Club Car TURF 272 Manual

Manual Number 102907711
Edition Code 1007B0810A
Turf 272, Carryall 272, Carryall 472,
XRT 1200, and XRT1200 SE
Gasoline Vehicles
2006-2010 Turf/Carryall
272/472, XRT1200/SE
Maintenance and Service
Manual

2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page i
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.
This manual provides detailed information for the maintenance and repair of the Turf/Carryall 272/472 and
XRT 1200/1200 SE vehicles, and should be thoroughly reviewed prior to servicing the vehicles. The proce-
dures provided must be properly implemented, and the DANGER, WARNING, and CAUTION statements
must be heeded.
This manual was written for the trained technician who already possesses knowledge and skills in electrical
and mechanical repair. If the technician does not have such knowledge and skills, attempted service or
repairs to the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or
service be performed by an authorized Club Car distributor/dealer representative or by a Club Car factory-
trained technician.
It is the policy of Club Car, LLC to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.
Club Car offers a full line of training and continuing education classes for technicians who want to learn more
about our products. For more information, contact your local dealer or Club Car’s Technical Services depart-
ment for a list of upcoming classes.
This manual covers all aspects of typical vehicle service; unique situations, however, sometimes occur when
servicing a vehicle. If it appears that a service question is not answered in this manual, you may write to us at:
Club Car, LLC, P.O. Box 204658; Augusta, GA 30917, Attention: Technical Services.
Copyright © 2006, 2007, 2010 Club Car, LLC
Club Car and Carryall
are registered trademarks of Club Car, LLC.
This manual effective July 25, 2005.

Page ii 2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual
ý WARNING
• Read Section 1 – Safety before attempting any service on this vehicle.
• Before servicing vehicle, read complete section(s) and any referenced information that may
be relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car, LLC, is
continually working to further improve its vehicles and other products. These improvements may
affect servicing procedures. Any modification and/or significant change in specifications or proce-
dures will be forwarded to all Club Car dealers and will, when applicable, appear in future editions
of this manual.
Damage to a vehicle or component thereof not resulting from a defect or that occurs due to unrea-
sonable or unintended use, overloading, abuse, or neglect (including failure to provide reasonable
or necessary maintenance as instructed in the vehicle owner’s manual), accident or alteration,
including increasing vehicle speed beyond factory specifications or modifications that affect the
stability of the vehicle or the operation thereof, will void the warranty.
Club Car, LLC, reserves the right to change specifications and designs at any time without notice
and without incurring any obligation or liability whatsoever.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle owner’s manual or write to Club Car, LLC, P.O. Box 204658, Augusta, Georgia 30917-4658
USA, Attention: Warranty Department.

2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ............................................................................................................................... 1-1
Disabling The Vehicle ................................................................................................................... 1-3
Disconnecting The Battery ............................................................................................................ 1-3
Connecting The Battery ................................................................................................................ 1-3
SECTION 2 – VEHICLE SPECIFICATIONS
General Information .......................................................................................................................... 2-1
SECTION 3 – GENERAL INFORMATION
General Information .......................................................................................................................... 3-1
Engine Identification ......................................................................................................................... 3-1
Serial Number Identification .............................................................................................................. 3-1
Storage ............................................................................................................................................. 3-2
Preparing The Vehicle For Extended Storage .............................................................................. 3-2
To Return Vehicle To Service ....................................................................................................... 3-3
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 4-1
Front Body Repair ............................................................................................................................. 4-2
Abrasions and Haze ..................................................................................................................... 4-2
Light Scratches ............................................................................................................................. 4-2
Large Scratches and Abrasions .................................................................................................... 4-2
Tube Bumper/Brush Guard ............................................................................................................... 4-2
Tube Bumper/Brush Guard Removal ........................................................................................... 4-2
Tube Bumper/Brush Guard Installation ........................................................................................ 4-2
Front Body Components ................................................................................................................... 4-3
Dashboard Removal ..................................................................................................................... 4-3
Dashboard Installation .................................................................................................................. 4-3
Front Body Removal ..................................................................................................................... 4-5
Front Fender Removal .................................................................................................................. 4-5
Front Fender Installation ............................................................................................................... 4-5
Front Body Installation .................................................................................................................. 4-5
Seat .................................................................................................................................................. 4-5
Seat Adjustment ........................................................................................................................... 4-7