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

Page iv 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Front Body – 850 .............................................................................................................................. 4-5
Bumper/Brush Guard (Standard) Removal .................................................................................. 4-5
Bumper/Brush Guard (Standard) Installation ............................................................................... 4-6
Bumper/Brush Guard (Heavy Duty) Removal .............................................................................. 4-7
Bumper/Brush Guard (Heavy Duty) Installation ........................................................................... 4-7
Front Removal .............................................................................................................................. 4-7
Front Body Installation .................................................................................................................. 4-7
Cargo Bed – 800 and 810 ................................................................................................................ 4-8
Cargo Bed Removal ..................................................................................................................... 4-8
Cargo Bed Installation .................................................................................................................. 4-9
Bed Latch Assembly ..................................................................................................................... 4-9
Bed Latch Assembly Installation .................................................................................................. 4-11
Seat Back Support Brackets – 800 and 810 .................................................................................... 4-11
Seat Back Support Bracket Removal ........................................................................................... 4-11
Seat Back Support Bracket Installation ........................................................................................ 4-12
Rear Body and Fenders – 800 and 810 ........................................................................................... 4-12
Rear Body Removal ..................................................................................................................... 4-12
Rear Fender Removal .................................................................................................................. 4-14
Rear Fender Installation ............................................................................................................... 4-14
Rear Body Installation .................................................................................................................. 4-15
Rear Body – 850 .............................................................................................................................. 4-15
Rear Body Removal ..................................................................................................................... 4-15
Rear Body Installation .................................................................................................................. 4-19
Floor Mat .......................................................................................................................................... 4-19
Floor Mat Removal ....................................................................................................................... 4-19
Floor Mat Installation .................................................................................................................... 4-19
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Brake Pedal and Park Brake ............................................................................................................ 5-1
Brake Pedal Removal ................................................................................................................... 5-1
Brake Pedal Installation ................................................................................................................ 5-2
Park Brake Removal .................................................................................................................... 5-3
Park Brake Installation ................................................................................................................. 5-4
Accelerator Pedal – Gasoline Vehicles ............................................................................................ 5-5
Accelerator Pedal Removal .......................................................................................................... 5-5
Accelerator Pedal Installation ....................................................................................................... 5-7
Accelerator Pedal – Electric Vehicles .............................................................................................. 5-8
Accelerator Pedal Removal .......................................................................................................... 5-8
Accelerator Pedal Installation ....................................................................................................... 5-10
Pedal Group Adjustment – Gasoline Vehicle ................................................................................... 5-11
Pedal Group Adjustment – Electric Vehicles .................................................................................... 5-16

2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page v
SECTION 6 – WHEEL BRAKE ASSEMBLIES
Brake Shoe Removal ........................................................................................................................ 6-1
Brake Assembly Cleaning ................................................................................................................. 6-5
Brake Shoe Installation ..................................................................................................................... 6-6
Brake Adjustment ............................................................................................................................. 6-8
Brake Cluster Removal and Installation ............................................................................................ 6-8
Brake Cluster Installation .............................................................................................................. 6-9
Brake Cable Removal and Installation .............................................................................................. 6-10
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information .......................................................................................................................... 7-1
Steering Wheel ................................................................................................................................. 7-1
Steering Wheel Removal .............................................................................................................. 7-1
Steering Wheel Installation ........................................................................................................... 7-2
Steering Column ............................................................................................................................... 7-2
Steering Column Removal ............................................................................................................ 7-2
Steering Column Disassembly ...................................................................................................... 7-4
Steering Column Assembly .......................................................................................................... 7-4
Steering Column Installation ......................................................................................................... 7-5
Steering Adjustment ......................................................................................................................... 7-6
Rack and Pinion ................................................................................................................................ 7-7
Rack and Pinion Removal ............................................................................................................ 7-7
Rack and Pinion Disassembly ...................................................................................................... 7-7
Rack and Pinion Assembly ........................................................................................................... 7-10
Rack and Pinion Installation ......................................................................................................... 7-12
Tie Rod and Drag Link ...................................................................................................................... 7-12
Tie Rod and Drag Link Removal ................................................................................................... 7-12
Tie Rod and Drag Link Installation ................................................................................................ 7-12
Front Suspension .............................................................................................................................. 7-13
Lubrication .................................................................................................................................... 7-13
Wheel Alignment ........................................................................................................................... 7-13
Front Suspension Components ........................................................................................................ 7-15
Tapered Leaf Spring Removal ...................................................................................................... 7-15
Tapered Leaf Spring Installation ................................................................................................... 7-15
Kingpin and Steering Spindle Removal ........................................................................................ 7-16
Kingpin and Steering Spindle Installation ..................................................................................... 7-16
Delta A-Plate Removal ................................................................................................................. 7-16
Delta A-Plate Installation .............................................................................................................. 7-19
Shock Absorber Removal ............................................................................................................. 7-19
Shock Absorber Installation .......................................................................................................... 7-19

