Club car Turf 252 2007 Manual

2007-2009Turf252,Carryall252

andXRT900Maintenanceand

ServiceManual

GasolineandElectricVehicles

ManualNumber103209112

EditionCode1008C0312B

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

ThismanualprovidesdetailedinformationforthemaintenanceandrepairoftheClubCarTurf252,Carryall252and

XRT900seriesvehicles,andshouldbethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovided

mustbeproperlyimplemented,andtheDANGER,WARNING,andCAUTIONstatementsmustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.

ItisthepolicyofClubCar,Inc.toassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledge

andfacilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,

periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublicationsalsorepresentClubCar’s

continuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar’sT echnicalServicesdepartmentfora

listofupcomingclasses.

Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga

vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized

ClubCardealerordistributorforassistance.Y oumayalsowritetousat:ClubCar,Inc.,P .O.Box204658;Augusta,

GA30917–4658USA,Attention:TechnicalServices.

WARNING

•ReadSeeSection1–Safety.beforeattemptinganyserviceonthevehicle.

•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe

relevanttotheserviceorrepairtobeperformed.

NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCariscontinuallyworking

tofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicingprocedures.

Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoallClubCar

dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.

ClubCarreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithoutthe

obligationofmakingchangestounitspreviouslysold.

Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle

Owner’sManual.

ClubCar,Carryall,andArmorFlex

areregisteredtrademarksofClubCar,LLC

ThismanualeffectiveJuly31,2006

2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManualPagei

CONTENTS

SECTION1–SAFETY......................................................................................................................................1-1

GeneralWarning...........................................................................................................................................1-1

DisablingtheVehicle..................................................................................................................................1-3

DisconnectingtheBattery–GasolineVehicles............................................................................................1-3

ConnectingtheBattery–GasolineVehicles................................................................................................1-3

DisconnectingtheBatteries–ElectricVehicles............................................................................................1-4

ConnectingtheBatteries–ElectricVehicles................................................................................................1-4

SECTION2–VEHICLESPECIFICATIONS........................................................................................................2-1

VehicleSpecications–GasolineVehicles......................................................................................................2-1

VehicleSpecications–ElectricVehicles........................................................................................................2-3

SECTION3–GENERALINFORMATION...........................................................................................................3-1

SerialNumberIdentication............................................................................................................................3-1

Storage–GasolineVehicle............................................................................................................................3-2

PreparingtheGasolineVehicleforExtendedStorage..................................................................................3-3

ReturningtheStoredGasolineVehicletoService........................................................................................3-4

Storage–ElectricVehicle...............................................................................................................................3-5

PreparingtheElectricVehicleforExtendedStorage.....................................................................................3-5

ReturningtheStoredElectricVehicletoService..........................................................................................3-6

SECTION4–BODYANDTRIM.........................................................................................................................4-1

CleaningtheVehicle......................................................................................................................................4-1

FrontBodyRepair.........................................................................................................................................4-2

StressLinesorStreaks..............................................................................................................................4-2

MinorImpactDamage/Deformations...........................................................................................................4-2

MinorScratchesandSurfaceBlemishes.....................................................................................................4-2

SmallScratchesThatCannotBeBuffedOut...............................................................................................4-3

Touch-UpPaintColorChart........................................................................................................................4-3

Gouges,Punctures,Tears,LargeScratches,andAbrasions.........................................................................4-3

FrontBody....................................................................................................................................................4-3

FrontBodyRemoval..................................................................................................................................4-3

FrontBodyInstallation...............................................................................................................................4-4

TiltBed.........................................................................................................................................................4-5

TiltBedRemoval.......................................................................................................................................4-5

TiltBedInstallation....................................................................................................................................4-5

RearFender..................................................................................................................................................4-7

RearFenderRemoval................................................................................................................................4-7

RearFenderInstallation.............................................................................................................................4-8

TrailerHitch(OptionalonSomeModels).........................................................................................................4-8

TrailerHitchRemoval.................................................................................................................................4-8

TrailerHitchInstallation..............................................................................................................................4-9

ReceiverHitch(OptionalOnSomeModels).....................................................................................................4-9

ReceiverHitchRemoval.............................................................................................................................4-9

ReceiverHitchInstallation..........................................................................................................................4-9

Tailskirt.......................................................................................................................................................4-10

TailskirtRemoval.....................................................................................................................................4-10

TailskirtInstallation...................................................................................................................................4-10

FloorMat.....................................................................................................................................................4-11

FrontFloorMatRemoval...........................................................................................................................4-11

FrontFloorMatInstallation........................................................................................................................4-11

SECTION5–ACCELERATORANDBRAKEPEDALGROUP............................................................................5-1

BrakePedalandParkBrake..........................................................................................................................5-1

BrakePedalRemoval................................................................................................................................5-1

2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManualPageiii

BrakePedalInstallation.............................................................................................................................5-3

ParkBrakeRemoval..................................................................................................................................5-3

ParkBrakeInstallation...............................................................................................................................5-4

AcceleratorPedal–GasolineVehicles............................................................................................................5-5

AcceleratorPedalRemoval–GasolineVehicles..........................................................................................5-5

AcceleratorPedalInstallation–GasolineVehicles.......................................................................................5-6

AcceleratorPedal–ElectricVehicles..............................................................................................................5-7

AcceleratorPedalRemoval–ElectricVehicles............................................................................................5-7

AcceleratorPedalInstallation–ElectricVehicles.......................................................................................5-10

PedalGroupAdjustment–GasolineVehicles................................................................................................5-10

PedalGroupAdjustment–ElectricVehicles..................................................................................................5-15

SECTION6–WHEELBRAKEASSEMBLIES....................................................................................................6-1

GeneralInformation.......................................................................................................................................6-1

BrakeShoeRemoval.....................................................................................................................................6-1

BrakeAssemblyCleaning(Manually-AdjustedBrakes)....................................................................................6-3

BrakeShoeInstallation(Manually-AdjustedBrakes)........................................................................................6-5

BrakeAdjustment(Manually-AdjustedBrakes)................................................................................................6-7

BrakeClusterAdjustment...........................................................................................................................6-7

BrakeCableEqualization..........................................................................................................................6-11

