and25x10–12
Front&
Rear:14psi
(0.97Bars)
Front:14psi
(0.97Bars)
Rear:21psi
(1.45Bars)
Front:14psi
(0.97Bars)
Rear:21psi
(1.45Bars)
Mudtires:
Carlisle56041525x9–12and25x11–12
Front&
Rear:16psi
(1.1Bars)
Front&
Rear:16psi
(1.1Bars)
Front&Rear:
16psi(1.1Bars)
OTR440MAGOffRoad25x9–12and25x11–12
Front&
Rear:14psi
(0.97Bars)
Front&
Rear:14psi
(0.97Bars)
Front&Rear:
14psi(0.97
Bars)
Page2-22009-2012XRT950MaintenanceandServiceManual

SECTION3–GENERALINFORMATION3
DANGER
•SeeGeneralWarningonpage1-2.
WARNING
•SeeGeneralWarningonpage1-2.
Throughoutthismanual,importantfeaturesuniquetoeachmodelarehighlighted.ClubCar,LLCrecommendsthe
owner/operatorreadandunderstandthismanualandpayspecialattentiontofeaturesspecictotheirvehicle(s).
Refertotheowner’smanualprovidedwiththevehicleforinformationonthefollowingtopics:
•ControlsandIndicators
•DrivingInstructions
•BedLatch
•BedLockingPin
•LoadingandUnloading
•T owingwiththeVehicle
•TransportingonaTrailer
•SubsequentOwnerRegistration
•Warranties
MODELIDENTIFICATION
SERIALNUMBER
Theserialnumberofthevehicleisprintedonabarcodedecalmountedontheframebelowthesteeringwheel
(Example:SD0601-123456)(Figure3-1,Page3-2).Thereisalsoasecondserialnumberdecalmountedontherear
bodyframeabovetheengine.SeefollowingNOTE.
NOTE:Havethevehicleserialnumberavailablewhenorderingpartsormakinginquiries.
Thetwolettersatthebeginningoftheserialnumberindicatethevehiclemodel.Thefollowingfourdigitsindicatethe
modelyearandproductionweekduringwhichthevehiclewasbuilt.Thesixdigitsfollowingthehyphenrepresentthe
uniquesequentialnumberassignedtoeachvehiclebuiltwithinagivenmodelyear.
2009-2012XRT950MaintenanceandServiceManualPage3-1

3StorageGENERALINFORMATION
SERIAL NUMBER
SD0601-123456
P O BOX 204658
AUGUST A GA 30917
190
Figure3-1SerialNumberDecal
STORAGE
SeeGeneralWarningonpage1-2.
DANGER
•Neverattempttodraingasolinewhentheengineishotorwhileitisrunning.
•Besuretocleanupanyspilledgasolinebeforeoperatingthevehicle.
•Storefuelinanapprovedfuelcontaineronly.Storeinawell-ventilatedareaawayfromsparks,open
ames,heaters,orheatsources.
•Keepfueloutofthereachofchildren.
•Donotsiphonfuelfromthevehicle.
WARNING
•TurnthekeyswitchtotheOFFposition,removethekey,andleavetheForward/Reversehandlein
theNEUTRALpositionduringstorage.Thisistopreventunintentionallystartingthevehicleora
rehazard.
•Turnthefuelshut-offvalve(1)theclosed(OFF)position(Figure3-2,Page3-3).
•Donotattempttochargefrozenbatteriesorbatterieswithbulgedcases.Discardthebattery.Frozen
batteriescanexplode.
Page3-22009-2012XRT950MaintenanceandServiceManual

