Club Car XRT 800 Manual

MANUAL NUMBER 103209106
EDITION CODE 0907D0808C
XRT 800, 810 and 850
GASOLINE/ELECTRIC
2007-2008
MAINTENANCE
SERVICE
MANUAL
Club Car, Inc.
P.O. Box 204658
Augusta, GA 30917-4658
USA
Web www.clubcar.com
Phone [phone]
1.800.ClubCar
Int’l +1 706.863.3000
Fax [phone]

2007-2008 XRT 800, 810 and 850 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 Club Car XRT 800, 810 and
850 series vehicles, and should be thoroughly reviewed prior to servicing the vehicle. The procedures pro-
vided 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 to assist its distributors and dealers in continually updating their service knowledge
and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical repre-
sentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other
service publications also represent Club Car’s continuing commitment to customer support.
This manual covers all aspects of typical vehicle service; however, unique situations sometimes occur when
servicing a vehicle. If it appears that a service question is not answered in this manual, you may write to us at:
Club Car, Inc., P.O. Box 204658; Augusta, GA 30917-4658 USA, Attention: Technical Services, or contact a
Club Car Technical Service Representative at [phone], ext. 3580.
Copyright © 2007, 2008 Club Car, Inc.
Club Car and Carryall are registered
trademarks of Club Car, Inc
This manual effective August 1, 2006.

Page ii 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
ý WARNING
• Read Section 1 – Safety before attempting any service on the vehicle.
• Before servicing vehicle, read complete section(s) and any referenced information that may
be relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car is contin-
ually working to further improve its vehicles and other products. These improvements may affect
servicing procedures. Any modification and/or significant change in specifications or procedures
will be forwarded to all Club Car dealers and will, when applicable, appear in future editions of this
manual.
Club Car reserves the right to change specifications and designs at any time without notice and
without the obligation of making changes to units previously sold.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle Owner’s Manual.

2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ............................................................................................................................... 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
800 and 810 Specifications ........................................................................................................... 2-1
850 Specifications ......................................................................................................................... 2-3
SECTION 3 – GENERAL INFORMATION
Serial Number Identification .............................................................................................................. 3-1
Storage – Gasoline Vehicle .............................................................................................................. 3-2
Preparing the Gasoline Vehicle for Extended Storage ................................................................. 3-2
Returning the Stored Gasoline Vehicle to Service ........................................................................ 3-4
Storage – Electric Vehicle ................................................................................................................. 3-4
Preparing the Electric Vehicle for Extended Storage .................................................................... 3-5
Returning the Stored Electric Vehicle to Service .......................................................................... 3-5
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 4-1
Seat Cleaning ............................................................................................................................... 4-1
Front and Rear Body Repair ............................................................................................................. 4-2
Minor Scratches and Surface Blemishes ...................................................................................... 4-2
Small Scratches That Cannot Be Buffed Out ............................................................................... 4-2
Gouges, Punctures, Tears, Large Scratches, and Abrasions ....................................................... 4-2
Front Body – 800 and 810 ................................................................................................................ 4-3
Bumper/Brush Guard Removal .....................................................................................................4-3
Bumper/Brush Guard Installation .................................................................................................. 4-3
Front Body Removal ..................................................................................................................... 4-3
Molded Dash Removal ................................................................................................................. 4-4
Molded Dash Installation .............................................................................................................. 4-4
Front Body Installation .................................................................................................................. 4-4