Club Car 2008 Turf Manual

Manual Number 103373104
Edition Code 0907C1108B
Turf 1, Turf 2, Turf 6,
Carryall 1, Carryall 2, Carryall 2 Plus, Carryall 6
Gasoline and Electric Vehicles
2008
Turf/Carryall
Maintenance and Service
Manual

2008 Turf/Carryall Vehicle Maintenance and Service Manual Page i
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.
This manual provides detailed information for the maintenance and repair of Turf and Carryall vehicles and
should be used in conjunction with the appropriate maintenance and service supplement.
If you do not have the appropriate maintenance and service supplement, you may order one from your local
Club Car representative. Maintenance and service supplements available include the following:
This manual and corresponding maintenance and service supplement should be thoroughly reviewed prior to
servicing the vehicle. The procedures provided must be properly implemented, and the DANGER, WARNING,
and CAUTION statements must be heeded.
This manual was written for the trained technician who already has 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 tech-
nician.
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, used in conjunction with the appropriate maintenance and service supplement, covers all
aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle.
If it appears that a service question is not answered in this manual, you may write to us at: Club Car, Inc., P.O.
Box 204658, Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech-
nical Service Representative at [phone], extension 3580.
2008 IQ System Vehicle Maintenance and Service Supplement Publication Part No. 103373106
2008 FE350 Gasoline Vehicle Maintenance and Service Supplement Publication Part No. 103373109
2008 IQ Plus System Vehicle Maintenance and Service Supplement Publication Part No. 103373107
Copyright © 2007 Club Car, Inc.
Club Car and Carryall
are registered trademarks of Club Car, Inc.
This manual effective August 1, 2007.

Page ii 2008 Turf/Carryall Vehicle Maintenance and Service Manual
ý WARNING
• Read Section 1 – Safety before attempting any service on the vehicle.
• Before servicing vehicle, read complete section(s) and any referenced information that may
be relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car, 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 distributors and dealers and will, when applicable, appear
in future editions of this manual.
Club Car, Inc. reserves the right to change specifications and designs at any time without notice
and without the obligation of making changes to units previously sold.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle owner’s manual or write to: Club Car, Inc., P.O. Box 204658, Augusta, GA 30917-4658,
USA, Attention: Warranty Administration.

2008 Turf/Carryall Vehicle Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ............................................................................................................................... 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
Vehicle Specifications – Electric Vehicles ........................................................................................ 2-1
Vehicle Specifications – Gasoline Vehicles ...................................................................................... 2-3
SECTION 3 – GENERAL INFORMATION
General Information .......................................................................................................................... 3-1
Serial Number Identification .............................................................................................................. 3-1
Storage – Gasoline Vehicle .............................................................................................................. 3-2
Preparing the Gasoline Vehicle for Extended Storage ................................................................. 3-2
Returning the Stored Gasoline Vehicle to Service ........................................................................ 3-4
Storage – Electric Vehicle ................................................................................................................. 3-4
Preparing the Electric Vehicle for Extended Storage .................................................................... 3-5
Returning the Stored Electric Vehicle to Service .......................................................................... 3-5
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 4-1
Front Body Repair ............................................................................................................................. 4-2
Stress Lines or Streaks ................................................................................................................. 4-2
Minor Impact Damage/Deformations ............................................................................................ 4-2
Minor Scratches and Surface Blemishes ...................................................................................... 4-2
Small Scratches That Cannot Be Buffed Out ............................................................................... 4-2
Touch-Up Paint Color Chart ......................................................................................................... 4-3
Gouges, Punctures, Tears, Large Scratches, and Abrasions ....................................................... 4-3
Front Body ........................................................................................................................................ 4-3
Front Body Removal ..................................................................................................................... 4-3
Front Body Installation .................................................................................................................. 4-4
Tilt Bed – Turf 1, 2, Carryall 1, 2 and 2 Plus ..................................................................................... 4-5
Tilt Bed Removal .......................................................................................................................... 4-5
Tilt Bed Installation ....................................................................................................................... 4-5
Flat Bed – Turf 6 and Carryall 6 ........................................................................................................ 4-7
Flat Bed Removal ......................................................................................................................... 4-7
Flat Bed Installation ...................................................................................................................... 4-7