FinalBrakeClusterAdjustment..................................................................................................................6-11

TestDriveVehicle....................................................................................................................................6-12

BrakeClusterRemovalandInstallation.........................................................................................................6-12

RearBrakeClusterRemoval....................................................................................................................6-12

RearBrakeClusterInstallation.................................................................................................................6-12

FrontBrakeClusterRemoval....................................................................................................................6-13

FrontBrakeClusterInstallation.................................................................................................................6-14

FrontBrakeCables......................................................................................................................................6-14

FrontBrakeCableRemoval.....................................................................................................................6-14

FrontBrakeCableInstallation...................................................................................................................6-15

RearBrakeCables......................................................................................................................................6-17

RearBrakeCableRemoval......................................................................................................................6-17

RearBrakeCableInstallation...................................................................................................................6-18

SECTION7–STEERINGANDFRONTSUSPENSION.......................................................................................7-1

GeneralInformation.......................................................................................................................................7-1

SteeringWheel..............................................................................................................................................7-1

SteeringWheelRemoval............................................................................................................................7-1

SteeringWheelInstallation.........................................................................................................................7-2

SteeringColumn............................................................................................................................................7-2

SteeringColumnRemoval..........................................................................................................................7-2

SteeringColumnDisassembly....................................................................................................................7-4

SteeringColumnAssembly........................................................................................................................7-4

SteeringColumnInstallation.......................................................................................................................7-4

SteeringAdjustment......................................................................................................................................7-5

RackandPinion............................................................................................................................................7-6

RackandPinionRemoval..........................................................................................................................7-6

RackandPinionDisassembly....................................................................................................................7-7

RackandPinionAssembly.........................................................................................................................7-9

RackandPinionInstallation......................................................................................................................7-11

TieRodandDragLink.................................................................................................................................7-12

TieRodandDragLinkRemoval...............................................................................................................7-12

TieRodandDragLinkInstallation............................................................................................................7-12

FrontSuspension........................................................................................................................................7-13

Lubrication..............................................................................................................................................7-13

WheelAlignment.....................................................................................................................................7-13

FrontSuspensionComponents.....................................................................................................................7-15

LeafSpringRemoval...............................................................................................................................7-15

LeafSpringInstallation.............................................................................................................................7-15

KingpinandSteeringSpindleRemoval.....................................................................................................7-15

KingpinandSteeringSpindleInstallation...................................................................................................7-19

DeltaA-PlateRemoval.............................................................................................................................7-19

Pageiv2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManual

DeltaA-PlateInstallation..........................................................................................................................7-19

ShockAbsorberRemoval.........................................................................................................................7-19

ShockAbsorberInstallation......................................................................................................................7-19

FrontWheelBearingsandHubs–4-WheelBrakeVehicles............................................................................7-20

FrontWheelFreePlayInspection.............................................................................................................7-20

FrontWheelBearingsandHubRemoval...................................................................................................7-20

FrontWheelBearingsandHubInstallation................................................................................................7-21

SECTION8–WHEELSANDTIRES..................................................................................................................8-1

GeneralInformation.......................................................................................................................................8-1

Wheels.........................................................................................................................................................8-1

WheelRemoval.........................................................................................................................................8-1

WheelInstallation......................................................................................................................................8-1

Tires.............................................................................................................................................................8-2

TireRemoval.............................................................................................................................................8-2

TireRepair................................................................................................................................................8-2

TireInstallation..........................................................................................................................................8-3

SECTION9–REARSUSPENSION...................................................................................................................9-1

GeneralInformation.......................................................................................................................................9-1

ShockAbsorbers...........................................................................................................................................9-1

ShockAbsorberInspectionandRemoval....................................................................................................9-1

ShockAbsorberInstallation........................................................................................................................9-1

Multi-LeafSprings..........................................................................................................................................9-2

Multi-LeafSpringRemoval.........................................................................................................................9-2

Multi-LeafSpringInstallation......................................................................................................................9-3

Snubber........................................................................................................................................................9-5

SnubberRemoval......................................................................................................................................9-5

SnubberInstallation...................................................................................................................................9-5

StabilizerBar.................................................................................................................................................9-6

StabilizerBarRemoval...............................................................................................................................9-6

StabilizerBarInstallation............................................................................................................................9-6

SECTION10–PERIODICMAINTENANCE......................................................................................................10-1

GeneralInformation.....................................................................................................................................10-1

Pre-OperationandDailySafetyChecklist......................................................................................................10-1

PerformanceInspection...........................................................................................................................10-2

PeriodicServiceSchedules..........................................................................................................................10-3

PeriodicLubricationSchedules....................................................................................................................10-6

EngineOil–GasolineVehicle.......................................................................................................................10-7

EngineOilLevelCheck............................................................................................................................10-8

EngineOilAndFilterChange...................................................................................................................10-8

SECTION11–TROUBLESHOOTINGANDELECTRICALSYSTEM:KEY-STARTWITHNEUTRALREVGAS

VEHICLE.........................................................................................................................................................11-1

GeneralInformation......................................................................................................................................11-1

TroubleshootingGuide..................................................................................................................................11-1

ElectricalSystem..........................................................................................................................................11-6

WiringDiagrams...........................................................................................................................................11-7

TestProcedures...........................................................................................................................................11-9

SECTION12–TROUBLESHOOTINGANDELECTRICALSYSTEM:PEDAL-STARTGASVEHICLE................12-1

GeneralInformation.....................................................................................................................................12-1

TroubleshootingGuide.................................................................................................................................12-1

WiringDiagram............................................................................................................................................12-6

ElectricalSystem.........................................................................................................................................12-9

TestProcedures..........................................................................................................................................12-9

2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManualPagev

SECTION13–ELECTRICALCOMPONENTS:KEY-STARTWITHNEUTRALREVGASVEHICLE...................13-1

Starter/Generator.........................................................................................................................................13-1

TestingtheStarter/Generator....................................................................................................................13-1

Starter/GeneratorRemoval......................................................................................................................13-1

DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................13-2

BrushInspectionandReplacement...........................................................................................................13-2

BrushSpringInspectionandReplacement................................................................................................13-3

Starter/GeneratorAssembly.....................................................................................................................13-3

DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................13-4

BearingCleaningandInspection..............................................................................................................13-4

BearingRemoval.....................................................................................................................................13-5

FieldCoilRemoval...................................................................................................................................13-6

VisualInspectionofArmatureandCommutator.........................................................................................13-7

CommutatorCleaningandInspection.......................................................................................................13-7

ArmatureGroundTest..............................................................................................................................13-8

VisualInspectionofFieldCoils.................................................................................................................13-8

Starter/GeneratorRework........................................................................................................................13-9

Starter/GeneratorAssembly.....................................................................................................................13-9

Starter/GeneratorInstallation...................................................................................................................13-10

BeltTensionAdjustment..........................................................................................................................13-12

VoltageRegulator.......................................................................................................................................13-13

VoltageRegulatorRemoval.....................................................................................................................13-13

VoltageRegulatorInstallation..................................................................................................................13-13

Diode.........................................................................................................................................................13-15

DiodeRemoval.......................................................................................................................................13-15

DiodeInstallation....................................................................................................................................13-15

KeySwitch.................................................................................................................................................13-17

KeySwitchRemoval...............................................................................................................................13-17

KeySwitchInstallation............................................................................................................................13-18

Solenoid.....................................................................................................................................................13-19

SolenoidRemoval..................................................................................................................................13-19

SolenoidInstallation................................................................................................................................13-19

Fuse..........................................................................................................................................................13-20

FuseRemoval........................................................................................................................................13-20

FuseInstallation.....................................................................................................................................13-20

NeutralLockoutLimitSwitch.......................................................................................................................13-21

NeutralLockoutLimitSwitchRemoval.....................................................................................................13-21

NeutralLockoutLimitSwitchInstallation...................................................................................................13-22

ReverseWarningBuzzer.............................................................................................................................13-23

ReverseWarningBuzzerRemoval..........................................................................................................13-23

ReverseWarningBuzzerInstallation........................................................................................................13-23

ReverseBuzzerLimitSwitch.......................................................................................................................13-24

ReverseBuzzerLimitSwitchRemoval.....................................................................................................13-24

ReverseBuzzerLimitSwitchInstallation..................................................................................................13-24

OilWarningLight........................................................................................................................................13-25

OilWarningLightRemoval......................................................................................................................13-25

OilWarningLightInstallation...................................................................................................................13-25

FuelGauge/HourMeter..............................................................................................................................13-26

FuelGauge/HourMeterRemoval............................................................................................................13-26

FuelGauge/HourMeterInstallation..........................................................................................................13-27

FuelLevelSendingUnit..............................................................................................................................13-27

RPMLimiter...............................................................................................................................................13-27

RPMLimiterRemoval.............................................................................................................................13-27

RPMLimiterInstallation..........................................................................................................................13-28

IgnitionCoil................................................................................................................................................13-29

IgnitionCoilRemoval..............................................................................................................................13-29

IgnitionCoilInstallation...........................................................................................................................13-30

OilLevelSensor.........................................................................................................................................13-32

OilLevelSensorRemoval.......................................................................................................................13-32

OilLevelSensorInstallation....................................................................................................................13-32

Headlights..................................................................................................................................................13-32

HeadlightBulbRemoval..........................................................................................................................13-33

HeadlightBulbInstallation.......................................................................................................................13-33

Pagevi2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManual

VoltageLimiter...........................................................................................................................................13-34

VoltageLimiterRemoval.........................................................................................................................13-34

VoltageLimiterInstallation.......................................................................................................................13-34

LightSwitch................................................................................................................................................13-35

LightSwitchRemoval.............................................................................................................................13-35

LightSwitchinstallation...........................................................................................................................13-35

Battery.......................................................................................................................................................13-35

GeneralInformation................................................................................................................................13-36

TestingtheBattery..................................................................................................................................13-36

PreventiveMaintenance..........................................................................................................................13-36

Self-Discharge........................................................................................................................................13-37

WaterLevel............................................................................................................................................13-37

VibrationDamage...................................................................................................................................13-38

MineralContent......................................................................................................................................13-38

BatteryRemoval.....................................................................................................................................13-39

ChargingtheBattery...............................................................................................................................13-39

BatteryInstallation..................................................................................................................................13-39

BatteryStorage......................................................................................................................................13-40

ChargingaDeadBattery.........................................................................................................................13-40

GroundCables...........................................................................................................................................13-40

SECTION14–ELECTRICALCOMPONENTS:PEDAL-STARTGASVEHICLE.................................................14-1

Starter/Generator.........................................................................................................................................14-1

Starter/GeneratorRemoval......................................................................................................................14-1

DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................14-2

BrushInspectionandReplacement...........................................................................................................14-2

BrushSpringInspectionandReplacement................................................................................................14-3

Starter/GeneratorAssembly.....................................................................................................................14-3

DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................14-4

BearingCleaningandInspection..............................................................................................................14-5

BearingRemoval.....................................................................................................................................14-5

FieldCoilRemoval...................................................................................................................................14-6

VisualInspectionofArmature...................................................................................................................14-6

CommutatorCleaningandInspection.......................................................................................................14-7

ArmatureGroundTest..............................................................................................................................14-8

VisualInspectionofFieldCoils.................................................................................................................14-9

Starter/GeneratorRework........................................................................................................................14-9

Starter/GeneratorAssembly.....................................................................................................................14-9

Starter/GeneratorInstallation...................................................................................................................14-10

BeltTensionAdjustment..........................................................................................................................14-12

VoltageRegulator.......................................................................................................................................14-12

VoltageRegulatorRemoval.....................................................................................................................14-12

VoltageRegulatorInstallation..................................................................................................................14-13

KeySwitch.................................................................................................................................................14-13

KeySwitchRemoval...............................................................................................................................14-13

KeySwitchInstallation............................................................................................................................14-15

Solenoid.....................................................................................................................................................14-15

SolenoidRemoval..................................................................................................................................14-15

SolenoidInstallation................................................................................................................................14-15

Fuse..........................................................................................................................................................14-16

FuseRemoval........................................................................................................................................14-16

FuseInstallation.....................................................................................................................................14-16

KillLimitSwitch..........................................................................................................................................14-16

