Club Car 2007 Carryall 295 Manual

Manual Number 103209114
Edition Code 1006F1208E
Gasoline, Diesel and IntelliTach, and Homologated Vehicles
2007 Carryall 295/295SE
and XRT 1550/1550SE
Maintenance and Service
Manual

2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S 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 Carryall 295, Carryall 295 SE,
XRT 1550, XRT 1550 SE and IntelliTach vehicles, and should be thoroughly reviewed prior to servicing the
vehicles. The procedures provided must be properly implemented, and the DANGER, WARNING, and CAU-
TION 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; however, unique situations sometimes occur when
servicing a vehicle. If it appears that a service question is not answered in this manual, you may write to us at:
Club Car, Inc.; P.O. Box 204658; Augusta, GA 30917; Attention: Technical Services, or contact a Club Car
Technical Service Representative at [phone], ext. 3580.
Copyright © 2006, 2007, 2008 Club Car, Inc.
Club Car and Carryall
are registered trademarks of Club Car, Inc.
This manual effective June 19, 2006.

Page ii 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
ý 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 its 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.
Damage to a vehicle or component thereof not resulting from a defect or that occurs due to unrea-
sonable or unintended use, overloading, abuse, or neglect (including failure to provide reasonable
or necessary maintenance as instructed in the vehicle owner’s manual), accident or alteration,
including increasing vehicle speed beyond factory specifications or modifications that affect the
stability of the vehicle or the operation thereof, will void the warranty.
Club Car, Inc., reserves the right to change specifications and designs at any time without notice
and without incurring any obligation or liability whatsoever.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle owner’s manual or write to Club Car, Inc., P.O. Box 204658, Augusta, GA 30917-4658
USA, Attention: Warranty Department.

2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ............................................................................................................................... 1-1
SECTION 2A – VEHICLE SPECIFICATIONS: HONDA GAS & KUBOTA DIESEL POW-
ERED
295/295 SE and 1550/1550 SE Specifications ............................................................................. 2a-1
IntelliTach Specifications .............................................................................................................. 2a-3
SECTION 2B – VEHICLE SPECIFICATIONS: KAWASAKI GAS & KUBOTA DIESEL
POWERED
295/295 SE and 1550/1550 SE Specifications ............................................................................. 2b-1
295 Homologated Specifications ................................................................................................. 2b-3
IntelliTach Specifications .............................................................................................................. 2b-5
SECTION 3 – GENERAL INFORMATION
General Information .......................................................................................................................... 3-1
Model Identification ........................................................................................................................... 3-1
Storage ............................................................................................................................................. 3-2
Preparing the Vehicle for Extended Storage ................................................................................ 3-3
Returning the Stored Vehicle to Service ....................................................................................... 3-4
Using A Booster Battery (Jump Starting) .......................................................................................... 3-5
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 4-1
Seat Cleaning ............................................................................................................................... 4-1
Front Body Repair ............................................................................................................................. 4-2
Light Scratches ............................................................................................................................. 4-2
Abrasions and Haze ..................................................................................................................... 4-2
Large Scratches and Abrasions .................................................................................................... 4-2

Page iv 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
Front Body Components .................................................................................................................. 4-3
Instrument Panel Removal ........................................................................................................... 4-3
Instrument Panel Installation ........................................................................................................ 4-3
Front Fascia Removal .................................................................................................................. 4-4
Front Fascia Installation ............................................................................................................... 4-4
Hood Removal .............................................................................................................................. 4-4
Hood Installation .......................................................................................................................... 4-4
Center Cowl Panel Removal ........................................................................................................ 4-4
Center Cowl Panel Installation ..................................................................................................... 4-5
Side Cowl Panel (Fender) Removal ............................................................................................. 4-5
Side Cowl Panel (Fender) Installation ..........................................................................................4-5
Front Fender Flare Removal ........................................................................................................ 4-6
Front Fender Flare Installation ..................................................................................................... 4-6
Roll-Over Protective Structure (ROPS) ............................................................................................ 4-6
ROPS Removal ............................................................................................................................ 4-7
ROPS Installation ......................................................................................................................... 4-8
Seat .................................................................................................................................................. 4-9
Seat Removal ............................................................................................................................... 4-9
Seat Adjustment ........................................................................................................................... 4-9
Seat Installation ............................................................................................................................ 4-9
Seat Support Removal ................................................................................................................. 4-10
Seat Support Installation .............................................................................................................. 4-10
Safety Belts ...................................................................................................................................... 4-10
Safety Belt Removal ..................................................................................................................... 4-10
Safety Belt Installation .................................................................................................................. 4-11
Cargo Bed – Electric Lift .................................................................................................................. 4-11
Testing the Bed Lift Motor ............................................................................................................ 4-11
Bed Lift Motor Removal ................................................................................................................ 4-11
Bed Lift Motor Installation ............................................................................................................. 4-12
Cargo Bed Removal ..................................................................................................................... 4-12
Cargo Bed Installation .................................................................................................................. 4-12
Cargo Bed – Manual Lift .................................................................................................................. 4-13
Cargo Bed Removal ..................................................................................................................... 4-13
Cargo Bed Installation .................................................................................................................. 4-13
Rear Fender ..................................................................................................................................... 4-15
Rear Fender Removal .................................................................................................................. 4-15
Rear Fender Installation ............................................................................................................... 4-15
Floor Mat .......................................................................................................................................... 4-15
Floor Mat Removal ....................................................................................................................... 4-15
Floor Mat Installation .................................................................................................................... 4-15