Page iv 2008 Turf/Carryall Vehicle Maintenance and Service Manual
Flat Bed Trim – Turf 6 and Carryall 6 ............................................................................................... 4-7
Flat Bed Trim Removal ................................................................................................................. 4-7
Flat Bed Trim Installation .............................................................................................................. 4-8
Access Door – Turf 6 and Carryall 6 ................................................................................................ 4-10
Access Door Removal .................................................................................................................. 4-10
Access Door Installation ............................................................................................................... 4-10
Side Door – Turf 6 and Carryall 6 .................................................................................................... 4-10
Side Door Removal ...................................................................................................................... 4-10
Side Door Installation ................................................................................................................... 4-10
Rear Fender ..................................................................................................................................... 4-10
Rear Fender Removal .................................................................................................................. 4-10
Rear Fender Installation ............................................................................................................... 4-12
Trailer Hitch (Optional on Some Models) ......................................................................................... 4-13
Trailer Hitch Removal ................................................................................................................... 4-13
Trailer Hitch Installation ................................................................................................................ 4-13
Tailskirt ............................................................................................................................................. 4-13
Tailskirt Removal .......................................................................................................................... 4-13
Tailskirt Installation ....................................................................................................................... 4-13
Floor Mat .......................................................................................................................................... 4-13
Front Floor Mat Removal .............................................................................................................. 4-13
Front Floor Mat Installation ........................................................................................................... 4-14
Rear Floor Mat Removal – Turf 6 and Carryall 6 Only ................................................................. 4-14
Rear Floor Mat Installation – Turf 6 and Carryall 6 Only .............................................................. 4-14
Bumper ............................................................................................................................................. 4-14
Bumper Removal .......................................................................................................................... 4-14
Bumper Installation ....................................................................................................................... 4-14
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Brake Pedal and Park Brake ............................................................................................................ 5-1
Brake Pedal Removal ................................................................................................................... 5-1
Brake Pedal Installation ................................................................................................................ 5-4
Park Brake Removal .................................................................................................................... 5-5
Park Brake Installation ................................................................................................................. 5-5
Accelerator Pedal – Gasoline Vehicles ............................................................................................5-6
Accelerator Pedal Removal – Gasoline Vehicles ......................................................................... 5-6
Accelerator Pedal Installation – Gasoline Vehicles ...................................................................... 5-8
Accelerator Pedal – Electric Vehicles .............................................................................................. 5-9
Accelerator Pedal Removal – Electric Vehicles ........................................................................... 5-9
Accelerator Pedal Installation – Electric Vehicles ........................................................................ 5-11
Pedal Group Adjustment – Gasoline Vehicles ................................................................................. 5-11
Pedal Group Adjustment – Electric Vehicles .................................................................................... 5-16

2008 Turf/Carryall Vehicle Maintenance and Service Manual Page v
SECTION 6 – WHEEL BRAKE ASSEMBLIES
General Information .......................................................................................................................... 6-1
Brake Shoe Removal ........................................................................................................................ 6-1
Brake Assembly Cleaning (Self-Adjusting Brakes) ........................................................................... 6-3
Brake Shoe Installation (Self-Adjusting Brakes) ............................................................................... 6-5
Brake Adjustment (Self-Adjusting Brakes) ........................................................................................ 6-8
Brake Assembly Cleaning (Manually-Adjusted Brakes) ................................................................... 6-9
Brake Shoe Installation (Manually-Adjusted Brakes) ........................................................................ 6-10
Brake Adjustment (Manually-Adjusted Brakes) ................................................................................ 6-12
Brake Cluster Adjustment ............................................................................................................. 6-13
Brake Cable Equalization ............................................................................................................. 6-16
Final Brake Cluster Adjustment .................................................................................................... 6-17
Test Drive Vehicle ......................................................................................................................... 6-17
Brake Cluster Removal and Installation ............................................................................................ 6-17
Rear Brake Cluster Removal ........................................................................................................ 6-17
Rear Brake Cluster Installation ..................................................................................................... 6-18
Front Brake Cluster Removal ....................................................................................................... 6-18
Front Brake Cluster Installation .................................................................................................... 6-19
Front Brake Cables ........................................................................................................................... 6-20
Front Brake Cable Removal ......................................................................................................... 6-20
Front Brake Cable Installation ...................................................................................................... 6-21
Rear Brake Cables ........................................................................................................................... 6-22
Rear Brake Cable Removal .......................................................................................................... 6-22
Rear Brake Cable Installation ....................................................................................................... 6-23
SECTION 7 – WHEELS AND TIRES
General Information .......................................................................................................................... 7-1
Wheels .............................................................................................................................................. 7-1
Wheel Removal ............................................................................................................................ 7-1
Wheel Installation ......................................................................................................................... 7-1
Tires .................................................................................................................................................. 7-2
Tire Removal ................................................................................................................................ 7-2
Tire Repair .................................................................................................................................... 7-3
Tire Installation ............................................................................................................................. 7-3
SECTION 8 – REAR SUSPENSION
General Information .......................................................................................................................... 8-1
Shock Absorbers .............................................................................................................................. 8-1
Shock Absorber Inspection and Removal ..................................................................................... 8-1
Shock Absorber Installation .......................................................................................................... 8-2