KillLimitSwitchRemoval........................................................................................................................14-16

KillLimitSwitchInstallation.....................................................................................................................14-17

NeutralLockoutLimitSwitch.......................................................................................................................14-18

NeutralLockoutLimitSwitchRemoval.....................................................................................................14-18

NeutralLockoutLimitSwitchInstallation...................................................................................................14-19

ReverseWarningBuzzer.............................................................................................................................14-19

ReverseWarningBuzzerRemoval..........................................................................................................14-19

ReverseWarningBuzzerInstallation........................................................................................................14-19

ReverseBuzzerLimitSwitch.......................................................................................................................14-21

ReverseBuzzerLimitSwitchRemoval.....................................................................................................14-21

2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManualPagevii

ReverseBuzzerLimitSwitchInstallation..................................................................................................14-21

LowOilWarningLight.................................................................................................................................14-22

LowOilWarningLightRemoval...............................................................................................................14-22

LowOilWarningLightInstallation............................................................................................................14-22

FuelGauge/HourMeter..............................................................................................................................14-23

GeneralInformation................................................................................................................................14-23

FuelGauge/HourMeterRemoval............................................................................................................14-23

FuelGauge/HourMeterInstallation..........................................................................................................14-24

FuelLevelSendingUnit..............................................................................................................................14-24

RPMLimiter...............................................................................................................................................14-24

RPMLimiterRemoval.............................................................................................................................14-24

RPMLimiterInstallation..........................................................................................................................14-25

IgnitionCoil................................................................................................................................................14-26

IgnitionCoilRemoval..............................................................................................................................14-26

IgnitionCoilInstallation...........................................................................................................................14-27

OilLevelSensor.........................................................................................................................................14-28

OilLevelSensorRemoval.......................................................................................................................14-29

OilLevelSensorInstallation....................................................................................................................14-29

Headlights..................................................................................................................................................14-29

HeadlightBulbRemoval..........................................................................................................................14-29

HeadlightBulbInstallation.......................................................................................................................14-30

VoltageLimiter...........................................................................................................................................14-30

VoltageLimiterRemoval.........................................................................................................................14-30

VoltageLimiterInstallation.......................................................................................................................14-30

HeadlightSwitch.........................................................................................................................................14-31

HeadlightSwitchRemoval.......................................................................................................................14-31

HeadlightSwitchinstallation....................................................................................................................14-31

Battery.......................................................................................................................................................14-32

GeneralInformation................................................................................................................................14-32

TestingtheBattery..................................................................................................................................14-32

PreventiveMaintenance..........................................................................................................................14-33

WaterLevel............................................................................................................................................14-33

Self-Discharge........................................................................................................................................14-33

VibrationDamage...................................................................................................................................14-34

MineralContent......................................................................................................................................14-34

BatteryRemoval.....................................................................................................................................14-35

ChargingtheBattery...............................................................................................................................14-35

BatteryInstallation..................................................................................................................................14-35

BatteryStorage......................................................................................................................................14-36

ChargingaDeadBattery.........................................................................................................................14-36

GroundCables...........................................................................................................................................14-36

SECTION15–S10FE350ENGINE................................................................................................................15-1

GeneralInformation.....................................................................................................................................15-1

BeforeServicing......................................................................................................................................15-1

EngineRotation.......................................................................................................................................15-1

SparkPlug..............................................................................................................................................15-1

CylinderHead.............................................................................................................................................15-3

GeneralInformation.................................................................................................................................15-3

BreatherValve(ReedValve).....................................................................................................................15-3

Crankcase...................................................................................................................................................15-3

EngineRemoval......................................................................................................................................15-3

CrankcaseCoverRemoval.......................................................................................................................15-4

OilLevelSensor......................................................................................................................................15-5

CrankcaseCoverInstallation....................................................................................................................15-6

IgnitionCoilandFlywheel.............................................................................................................................15-7

IgnitionCoilandFlywheelRemoval..........................................................................................................15-7

FlywheelInstallation................................................................................................................................15-8

IgnitionCoilInspectionandRepair............................................................................................................15-9

IgnitionCoilInstallation............................................................................................................................15-9

CrankcaseCoverInstallation....................................................................................................................15-9

EngineInstallation.......................................................................................................................................15-9

TorqueSpecications..............................................................................................................................15-10

Pageviii2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManual

AdjustmentsandSettings........................................................................................................................15-11

SECTION16–S27FE350ENGINE................................................................................................................16-1

GeneralInformation.....................................................................................................................................16-1

BeforeServicing......................................................................................................................................16-1

EngineRotation.......................................................................................................................................16-1

SparkPlug..............................................................................................................................................16-1

CylinderHead.............................................................................................................................................16-3

GeneralInformation.................................................................................................................................16-3

BreatherValve(ReedValve).....................................................................................................................16-3

ValveClearanceCheckandAdjustment....................................................................................................16-3

Crankcase...................................................................................................................................................16-4

EngineRemoval......................................................................................................................................16-4

CrankcaseCoverRemoval.......................................................................................................................16-4

OilLevelSensor......................................................................................................................................16-6

CrankcaseCoverInstallation....................................................................................................................16-7

IgnitionCoilandFlywheel.............................................................................................................................16-8

IgnitionCoilandFlywheelRemoval..........................................................................................................16-8

FlywheelInstallation................................................................................................................................16-9

IgnitionCoilInspectionandRepair...........................................................................................................16-10

IgnitionCoilInstallation...........................................................................................................................16-10

CrankcaseCoverInstallation...................................................................................................................16-10

EngineInstallation......................................................................................................................................16-10

TorqueSpecications..............................................................................................................................16-11

AdjustmentsandSettings........................................................................................................................16-12

SECTION17–S10FE350FUELSYSTEM......................................................................................................17-1

GeneralInformation.....................................................................................................................................17-1

Carburetor...................................................................................................................................................17-1

MainJetElevation/SizeChart...................................................................................................................17-2

ChangingtheMainJet.............................................................................................................................17-3

EngineControlLinkage................................................................................................................................17-6

GeneralInformation.................................................................................................................................17-6

AcceleratorRod.......................................................................................................................................17-6

GovernorCable.......................................................................................................................................17-8