2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page v
SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES
Accelerator Pedal ............................................................................................................................. 5-1
Accelerator Pedal Removal .......................................................................................................... 5-1
Accelerator Pedal Installation ....................................................................................................... 5-2
Accelerator Pedal and RPM Adjustment ...................................................................................... 5-2
Brake Pedal ...................................................................................................................................... 5-3
Brake Pedal Removal ................................................................................................................... 5-3
Brake Pedal Installation ................................................................................................................ 5-3
Brake Pedal Adjustment ............................................................................................................... 5-4
Park Brake Pedal .............................................................................................................................. 5-4
Park Brake Pedal Assembly Removal .......................................................................................... 5-4
Park Brake Pedal Assembly Installation ....................................................................................... 5-4
SECTION 6 – HYDRAULIC AND PARK BRAKE SYSTEMS
Brake System Inspection .................................................................................................................. 6-1
Brake System Troubleshooting ......................................................................................................... 6-3
Brake Pads and Caliper .................................................................................................................... 6-5
Front Brake Pad and Caliper Removal ......................................................................................... 6-5
Front Brake Pad and Caliper Installation ...................................................................................... 6-7
Rear Brake Pad and Caliper Removal .......................................................................................... 6-8
Rear Brake Pad and Caliper Installation ....................................................................................... 6-9
Brake Disc and Hub .......................................................................................................................... 6-10
Front Wheel Disc and Hub Removal ............................................................................................ 6-10
Front Wheel Disc and Hub Installation ......................................................................................... 6-14
Rear Wheel Disc Removal ............................................................................................................ 6-15
Rear Wheel Disc Installation ......................................................................................................... 6-16
Hydraulic Line Replacement ............................................................................................................. 6-17
Front Brake Line Removal ............................................................................................................ 6-17
Front Brake Line Installation ......................................................................................................... 6-17
Rear Brake Line Removal ............................................................................................................. 6-18
Rear Brake Line Installation .......................................................................................................... 6-19
Master Cylinder and Reservoir ......................................................................................................... 6-20
Filling the Hydraulic System ......................................................................................................... 6-20
Reservoir Removal ....................................................................................................................... 6-20
Reservoir Installation .................................................................................................................... 6-20
Master Cylinder Removal ............................................................................................................. 6-21
Master Cylinder Installation .......................................................................................................... 6-21
Bleeding the Hydraulic Brake System .............................................................................................. 6-22
Bleeding Brakes on a DOT 5 Fluid Filled System ......................................................................... 6-22
Purging the Hydraulic System ...................................................................................................... 6-24