Page vi 2008 Turf/Carryall Vehicle Maintenance and Service Manual
Multi-Leaf Springs ............................................................................................................................ 8-2
Multi-Leaf Spring Removal ........................................................................................................... 8-2
Multi-Leaf Spring Installation ........................................................................................................ 8-3
Snubber ............................................................................................................................................ 8-6
Snubber Removal ......................................................................................................................... 8-6
Snubber Installation ..................................................................................................................... 8-6
Stabilizer Bar .................................................................................................................................... 8-7
Stabilizer Bar Removal ................................................................................................................. 8-7
Stabilizer Bar Installation .............................................................................................................. 8-8
Jounce Bumpers .............................................................................................................................. 8-8
Jounce Bumper Removal ............................................................................................................. 8-8
Jounce Bumper Installation .......................................................................................................... 8-8
SECTION 9 – STEERING AND FRONT SUSPENSION
General Information ......................................................................................................................... 9-1
Steering Wheel ................................................................................................................................. 9-1
Steering Wheel Removal .............................................................................................................. 9-1
Steering Wheel Installation ........................................................................................................... 9-2
Steering Column .............................................................................................................................. 9-2
Steering Column Removal ........................................................................................................... 9-2
Steering Column Disassembly ..................................................................................................... 9-4
Steering Column Assembly .......................................................................................................... 9-5
Steering Column Installation ........................................................................................................ 9-5
Steering Adjustment ......................................................................................................................... 9-7
Rack and Pinion ............................................................................................................................... 9-8
Rack and Pinion Removal ............................................................................................................ 9-8
Rack and Pinion Disassembly ...................................................................................................... 9-8
Rack and Pinion Assembly ........................................................................................................... 9-10
Rack and Pinion Installation ......................................................................................................... 9-12
Tie Rod and Drag Link ..................................................................................................................... 9-13
Tie Rod and Drag Link Removal ..................................................................................................9-13
Tie Rod and Drag Link Installation ............................................................................................... 9-13
Front Suspension ............................................................................................................................. 9-14
Lubrication .................................................................................................................................... 9-14
Wheel Alignment .......................................................................................................................... 9-14

2008 Turf/Carryall Vehicle Maintenance and Service Manual Page vii
Front Suspension Components ........................................................................................................ 9-16
Leaf Spring Removal .................................................................................................................... 9-16
Leaf Spring Installation ................................................................................................................. 9-16
Kingpin and Steering Spindle Removal ........................................................................................ 9-17
Kingpin and Steering Spindle Installation ..................................................................................... 9-22
Delta A-Plate Removal ................................................................................................................. 9-22
Delta A-Plate Installation .............................................................................................................. 9-22
Shock Absorber Removal ............................................................................................................. 9-22
Shock Absorber Installation .......................................................................................................... 9-23
Front Wheel Bearings and Hubs - 4-Wheel Brake Vehicles ............................................................. 9-23
Front Wheel Free Play Inspection ................................................................................................ 9-23
Front Wheel Bearings and Hub Removal ..................................................................................... 9-24
Front Wheel Bearings and Hub Installation .................................................................................. 9-24
SECTION i – INDEX