AcceleratorCable...................................................................................................................................17-10

ClosedThrottleorIdleAdjustment...........................................................................................................17-10

EngineRPMAdjustment.........................................................................................................................17-11

ChokeandAirIntakeSystem......................................................................................................................17-12

GeneralInformation................................................................................................................................17-12

ChokeCableRemoval............................................................................................................................17-12

ChokeCableInstallation.........................................................................................................................17-12

AirBoxRemoval.....................................................................................................................................17-12

AirBoxInstallation..................................................................................................................................17-13

IntakeDuctRemoval...............................................................................................................................17-13

IntakeDuctInstallation............................................................................................................................17-14

IntakeDuctRepair..................................................................................................................................17-16

AirFilter.................................................................................................................................................17-16

FuelFilters.................................................................................................................................................17-16

FuelFilterRemoval.................................................................................................................................17-16

FuelFilterInstallation..............................................................................................................................17-17

FuelPump.................................................................................................................................................17-19

GeneralInformation................................................................................................................................17-19

FuelPumpRemoval...............................................................................................................................17-19

FuelPumpDisassembly..........................................................................................................................17-19

FuelPumpCleaningandInspection.........................................................................................................17-20

FuelPumpAssembly..............................................................................................................................17-20

FuelPumpInstallation.............................................................................................................................17-21

FuelTank...................................................................................................................................................17-22

GeneralInformation................................................................................................................................17-22

FuelTankRemoval.................................................................................................................................17-22

FuelTankDisposal.................................................................................................................................17-23

2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManualPageix

FuelTankStorage..................................................................................................................................17-23

FuelTankInstallation..............................................................................................................................17-24

FuelLines..................................................................................................................................................17-25

FuelShut-OffValve.....................................................................................................................................17-26

FuelingInstructions.....................................................................................................................................17-26

SECTION18–S27FE350FUELSYSTEM......................................................................................................18-1

GeneralInformation.....................................................................................................................................18-1

Carburetor...................................................................................................................................................18-1

MainJetElevation/SizeChart...................................................................................................................18-2

ChangingtheMainJet.............................................................................................................................18-3

EngineControlLinkage................................................................................................................................18-5

GeneralInformation.................................................................................................................................18-6

AcceleratorRod.......................................................................................................................................18-6

GovernorCable.......................................................................................................................................18-8

AcceleratorCable....................................................................................................................................18-9

ClosedThrottleorIdleAdjustment...........................................................................................................18-10

EngineRPMAdjustment.........................................................................................................................18-11

ChokeandAirIntakeSystem......................................................................................................................18-11

GeneralInformation................................................................................................................................18-11

ChokeCableRemoval............................................................................................................................18-12

ChokeCableInstallation.........................................................................................................................18-12

AirBoxRemoval.....................................................................................................................................18-14

AirBoxInstallation..................................................................................................................................18-14

IntakeDuctRemoval...............................................................................................................................18-14

IntakeDuctInstallation............................................................................................................................18-15

IntakeDuctRepair..................................................................................................................................18-15

AirFilter.................................................................................................................................................18-15

FuelFilters.................................................................................................................................................18-17

GeneralInformation................................................................................................................................18-17

FuelFilterRemoval.................................................................................................................................18-17

FuelFilterInstallation..............................................................................................................................18-17

FuelPump.................................................................................................................................................18-19

GeneralInformation................................................................................................................................18-19

FuelPumpRemoval...............................................................................................................................18-19

FuelPumpDisassembly..........................................................................................................................18-20

FuelPumpCleaningandInspection.........................................................................................................18-20

FuelPumpAssembly..............................................................................................................................18-21

FuelPumpInstallation.............................................................................................................................18-21

FuelTank...................................................................................................................................................18-23

GeneralInformation................................................................................................................................18-23

FuelTankRemoval.................................................................................................................................18-23

FuelTankDisposal.................................................................................................................................18-24

FuelTankStorage..................................................................................................................................18-24

FuelTankInstallation..............................................................................................................................18-24

FuelLines..................................................................................................................................................18-26

FuelShut-OffValve.....................................................................................................................................18-26

SECTION19–EXHAUSTSYSTEM:GASOLINEVEHICLES............................................................................19-1

Mufer........................................................................................................................................................19-1

MuferRemoval......................................................................................................................................19-1

MuferInstallation....................................................................................................................................19-1

SECTION20–UNITIZEDTRANSAXLE:DASH-MOUNTEDSHIFTER..............................................................20-1

GeneralInformation.....................................................................................................................................20-1

ShifterLever............................................................................................................................................20-1

NeutralLockout.......................................................................................................................................20-1

GovernorSystem.....................................................................................................................................20-2

UnitizedTransaxleService.......................................................................................................................20-2

ToolsRequiredForThisSection...............................................................................................................20-3

Lubrication..............................................................................................................................................20-3

Pagex2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManual

AxleShaft...................................................................................................................................................20-3

AxleShaftandOilSealRemoval..............................................................................................................20-3

AxleBearing............................................................................................................................................20-4

AxleShaftInstallation..............................................................................................................................20-6

UnitizedTransaxleRemoval.........................................................................................................................20-7

UnitizedTransaxleInstallation.....................................................................................................................20-14

Forward/ReverseShifterCable....................................................................................................................20-20

Forward/ReverseShifterCableRemoval..................................................................................................20-20

Forward/ReverseShifterCableInstallation...............................................................................................20-20

Forward/ReverseShifterCableAdjustment..............................................................................................20-22

SECTION21–TORQUECONVERTER:GASOLINEVEHICLES.......................................................................21-1

GeneralInformation.....................................................................................................................................21-1

Troubleshooting...........................................................................................................................................21-1

DriveBelt....................................................................................................................................................21-2

DriveBeltRemoval..................................................................................................................................21-3

DriveBeltInstallation...............................................................................................................................21-3

DriveClutch................................................................................................................................................21-4

DriveClutchRemoval..............................................................................................................................21-4

DriveClutchCleaningandInspection........................................................................................................21-5

DriveClutchDisassembly.........................................................................................................................21-7

InspectionofDriveClutchParts................................................................................................................21-9

DriveClutchAssembly............................................................................................................................21-10