Page vi 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
Park Brake System .......................................................................................................................... 6-25
Park Brake Adjustment ................................................................................................................. 6-25
Park Brake Cable Adjustment ...................................................................................................... 6-25
Park Brake Wheel Cables ............................................................................................................ 6-26
Front Park Brake Cable Removal .................................................................................................6-27
Front Park Brake Cable Installation .............................................................................................. 6-28
Park Brake Equalizer Removal .................................................................................................... 6-28
Park Brake Equalizer Installation ................................................................................................. 6-28
SECTION 7 – STEERING AND FRONT SUSPENSION
Steering Wheel ................................................................................................................................. 7-1
Steering Wheel Removal .............................................................................................................. 7-1
Steering Wheel Installation ........................................................................................................... 7-2
Steering Column .............................................................................................................................. 7-2
Steering Column Removal ........................................................................................................... 7-2
Steering Column Installation ........................................................................................................ 7-3
Rack and Pinion ............................................................................................................................... 7-3
Rack and Pinion Removal ............................................................................................................ 7-3
Rack and Pinion Installation ......................................................................................................... 7-4
Rack and Pinion Disassembly ...................................................................................................... 7-5
Rack and Pinion Assembly ........................................................................................................... 7-9
Front Suspension ............................................................................................................................. 7-11
Wheel Alignment .......................................................................................................................... 7-11
Front Suspension Components ........................................................................................................ 7-13
Steering Upright Removal ............................................................................................................ 7-13
Upper A-Arm Removal ................................................................................................................. 7-14
Upper A-Arm Installation .............................................................................................................. 7-16
Lower A-Arm Removal ................................................................................................................. 7-16
Lower A-Arm Installation .............................................................................................................. 7-17
Front Coil-Over Shock Absorber Removal ................................................................................... 7-18
Front Coil-Over Shock Absorber Installation ................................................................................ 7-19
Steering Upright Installation ......................................................................................................... 7-19
SECTION 8 – WHEELS AND TIRES
General Information ......................................................................................................................... 8-1
Wheels ............................................................................................................................................. 8-2
Wheel Removal ............................................................................................................................ 8-2
Wheel Installation ......................................................................................................................... 8-2

2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page vii
Tires .................................................................................................................................................. 8-2
Tire Removal ................................................................................................................................ 8-2
Tire Installation ............................................................................................................................. 8-3
SECTION 9 – REAR SUSPENSION
Rear Coil-Over Shock Absorber ....................................................................................................... 9-1
Swing Arms ....................................................................................................................................... 9-2
Swing Arm Removal ..................................................................................................................... 9-2
Swing Arm Installation .................................................................................................................. 9-3
SECTION 10A – PERIODIC MAINTENANCE: HONDA GASOLINE & KUBOTA DIESEL
POWERED VEHICLES
Periodic Service Schedule ................................................................................................................ 10a-1
Periodic Lubrication Schedule .......................................................................................................... 10a-4
Lubricating The Attachment Arm And Interface ................................................................................ 10a-6
Brake Fluid Reservoir ....................................................................................................................... 10a-7
Brake Fluid .................................................................................................................................... 10a-7
Engine Oil ......................................................................................................................................... 10a-7
Oil Pressure – Gasoline Engine .................................................................................................... 10a-7
Engine Oil Level Check ................................................................................................................ 10a-8
Engine Oil and Filter Change ........................................................................................................ 10a-8
Oil Viscosity .................................................................................................................................. 10a-12
Gearcase Lubrication ........................................................................................................................ 10a-13
Lubrication Level Check for Front Differential, Transmission, and Rear Differential .................... 10a-13
Lubrication Change for Front Differential, Transmission, and Rear Differential ........................... 10a-13
Hydraulic System – Intellitach Vehicle .............................................................................................. 10a-15
Engine Coolant – Diesel Vehicles ..................................................................................................... 10a-16
Engine Coolant Level Check ........................................................................................................ 10a-16
Fueling Instructions ........................................................................................................................... 10a-16
Draining Water from Fuel Filter ..................................................................................................... 10a-17
Battery .............................................................................................................................................. 10a-18
SECTION 10B – PERIODIC MAINTENANCE: KAWASAKI GASOLINE & KUBOTA DIE-
SEL POWERED VEHICLES
Periodic Service Schedule ................................................................................................................ 10b-1
Periodic Lubrication Schedule .......................................................................................................... 10b-4
Lubricating The Attachment Arm And Interface ................................................................................ 10b-6
Brake Fluid Reservoir ....................................................................................................................... 10b-7
Brake Fluid .................................................................................................................................... 10b-7