GENERALINFORMATIONStorage3
CAUTION
•Batteriesinalowstateofchargewillfreezeatlowtemperatures.
PREPARINGTHEVEHICLEFOREXTENDEDSTORAGE
1.Unloadthevehiclesothatthetiresaresupportingonlytheweightofthevehicle.
2.Storethevehicleinacool,dryplace.Thiswillminimizebatteryself-discharge.Ifthebatteryappearstobeweak,
haveitchargedbyatrainedtechnician.Useanautomotive-type12-voltbatterychargerratedat10ampsorless.
Checkelectrolytelevelafterchargingandadddistilledwaterifnecessary.
3.MakesurethekeyswitchisintheOFFpositionandtheForward/ReversehandleisintheNEUTRALposition.
Chockthewheels.
4.Preparethefueltank.
4.1.Fillthetankwithfreshfuel.
4.2.Followingthemanufacturer’sdirections,addacommerciallyavailablefuelstabilizer(suchasSta-Bil®).Run
theengineinawell-ventilatedareatoallowtreatedfueltoreplaceuntreatedfuelinthecarburetor.
4.3.Turnthefuelshut-offvalve(1)totheclosed(OFF)position(Figure3-2,Page3-3).
1
2
3
1.FuelShut-offValve2.Closed(OFF)3.Open(ON)NOTE:
Whenselectingvalveposition,ensurethatitisfullyopenedor
fullyclosed.
823
Figure3-2FuelShut-offValve
4.4.Disconnectthefuelventlinefromthefueltankventnipple.
4.5.Plugthefueltankventnipplesothatitisairtight.ClubCarrecommendsusingaslip-onvinylcap.
5.Removebothsparkplugs,andpour1/2ounce(14.2mL)ofSAE10weightoilthrougheachofthetwosparkplug
holes.Rotatetheenginecrankshaftbyhandseveraltimes,theninstallbothsparkplugs.
6.Changeengineoil.SeeEngineOilandFilterChangeonpage10-8.
7.Disconnectthebatterycables,negative(–)cablerst.SeeDisconnectingtheBattery–GasolineVehicles
onpage1-4.
8.Thebatteryshouldbecleanandfreeofcorrosion.Washthebatterytopandterminalswithasolutionofbaking
sodaandwater(1cup(237mL)bakingsodaper1gallon(3.8L)ofwater).Rinsethesolutionoffthebattery.
Donotallowthissolutiontoenterthebattery.LettheterminalsdryandthencoatthemwithBatteryT erminal
ProtectorSpray(CCP/N1014305).
2009-2012XRT950MaintenanceandServiceManualPage3-3

3LiftingTheVehicleGENERALINFORMATION
9.Adjustthetirestotherecommendedtirepressure.SeeSection2–VehicleSpecications.
10.Performsemiannualperiodiclubrication.SeePeriodicMaintenanceonpage10-1.
11.Thoroughlycleanthefrontbody,rearbody,seats,cargobed,enginecompartment,andundersideofvehicle.
12.Donotengagetheparkbrake.Chockthewheelstopreventthevehiclefromrolling.
RETURNINGTHESTOREDVEHICLETOSERVICE
1.MakesurethekeyswitchisintheOFFpositionandtheForward/ReversehandleisintheNEUTRALposition.
Chockthewheels.
2.Restorethefuelsystemtooperation.
2.1.Removetheplugfromthefueltankvent.
2.2.Connecttheventtubetothefueltankvent.
3.Connectbatteryandsparkplugwire(s).SeeConnectingtheBattery–GasolineVehiclesonpage1-4.
4.Completelyopenthefuelshut-offvalve(Figure3-2,Page3-3).Ensurethevalveisfullyopen.Apartiallyclosed
fuelshut-offvalvecombinedwiththeuseofthechokecanresultinafouledsparkplugandenginefailure.
5.PlacetheForward/ReversehandleintheNEUTRALposition.Cranktheengineuntilfuelispumpedintothe
carburetorandthefuellinesandtheenginestarts.Turntheengineoff.SeefollowingNOTE.
NOTE:Duetotheoiladdedtothegasolineengineinpreparationforstorage,theenginemaysmokeexcessivelyfora
shorttimewhenitisrunforthersttimeafterstorage.
6.PerformthePre-OperationandDailySafetyChecklistandthePerformanceInspectiononpage10-2.
LIFTINGTHEVEHICLE
SeeGeneralWarningonpage1-2.
LIFTINGONLYTHEFRONT
1.Placevehicleonalevelsurface.
2.TurnthekeyswitchOFFandremovethekey.PlacetheForward/ReversehandleinNEUTRALandsetthepark
brake.Chocktherearwheels.
3.Disconnectbatteryandsparkplugwire(s).SeeDisconnectingtheBattery–GasolineVehiclesonpage1-4.
4.Ifremovingwheel,loosenthefrontwheellugnuts.
5.Liftfrontofvehicleandsupportonjackstands(Figure3-3,Page3-5).SeeWARNING“Liftonlyoneend...”in
GeneralWarningonpage1-2.
6.Removethewheel.
Page3-42009-2012XRT950MaintenanceandServiceManual