DriveClutchInstallation..........................................................................................................................21-11

DrivenClutch.............................................................................................................................................21-12

DrivenClutchRemoval...........................................................................................................................21-12

DrivenClutchDisassembly......................................................................................................................21-12

DrivenClutchInspection.........................................................................................................................21-13

DrivenClutchAssembly..........................................................................................................................21-13

DrivenClutchInstallation.........................................................................................................................21-16

SECTION22–ELECTRICALSYSTEMANDTESTING:ELECTRICVEHICLES................................................22-1

GeneralInformation.....................................................................................................................................22-1

WiringDiagrams..........................................................................................................................................22-2

Troubleshooting...........................................................................................................................................22-4

TroubleshootingtheVehiclewiththeIQDM...............................................................................................22-4

TroubleshootingGuide1..........................................................................................................................22-5

TroubleshootingGuide2..........................................................................................................................22-8

TestProcedures.........................................................................................................................................22-10

CommunicationDisplayModule(CDM)........................................................................................................22-36

UsingtheCDMtoRetrieveDatafromtheOnboardComputer...................................................................22-37

CDMTroubleshootingGuide...................................................................................................................22-38

SECTION23–IQDISPLAYMODULE(IQDM)SERIES2ANDIQDM-PDIAGNOSTICS.....................................23-1

PluggingtheHandsetintotheVehicle...........................................................................................................23-1

IntroductoryDisplay.....................................................................................................................................23-2

MenuNavigation.........................................................................................................................................23-2

Program(IQDM-Ponly)...........................................................................................................................23-3

MonitorMenu..............................................................................................................................................23-4

SpeedIn.................................................................................................................................................23-4

Throttle%...............................................................................................................................................23-4

BattVoltage.............................................................................................................................................23-4

HeatsinkTemp........................................................................................................................................23-4

Mode......................................................................................................................................................23-5

ArmCurrent............................................................................................................................................23-5

FieldCurrent...........................................................................................................................................23-5

ArmPWM...............................................................................................................................................23-5

FieldPWM..............................................................................................................................................23-5

FootInput...............................................................................................................................................23-5

KeyInput................................................................................................................................................23-5

ForwardInput..........................................................................................................................................23-5

2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManualPagexi

ReverseInput..........................................................................................................................................23-6

ModeSwitch...........................................................................................................................................23-6

WKAwayRelay.......................................................................................................................................23-6

MainCont...............................................................................................................................................23-6

PasswordTries(IQDM-Ponly).................................................................................................................23-6

CirBRKROpen#....................................................................................................................................23-6

THRTLFault#.........................................................................................................................................23-6

Undervoltage#........................................................................................................................................23-6

Overvoltage#..........................................................................................................................................23-7

TempCutback#......................................................................................................................................23-7

HPD#.....................................................................................................................................................23-7

MainWelded#........................................................................................................................................23-7

RelayWelded#.......................................................................................................................................23-7

SPDSensor#.........................................................................................................................................23-7

MainDRVOn#.......................................................................................................................................23-7

MainCoilOPN#......................................................................................................................................23-7

MainDropout#........................................................................................................................................23-7

MotorStall#............................................................................................................................................23-8

MainDRVROff#......................................................................................................................................23-8

RelayDNC#...........................................................................................................................................23-8

CurrentSense#......................................................................................................................................23-8

M-Shorted#............................................................................................................................................23-8

RelayCoil#.............................................................................................................................................23-8

Precharge#............................................................................................................................................23-8

FLDMissing#.........................................................................................................................................23-8

HWFailsafe#..........................................................................................................................................23-8

DRVROvercur#......................................................................................................................................23-9

RLYDRVROn#......................................................................................................................................23-9

RLYDRVROff#......................................................................................................................................23-9

Milesx1000............................................................................................................................................23-9

Milesx100..............................................................................................................................................23-9

Milesx10...............................................................................................................................................23-9

Milesx1.................................................................................................................................................23-9

Milesx0.1...............................................................................................................................................23-9

FaultsMenu................................................................................................................................................23-9

SystemFaults........................................................................................................................................23-10

FaultRecovery.......................................................................................................................................23-11

FaultDescriptions...................................................................................................................................23-12

FunctionsMenu..........................................................................................................................................23-14

GetSettingsFromController...................................................................................................................23-14

WriteSettingstoController......................................................................................................................23-16

ResetAllSettings...................................................................................................................................23-17

Information.................................................................................................................................................23-18

ModelNumber........................................................................................................................................23-18

SerialNumber........................................................................................................................................23-18

MFGDate..............................................................................................................................................23-18

SoftwareVersion....................................................................................................................................23-18

ProgrammerSetup.....................................................................................................................................23-18

Program.................................................................................................................................................23-18

Faults....................................................................................................................................................23-18

Information.............................................................................................................................................23-19

IQDMandIQDM-PHandsetTroubleshooting...............................................................................................23-19

TestProcedures.........................................................................................................................................23-20

SECTION24–ELECTRICALCOMPONENTS:ELECTRICVEHICLES.............................................................24-1

KeySwitch..................................................................................................................................................24-1

KeySwitchRemoval................................................................................................................................24-1

KeySwitchInstallation.............................................................................................................................24-2

Forward/ReverseRockerSwitch...................................................................................................................24-3

Forward/ReverseRockerSwitchRemoval.................................................................................................24-3

Forward/ReverseRockerSwitchInstallation..............................................................................................24-3

Tow/RunSwitch...........................................................................................................................................24-4

Tow/RunSwitchRemoval.........................................................................................................................24-4

Pagexii2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManual

Tow/RunSwitchInstallation......................................................................................................................24-4

CircuitBreaker............................................................................................................................................24-5

CircuitBreakerRemoval..........................................................................................................................24-5

CircuitBreakerInstallation........................................................................................................................24-5

MotorControllerOutputRegulator(MCOR)...................................................................................................24-6

MCORRemoval......................................................................................................................................24-6

MCORInstallation...................................................................................................................................24-6

ReverseBuzzer...........................................................................................................................................24-7

ReverseBuzzerRemoval.........................................................................................................................24-7

ReverseBuzzerInstallation......................................................................................................................24-8

Speedcontrollercover.................................................................................................................................24-8