Page viii 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
Engine Oil ......................................................................................................................................... 10b-7
Oil Pressure – Gasoline Engine ................................................................................................... 10b-7
Engine Oil Level Check ................................................................................................................ 10b-8
Engine Oil and Filter Change ....................................................................................................... 10b-8
Oil Viscosity .................................................................................................................................. 10b-11
Spark Plugs ...................................................................................................................................... 10b-12
Spark Plug Cleaning And Inspection ............................................................................................ 10b-12
Spark Plug Gap Inspection ........................................................................................................... 10b-12
Gearcase Lubrication ....................................................................................................................... 10b-13
Lubrication Level Check for Front Differential, Transmission, and Rear Differential .................... 10b-13
Lubrication Change for Front Differential, Transmission, and Rear Differential ........................... 10b-13
Hydraulic System – Intellitach Vehicle ............................................................................................. 10b-15
Engine Coolant – Diesel Vehicles .................................................................................................... 10b-16
Engine Coolant Level Check ........................................................................................................ 10b-16
Fueling Instructions .......................................................................................................................... 10b-16
Draining Water from Fuel Filter .................................................................................................... 10b-17
Battery .............................................................................................................................................. 10b-18
SECTION 11A – TROUBLESHOOTING AND ELECTRICAL SYSTEM: KAWASAKI
POWERED GASOLINE VEHICLES
Troubleshooting Guide ..................................................................................................................... 11a-1
Wiring Diagram ................................................................................................................................ 11a-6
Test Procedures ............................................................................................................................... 11a-8
Index of Test Procedures ............................................................................................................. 11a-8
SECTION 11B – TROUBLESHOOTING AND ELECTRICAL SYSTEM: HONDA POW-
ERED GASOLINE VEHICLES
Troubleshooting Guide ..................................................................................................................... 11b-1
Wiring Diagram ................................................................................................................................ 11b-6
Test Procedures ............................................................................................................................... 11b-8
Index of Test Procedures ............................................................................................................. 11b-8
SECTION 11C – TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHI-
CLES
Troubleshooting Guide ..................................................................................................................... 11c-1
Wiring Diagram ................................................................................................................................ 11c-6
Test Procedures ............................................................................................................................... 11c-12
Index of Test Procedures ............................................................................................................. 11c-12

2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page ix
SECTION 12A – ELECTRICAL COMPONENTS: KAWASAKI POWERED GASOLINE
VEHICLES
Starter and Starter Solenoid ............................................................................................................. 12a-1
Relays ............................................................................................................................................... 12a-1
Neutral Switch ................................................................................................................................... 12a-2
Carburetor Solenoid .......................................................................................................................... 12a-2
Carburetor Heater ............................................................................................................................. 12a-3
Voltage Regulator ............................................................................................................................. 12a-4
Warning Lights .................................................................................................................................. 12a-5
Fuel Gauge/Hour Meter .................................................................................................................... 12a-6
Key Switch ........................................................................................................................................ 12a-7
12-Volt Accessory Receptacle .......................................................................................................... 12a-8
Bed Lift Switch .................................................................................................................................. 12a-9
Bed Lift Circuit Breaker ..................................................................................................................... 12a-9
Light Switch ...................................................................................................................................... 12a-10
Fuse .................................................................................................................................................. 12a-10
Reverse Warning Buzzer (If Equipped) ............................................................................................ 12a-11
Reverse Warning Buzzer Limit Switch (If Equipped) ........................................................................ 12a-12
Front Differential Limit Switch ........................................................................................................... 12a-13
Fuel Level Sending Unit .................................................................................................................... 12a-14
Ignition Coil and Charge Coil ............................................................................................................ 12a-14
Oil Pressure Sensor .......................................................................................................................... 12a-15
Headlights ......................................................................................................................................... 12a-15
Wire Harness Diodes ........................................................................................................................ 12a-16
Battery .............................................................................................................................................. 12a-17
General Information ...................................................................................................................... 12a-17
SECTION 12B – ELECTRICAL COMPONENTS: HONDA POWERED GASOLINE VEHI-
CLES
Starter and Starter Solenoid ............................................................................................................. 12b-1
Relays ............................................................................................................................................... 12b-1
Neutral Switch ................................................................................................................................... 12b-2
Carburetor Solenoid .......................................................................................................................... 12b-2
Voltage Regulator ............................................................................................................................. 12b-3
Warning Lights .................................................................................................................................. 12b-4
Fuel Gauge/Hour Meter .................................................................................................................... 12b-5
Key Switch ........................................................................................................................................ 12b-6
12-Volt Accessory Receptacle .......................................................................................................... 12b-7
Bed Lift Switch .................................................................................................................................. 12b-8
Bed Lift Circuit Breaker ..................................................................................................................... 12b-8