RemovingtheSpeedControllerCover......................................................................................................24-8

InstallingtheSpeedControllerCover........................................................................................................24-8

Solenoid......................................................................................................................................................24-9

SolenoidRemoval...................................................................................................................................24-9

SolenoidInstallation................................................................................................................................24-10

OnboardComputer(OBC)...........................................................................................................................24-10

OnboardComputerRemoval...................................................................................................................24-10

OnboardComputerInstallation................................................................................................................24-11

SolidStateSpeedController.......................................................................................................................24-12

SpeedControllerRemoval......................................................................................................................24-12

SpeedControllerInstallation....................................................................................................................24-12

ChargerReceptacle....................................................................................................................................24-13

ChargerReceptacleInspection................................................................................................................24-13

ChargerReceptacleRemoval..................................................................................................................24-14

ChargerReceptacleInstallation...............................................................................................................24-14

ReceptacleFuseLink.................................................................................................................................24-15

ReceptacleFuseLinkRemoval...............................................................................................................24-15

ReceptacleFuseLinkInstallation.............................................................................................................24-16

BatteryWarningLight..................................................................................................................................24-16

BatteryWarningLightRemoval...............................................................................................................24-16

BatteryWarningLightInstallation.............................................................................................................24-16

SECTION25–BATTERIES:ELECTRICVEHICLES.........................................................................................25-1

GeneralInformation.....................................................................................................................................25-1

BatteryReplacement...................................................................................................................................25-2

BatteryCare................................................................................................................................................25-3

PreventiveMaintenance...........................................................................................................................25-3

Self-Discharge.........................................................................................................................................25-3

ElectrolyteLevel......................................................................................................................................25-3

MineralContent.......................................................................................................................................25-4

VibrationDamage....................................................................................................................................25-5

BatteryCharging.........................................................................................................................................25-5

ChargerShutsOffAfter16Hours.............................................................................................................25-5

Deep-Discharge......................................................................................................................................25-6

EarlyExcessiveDischarging....................................................................................................................25-6

IncomingACService...............................................................................................................................25-6

FleetRotation..........................................................................................................................................25-6

NumberingVehiclesandChargers............................................................................................................25-6

BatteryTroubleshootingChart......................................................................................................................25-7

BatteryTesting............................................................................................................................................25-8

BatteryChargerTest................................................................................................................................25-8

On-ChargeVoltageT est...........................................................................................................................25-8

HydrometerTest......................................................................................................................................25-8

DischargeTest.......................................................................................................................................25-10

BatteryTroubleshootingExamples...........................................................................................................25-11

BatteryStorage..........................................................................................................................................25-12

ChargingaBatteryPackthathasLowVoltage.............................................................................................25-12

2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManualPagexiii

SECTION26–BATTERYCHARGER..............................................................................................................26-1

SECTION27–MOTOR(MODELDA5-4006):ELECTRICVEHICLES...............................................................27-1

GeneralInformation.....................................................................................................................................27-1

ExternalMotorTesting.................................................................................................................................27-1

Motor..........................................................................................................................................................27-2

MotorRemoval........................................................................................................................................27-2

MotorDisassembly..................................................................................................................................27-4

MotorComponentTestingandInspection......................................................................................................27-7

ArmatureInspectionandTesting...............................................................................................................27-7

MotorFrameandFieldWindingsInspection..............................................................................................27-8

MotorBrush,Spring,andTerminalInsulatorInspection..............................................................................27-8

ReconditioningtheMotor............................................................................................................................27-11

MotorSpecications...............................................................................................................................27-11

MotorAssembly..........................................................................................................................................27-11

MotorInstallation........................................................................................................................................27-13

SECTION28–TRANSAXLE(TYPEG):ELECTRICVEHICLES........................................................................28-1

Lubrication..................................................................................................................................................28-1

AxleBearingandShaft................................................................................................................................28-1

AxleShaft...............................................................................................................................................28-1

AxleBearing............................................................................................................................................28-4

Transaxle....................................................................................................................................................28-5

TransaxleRemoval..................................................................................................................................28-5

TransaxleDisassembly,Inspection,andAssembly.........................................................................................28-7

TransaxleDisassemblyandInspection......................................................................................................28-7

TransaxleAssembly.................................................................................................................................28-9

TransaxleInstallation..................................................................................................................................28-11

SECTION29–IQDISPLAYMODULE(IQDM-P)SERIES2PROGRAMMING....................................................29-1

PluggingtheHandsetintotheVehicle...........................................................................................................29-1

ProgramMenu............................................................................................................................................29-2

M1/M2Speed..........................................................................................................................................29-2

M1/M2FastAccel....................................................................................................................................29-2

M1/M2PedalUp......................................................................................................................................29-2

M1/M2SpeedCal....................................................................................................................................29-3

CodeA,CodeB,andCodeC...................................................................................................................29-4

SECTIONi–INDEX

Pagexiv2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManual

SECTION1–SAFETY1

ToensurethesafetyofthoseservicingClubCarvehicles,andtoprotectthevehiclesfrompossibledamageresulting

fromimproperserviceormaintenance,theproceduresinthismanualmustbefollowed.

ItisimportanttonotethatthroughoutthismanualtherearestatementslabeledDANGER,WARNING,orCAUTION.

Thesespecialstatementsrelatetospecicsafetyissues,andmustberead,understood,andheededbefore

proceedingwithprocedures.TherearestatementslabeledNOTE,whichprovideotheressentialserviceor

maintenanceinformation.

DANGER

•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.

WARNING

•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.

CAUTION

•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin

minorpersonalinjury.

CAUTION

•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould

resultinpropertydamage.

GENERALWARNING

Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Service

techniciansshouldbecomefamiliarwiththesegeneralsafetystatements.Also,otherspecicsafetystatementsappear

throughoutthismanualandonthevehicle.

DANGER

•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice

area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

•Battery–Poison!Containsacid!Causessevereburns.Avoidcontactwithskin,eyes,orclothing.

Antidotes:

–External:Flushwithwater.Callaphysicianimmediately.

–Internal:Drinklargequantitiesofmilkorwater.Followwithmilkofmagnesiaorvegetable

oil.Callaphysicianimmediately.