Page x 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
Light Switch ...................................................................................................................................... 12b-9
Fuse ................................................................................................................................................. 12b-9
Reverse Warning Buzzer ................................................................................................................. 12b-10
Reverse Warning Buzzer Limit Switch ............................................................................................. 12b-11
Fuel Level Sending Unit ................................................................................................................... 12b-12
Ignition Coil and Charge Coil ........................................................................................................... 12b-12
Charge Coil ...................................................................................................................................... 12b-13
Oil Pressure Sensor ......................................................................................................................... 12b-13
Headlights ........................................................................................................................................ 12b-13
Wire Harness Diodes ....................................................................................................................... 12b-14
Battery .............................................................................................................................................. 12b-15
General Information ...................................................................................................................... 12b-15
SECTION 12C – ELECTRICAL COMPONENTS: DIESEL VEHICLES
Starter and Starter Solenoid ............................................................................................................. 12c-1
Relays .............................................................................................................................................. 12c-1
Neutral Switch .................................................................................................................................. 12c-2
Fuel Solenoid ................................................................................................................................... 12c-2
60-Amp Fusible Link ........................................................................................................................ 12c-3
Warning Lights ................................................................................................................................. 12c-5
Fuel Gauge/Hour Meter ................................................................................................................... 12c-6
Key Switch ....................................................................................................................................... 12c-7
12-Volt Accessory Receptacle ......................................................................................................... 12c-7
Bed Lift Switch ................................................................................................................................. 12c-8
Bed Lift Circuit Breaker .................................................................................................................... 12c-9
Light Switch ...................................................................................................................................... 12c-9
Fuse ................................................................................................................................................. 12c-10
Reverse Warning Buzzer (If Equipped) ............................................................................................ 12c-10
Reverse Warning Buzzer Limit Switch (If Equipped) ....................................................................... 12c-11
Front Differential Limit Switch .......................................................................................................... 12c-13
Electric Fuel Pump ........................................................................................................................... 12c-14
Fuel Level Sending Unit ................................................................................................................... 12c-14
Alternator .......................................................................................................................................... 12c-14
Oil Pressure Sensor ......................................................................................................................... 12c-16
Headlights ........................................................................................................................................ 12c-16
Thermostat Switch ........................................................................................................................... 12c-17
Fan ................................................................................................................................................... 12c-19
Wire Harness Diodes ....................................................................................................................... 12c-20
Battery .............................................................................................................................................. 12c-21
General Information ...................................................................................................................... 12c-21

2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page xi
SECTION 13A – KAWASAKI GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND
CLUTCHES
Gasoline Engine ............................................................................................................................... 13a-1
Engine Removal ........................................................................................................................... 13a-1
Engine Installation ........................................................................................................................ 13a-3
Oil Filter Hoses ............................................................................................................................. 13a-5
Exhaust System ................................................................................................................................ 13a-6
Muffler Removal ............................................................................................................................ 13a-6
Intermediate Pipe Removal .......................................................................................................... 13a-7
Intermediate Pipe Installation ....................................................................................................... 13a-7
Muffler Installation ......................................................................................................................... 13a-8
Fuel System ...................................................................................................................................... 13a-9
Fuel Lines ..................................................................................................................................... 13a-9
Fuel Filter ...................................................................................................................................... 13a-10
Fuel Pump .................................................................................................................................... 13a-10
Carburetor ..................................................................................................................................... 13a-10
Fuel Level Sending Unit ................................................................................................................ 13a-11
Fuel Tank ...................................................................................................................................... 13a-14
Fuel Shut-Off Valve ...................................................................................................................... 13a-17
Engine Control Linkages ................................................................................................................... 13a-18
Accelerator Cable ......................................................................................................................... 13a-18
Choke Cable ................................................................................................................................. 13a-20
Engine Governor Arm ................................................................................................................... 13a-21
Engine RPM Adjustment ............................................................................................................... 13a-22
Air Intake System .............................................................................................................................. 13a-23
Air Filter Replacement .................................................................................................................. 13a-23
Air Canister Removal .................................................................................................................... 13a-24
Air Canister Installation ................................................................................................................. 13a-24
Air Filter Intake Hose Removal ..................................................................................................... 13a-25
Air Filter Intake Hose Installation .................................................................................................. 13a-25
Air Filter Outlet Hose Removal ..................................................................................................... 13a-26
Air Filter Outlet Hose Installation .................................................................................................. 13a-26
Clutches ............................................................................................................................................ 13a-27
Clutch Troubleshooting ................................................................................................................. 13a-27
Drive Belt ...................................................................................................................................... 13a-28
Drive Clutch .................................................................................................................................. 13a-29
Driven Clutch ................................................................................................................................ 13a-34
Clutch Cover ................................................................................................................................. 13a-37

Page xii 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
SECTION 13B – HONDA GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND
CLUTCHES
Gasoline Engine ............................................................................................................................... 13b-1
Engine Removal ........................................................................................................................... 13b-1
Engine Installation ........................................................................................................................ 13b-3
Exhaust System ............................................................................................................................... 13b-5
Muffler Removal ........................................................................................................................... 13b-5
Intermediate Pipe Removal .......................................................................................................... 13b-5
Intermediate Pipe Installation ....................................................................................................... 13b-6
Muffler Installation ........................................................................................................................ 13b-6
Fuel System ..................................................................................................................................... 13b-7
Fuel Lines ..................................................................................................................................... 13b-8
Fuel Filter ..................................................................................................................................... 13b-8
Fuel Pump .................................................................................................................................... 13b-8
Carburetor .................................................................................................................................... 13b-8
Fuel Level Sending Unit ............................................................................................................... 13b-9
Fuel Tank ..................................................................................................................................... 13b-12
Fuel Shut-Off Valve ...................................................................................................................... 13b-15
Oil Filter Hoses ............................................................................................................................. 13b-16
Engine Control Linkages .................................................................................................................. 13b-16
Accelerator Cable ......................................................................................................................... 13b-16
Governor Guard ........................................................................................................................... 13b-19
Governor Cable ............................................................................................................................ 13b-19
Accelerator Cable Retention Clip Adjustment .............................................................................. 13b-20
Ground Speed (Transmission) Governor Arm Adjustment ........................................................... 13b-21
Engine Governor Arm ................................................................................................................... 13b-23
Engine RPM Adjustment .............................................................................................................. 13b-23
Choke and Air Intake System ........................................................................................................... 13b-24
Air Filter Replacement .................................................................................................................. 13b-24
Choke Cable Removal ................................................................................................................. 13b-25
Choke Cable Installation .............................................................................................................. 13b-26
Air Canister Removal ................................................................................................................... 13b-26
Air Canister Installation ................................................................................................................ 13b-27
Air Filter Intake Hose Removal ..................................................................................................... 13b-27
Air Filter Intake Hose Installation .................................................................................................. 13b-28
Air Filter Outlet Hose Removal ..................................................................................................... 13b-28
Air Filter Outlet Hose Installation .................................................................................................. 13b-29

2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page xiii
Clutches ............................................................................................................................................ 13b-29
Clutch Troubleshooting ................................................................................................................. 13b-30
Drive Belt ...................................................................................................................................... 13b-30
Drive Clutch .................................................................................................................................. 13b-31
Driven Clutch ................................................................................................................................ 13b-36
Clutch Cover ................................................................................................................................. 13b-39
SECTION 13C – DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Diesel Engine .................................................................................................................................... 13c-1
Engine Removal ........................................................................................................................... 13c-1
Engine Installation ........................................................................................................................ 13c-3
Exhaust System ................................................................................................................................ 13c-5
Muffler Removal ............................................................................................................................ 13c-5
Intermediate Pipe Removal .......................................................................................................... 13c-5
Manifold Pipe Removal ................................................................................................................. 13c-6
Manifold Pipe Installation .............................................................................................................. 13c-6
Intermediate Pipe Installation ....................................................................................................... 13c-6
Muffler Installation ......................................................................................................................... 13c-7
Fuel System ..................................................................................................................................... 13c-8
Fuel Lines ..................................................................................................................................... 13c-9
Fuel Filter Replacement ................................................................................................................ 13c-9
Draining Water from the Secondary Fuel Filter ............................................................................ 13c-9
Electric Fuel Pump ........................................................................................................................ 13c-11
Fuel Level Sending Unit ................................................................................................................ 13c-12
Fuel Tank ...................................................................................................................................... 13c-16
Engine Control Linkages ................................................................................................................... 13c-19
Accelerator Cable ......................................................................................................................... 13c-19
Engine RPM Adjustment ............................................................................................................... 13c-20
Air Intake System .............................................................................................................................. 13c-23
Air Filter Replacement .................................................................................................................. 13c-23
Air Canister Removal .................................................................................................................... 13c-23
Air Canister Installation ................................................................................................................. 13c-24
Air Filter Intake Hose Removal ..................................................................................................... 13c-24
Air Filter Intake Hose Installation .................................................................................................. 13c-25
Air Filter Outlet Hose Removal ..................................................................................................... 13c-26
Air Filter Outlet Hose Installation .................................................................................................. 13c-26