–Eyes:Flushwithwaterfor15minutes.Callaphysicianimmediately.

DANGERCONTINUEDONNEXTPAGE

2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManualPage1-1

1GeneralWarningSAFETY

DANGER

•Gasoline–Flammable!Explosive!Donotsmoke.Keepsparksandamesawayfromthevehicleand

servicearea.Serviceonlyinawell-ventilatedarea.

•Donotoperategasolinevehicleinanenclosedareawithoutproperventilation.Theengineproduces

carbonmonoxide,whichisanodorless,deadlypoison.

WARNING

•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and

CAUTIONstatementsinthismanualaswellasthoseonthevehicle.

•Onlytrainedtechniciansshouldserviceorrepairthevehicle.Anyonedoingevensimplerepairsor

serviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.Theappropriate

instructionsmustbeusedwhenperformingmaintenance,service,oraccessoryinstallation.

•Priortoservicingthevehicleorleavingthevehicleunattended,turnthekeyswitchOFF,remove

thekey,andplacetheForward/ReversehandleintheNEUTRALposition.Chockthewheelswhen

servicingthevehicle.

Gasolinevehiclesonly:

•Toavoidunintentionallystartingagasolinevehicle,disconnectthebatteryandsparkplugwire.See

DisconnectingtheBattery–GasolineVehiclesonpage1-3.

•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery

cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or

anyothermetalcomponent.

Electricvehiclesonly:

•PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto

heedthiswarningcouldresultinabatteryexplosionorseverepersonalinjury.

•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe

controller.SeeDisconnectingtheBatteries–ElectricVehiclesonpage1-4.

•Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.

•IQPlusvehiclesonly:Useonly4-gauge(AWG)withlowresistanceterminalstoreplacebatterywires.

Allvehicles:

•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicle.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthevehicle.

•Movingparts!Donotattempttoservicethevehiclewhileitisrunning.

•Ensurebatteryconnectionsarecleanandproperlytightened.SeeBatteryCareonpage25-3.

•Hot!Donotattempttoservicehotengineorexhaustsystem.Failuretoheedthiswarningcould

resultinsevereburns.

•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto

avoidshortingofcomponentsorwiring.

•Checkthevehicleowner’smanualforproperlocationofallvehiclesafetyandoperationdecalsand

makesuretheyareinplaceandareeasytoread.

WARNINGCONTINUEDONNEXTPAGE

Page1-22007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManual

SAFETYGeneralWarning1

WARNING

•Anymodicationorchangetothevehiclethataffectsthestabilityorhandlingofthevehicle,or

increasesmaximumvehiclespeedbeyondfactoryspecications,couldresultinseverepersonal

injuryordeath.

•Liftonlyoneendofthevehicleatatime.Useasuitableliftingdevice(chainhoistorhydraulicoor

jack)with1000lb.(454kg)minimumliftingcapacity.Donotuseliftingdevicetoholdvehicleinraised

position.Useapprovedjackstandsofproperweightcapacitytosupportthevehicleandchock

thewheelsthatremainontheoor.Whennotperformingatestorserviceprocedurethatrequires

movementofthewheels,lockthebrakes.

•Ifwiresareremovedorreplaced,makesurewiringandwireharnessareproperlyroutedandsecured.

Failuretoproperlyrouteandsecurewiringcouldresultinvehiclemalfunction,propertydamage,

personalinjury,ordeath.

•Forvehicleswithcargobeds,removeallcargobeforeraisingthebedorservicingthevehicle.Ifthe

vehicleisequippedwithaproprod,ensurethatitissecurelyengagedwhilebedisraised.Donot

closebeduntilallpersonsareclearofcargobedarea.Keephandsclearofallcrushareas.Donot

dropcargobed;lowergentlyandkeepentirebodyclear.Failuretoheedthiswarningcouldresultin

severepersonalinjuryordeath.

•Improperuseofthevehicleorfailuretoproperlymaintainitcouldresultindecreasedvehicle

performance,severepersonalinjury,ordeath.

•Donotleavechildrenunattendedonvehicle.

DISABLINGTHEVEHICLE

1.Settheparkbrake.

2.TurnthekeyswitchOFFandremovethekey.

3.PlacetheForward/ReversecontrolintheNEUTRALposition.

4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.

DISCONNECTINGTHEBATTERY–GASOLINEVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.

2.Disconnectthebatterycables,negative(–)cablerst,asshown(Figure1-1,Page1-4).

3.Disconnectthesparkplugwire(s)fromthesparkplug(s).

CONNECTINGTHEBATTERY–GASOLINEVEHICLES

1.Connectthebatterycables,positive(+)cablerst.

2.Tightenbatteryterminalsto80in-lb(9N·m).

3.CoatterminalswithBatteryT erminalProtectorSpray(CCIP/N1014305)tominimizecorrosion.

4.Connectthesparkplugwire(s)tothesparkplug(s).

2007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManualPage1-3

1GeneralWarningSAFETY

(Viewedfrompassengersideofvehicle)

1.Removenegativebatterycable.

2.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

(+)

(–)

(Viewedfromdriversideofvehicle)

1.PlaceTOW/RUNSwitchinTOWbeforedisconnectingorconnecting

batterycables.

2.Removenegativebatterycable.

3.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

Figure1-1GasolineVehicle

Figure1-2IQPlusElectricVehicle

DISCONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.

2.PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failuretoheed

thiswarningcouldresultinabatteryexplosionorseverepersonalinjury.

3.Disconnectthebatteries,negative(–)cablerst,asshown(Figure1-2,Page1-4).

4.Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.

CONNECTINGTHEBATTERIES–ELECTRICVEHICLES

CAUTION

•IQPlusvehiclesonly:Useonly4-gauge(AWG)withlowresistanceterminalstoreplacebatterywires.

1.EnsuretheTow/RunswitchisintheTOWposition.

2.Connectthebatterycables,positive(+)cablerst.

3.Tightenbatteryterminalsto110in-lb(12.4N·m).

4.CoatterminalswithBatteryT erminalProtectorSpray(CCIP/N1014305)tominimizecorrosion.

Page1-42007-2009Turf252,Carryall252andXRT900MaintenanceandServiceManual

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