Page xiv 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
Clutches ........................................................................................................................................... 13c-27
Clutch Troubleshooting ................................................................................................................ 13c-27
Drive Belt ...................................................................................................................................... 13c-28
Drive Clutch .................................................................................................................................. 13c-29
Driven Clutch ................................................................................................................................ 13c-33
Clutch Cover ................................................................................................................................. 13c-35
SECTION 14 – DRIVETRAIN COMPONENTS
Half Shafts ........................................................................................................................................ 14-1
Half Shaft Removal ...................................................................................................................... 14-1
Half Shaft Installation ................................................................................................................... 14-3
Front Differential ............................................................................................................................... 14-4
Front Differential Removal ............................................................................................................ 14-4
Front Differential Installation ......................................................................................................... 14-6
Front Driveshaft ................................................................................................................................ 14-6
Front Driveshaft Removal ............................................................................................................. 14-6
Front Driveshaft Installation .......................................................................................................... 14-7
Rear Receiver Hitch ......................................................................................................................... 14-7
Rear Receiver Hitch Removal ...................................................................................................... 14-7
Rear Receiver Hitch Installation ................................................................................................... 14-7
Rear Axle ......................................................................................................................................... 14-8
Rear Axle Removal ...................................................................................................................... 14-8
Rear Axle Installation ................................................................................................................... 14-10
Rear Driveshaft ................................................................................................................................ 14-11
Rear Driveshaft Removal ............................................................................................................. 14-11
Rear Driveshaft Installation .......................................................................................................... 14-12
Transmission .................................................................................................................................... 14-12
Transmission Removal ................................................................................................................. 14-12
Transmission Installation .............................................................................................................. 14-14
Forward/Reverse Shifter Cable .................................................................................................... 14-15
Forward/Reverse Shifter Handle .................................................................................................. 14-18
Rear Differential and Axle Shafts ..................................................................................................... 14-18
Rear Differential and Axle Shaft Removal .................................................................................... 14-18
Rear Differential and Axle Shaft Installation ................................................................................. 14-20
Rear Wheel Bearings ................................................................................................................... 14-20
SECTION 15 – RADIATOR AND COOLANT SYSTEM (DIESEL)
General Information ......................................................................................................................... 15-1
Engine Coolant Level Check ........................................................................................................ 15-1
Engine Coolant Change ............................................................................................................... 15-1

2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page xv
Coolant Reservoir ............................................................................................................................. 15-3
Coolant Reservoir Removal .......................................................................................................... 15-3
Coolant Reservoir Installation ....................................................................................................... 15-4
Radiator ............................................................................................................................................ 15-4
Radiator Removal ......................................................................................................................... 15-4
Radiator Installation ...................................................................................................................... 15-5
Coolant Pipe Weldment .................................................................................................................... 15-6
Coolant Pipe Weldment Removal ................................................................................................. 15-6
Coolant Pipe Weldment Installation .............................................................................................. 15-6
Fan .................................................................................................................................................... 15-7
Fan Removal ................................................................................................................................ 15-7
Fan Installation ............................................................................................................................. 15-7
SECTION 16 – HYDRAULIC ATTACHMENT SYSTEM
Model Identification ....................................................................................................................... 16-1
Relieving Hydraulic System Pressure ............................................................................................... 16-1
To Relieve Hydraulic Fluid Pressure ............................................................................................16-1
Attachment Interface ......................................................................................................................... 16-2
Inspection ..................................................................................................................................... 16-2
Removing and Installing the Attachment Arm Mechanism ........................................................... 16-3
Electrical ........................................................................................................................................... 16-8
Joystick ......................................................................................................................................... 16-10
Joystick ON/OFF Switch ............................................................................................................... 16-12
Attachment Arm Float Switch ....................................................................................................... 16-14
Auxiliary Hydraulic Switch ............................................................................................................. 16-15
Relays ........................................................................................................................................... 16-17
Solenoid ........................................................................................................................................ 16-19
Circuit Breaker .............................................................................................................................. 16-20
Control Valves .............................................................................................................................. 16-21
Hoses ................................................................................................................................................ 16-23
Hose Routing ................................................................................................................................ 16-23
Hose Removal .............................................................................................................................. 16-24
Hose Installation ........................................................................................................................... 16-24
Quick Connect Fittings (Auxiliary Hydraulic Circuit only) .................................................................. 16-25
Quick Connect Removal ............................................................................................................... 16-25
Quick Connect Installation ............................................................................................................ 16-25

Page xvi 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
Cylinders .......................................................................................................................................... 16-26
Vehicle Mounted Cylinders ........................................................................................................... 16-26
Auxiliary Cylinder (Optional) ......................................................................................................... 16-27
Cylinder Disassembly ................................................................................................................... 16-29
Cylinder Assembly ........................................................................................................................ 16-32
Cylinder Bushings (If Equipped) ................................................................................................... 16-37
Angle Frame Bushings ..................................................................................................................... 16-39
Snow Blade Angle Frame ............................................................................................................. 16-39
Whisk Broom Angle Frame .......................................................................................................... 16-40
Front Mount ...................................................................................................................................... 16-41
Front Mount Removal ................................................................................................................... 16-41
Front Mount installation ................................................................................................................ 16-42
Hydraulic Pump Assembly ............................................................................................................... 16-43
Fluid Level Inspection ................................................................................................................... 16-43
Fluid Change ................................................................................................................................ 16-43
Pump Assembly ........................................................................................................................... 16-44
Reservoir ...................................................................................................................................... 16-47
Motor ............................................................................................................................................ 16-48
Pump ............................................................................................................................................ 16-49
Priming the Pump ......................................................................................................................... 16-49
SECTION i – INDEX

2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 1-1
1
SECTION 1 – SAFETY
To ensure the safety of those servicing these vehicles, and to protect the vehicles from damage resulting from
improper service or maintenance, the procedures in this manual must be followed. It is important to note that
throughout this manual there are statements contained within headings labeled DANGER, WARNING, CAU-
TION, or NOTE. These special statements relate to specific safety issues, and must be read, understood, and
heeded before proceeding.
ý DANGER
• A DANGER indicates an immediate hazard that will result in severe personal injury or death.
ý WARNING
• A WARNING indicates an immediate hazard that could result in severe personal injury or
death.
ý CAUTION
• A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could
result in minor personal injury.
CAUTION
• A CAUTION without the safety alert symbol indicates a potentially hazardous situation that
could result in property damage.
GENERAL WARNING
The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser-
viced. Service technicians should become familiar with these safety statements, which can be found through-
out this manual. Also, other specific safety statements appear throughout this manual and on the vehicle.
ý DANGER
• Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full
face shield and rubber gloves when working on or near batteries.
• Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or
clothing. Antidotes:
- External: Flush with water. Call a physician immediately.
- Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
- Eyes: Flush with water for 15 minutes. Call a physician immediately.
• Gasoline/Diesel – Flammable! Explosive! Do not smoke. Keep sparks and flames away from
the vehicle and service area. Service only in a well-ventilated area.
• Do not operate engine in an enclosed area without proper ventilation. The engine produces
carbon monoxide, which is an odorless, deadly poison.

SAFETY General Warning
Page 1-2 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
1
ý WARNING
• Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and
CAUTION statements in this manual as well as those on the vehicle.
• Only trained technicians should service or repair the vehicle. Anyone doing even simple
repairs or service should have knowledge and experience in electrical and mechanical repair.
The appropriate instructions must be used when performing maintenance, service, or
accessory installation.
• Prior to servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF,
remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Chock the
wheels when servicing the vehicle.
• To avoid unintentionally starting the vehicle:
• Disconnect battery cables, negative (–) cable first (Figure 1-2, Page 1-3).
• Gasoline vehicles only: Disconnect the spark plug wires from the spark plugs.
• Frame ground – Do not allow tools or other metal objects to contact frame when
disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch
the vehicle frame, engine, or any other metal component.
• Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face
shield and rubber gloves when working on or near batteries.
• Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the
vehicle.
• Moving parts! Do not attempt to service the vehicle while it is running.
• Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning
could result in severe burns.
• Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
• Check the vehicle owner’s manual for proper location of all vehicle safety and operation
decals and make sure they are in place and are easy to read.
• Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
• The diameter of all tires on the vehicle must be equal, otherwise the all-wheel drive system
will not operate as intended and could result in severe personal injury or death. Never install
tires of different diameters on the vehicle.
• Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic
floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold
vehicle in raised position. Use approved jack stands of proper weight capacity to support the
vehicle and chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
• When servicing the vehicle with part of the vehicle on jack stands, do not operate the engine
with the Forward/Reverse handle in either the FORWARD or REVERSE position. The all-wheel
drive system will engage any wheel(s) with traction. See Figure 1-1, Page 1-3.