Page vi 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Front Wheel Bearings and Hubs ...................................................................................................... 7-19
Front Wheel Free Play Inspection ................................................................................................ 7-19
Front Hub Removal ...................................................................................................................... 7-19
Front Hub Installation ................................................................................................................... 7-20
SECTION 8 – WHEELS AND TIRES
General Information ......................................................................................................................... 8-1
Wheels ............................................................................................................................................. 8-1
Wheel Removal ............................................................................................................................ 8-1
Wheel Installation ......................................................................................................................... 8-1
Tires ................................................................................................................................................. 8-1
Tire Removal ................................................................................................................................ 8-1
Tire Repair .................................................................................................................................... 8-2
Tire Installation ............................................................................................................................. 8-3
SECTION 9 – REAR SUSPENSION
General Information ......................................................................................................................... 9-1
Shock Absorbers .............................................................................................................................. 9-1
Shock Absorber Removal and Inspection .................................................................................... 9-1
Shock Absorber Installation .......................................................................................................... 9-1
Leaf Springs ..................................................................................................................................... 9-2
Leaf Spring Removal – 800 and 810 ............................................................................................ 9-2
Leaf Spring Removal – 850 .......................................................................................................... 9-4
Leaf Spring Installation – All Vehicles .......................................................................................... 9-4
Stabilizer Bar Removal ................................................................................................................. 9-7
Stabilizer Bar Installation .............................................................................................................. 9-7
SECTION 10 – PERIODIC MAINTENANCE
General Information ......................................................................................................................... 10-1
Periodic Service Schedules ............................................................................................................. 10-1
Periodic Lubrication Schedules ...................................................................................................... 10-4
Engine Oil – Gasoline Vehicles ........................................................................................................ 10-6
Engine Oil Level Check ................................................................................................................ 10-6
Engine Oil And Filter Change ....................................................................................................... 10-7
Oil Viscosity .................................................................................................................................. 10-9
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: 800 AND 810 GAS
General Information ......................................................................................................................... 11-1
Troubleshooting Guide ..................................................................................................................... 11-1

2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page vii
Electrical System .............................................................................................................................. 11-5
Lockout Cam ..................................................................................................................................... 11-5
Wiring Diagrams ............................................................................................................................... 11-6
Test Procedures ............................................................................................................................... 11-8
Index of Test Procedures .............................................................................................................. 11-8
SECTION 12 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: 850 GAS
General Information .......................................................................................................................... 12-1
Troubleshooting Guide ..................................................................................................................... 12-1
Wiring Diagram ................................................................................................................................. 12-6
Electrical System .............................................................................................................................. 12-8
Test Procedures ............................................................................................................................... 12-8
Index of Test Procedures .............................................................................................................. 12-8
SECTION 13 – ELECTRICAL COMPONENTS: 800 AND 810 GASOLINE VEHICLES
Starter/Generator .............................................................................................................................. 13-1
Voltage Regulator ............................................................................................................................. 13-11
Diode ................................................................................................................................................ 13-12
Key Switch ........................................................................................................................................ 13-14
Solenoid ............................................................................................................................................ 13-15
Fuse .................................................................................................................................................. 13-16
Lockout Cam Limit Switch ................................................................................................................ 13-17
Lockout Cam ..................................................................................................................................... 13-18
Reverse Warning Buzzer .................................................................................................................. 13-19
Reverse Buzzer Limit Switch ............................................................................................................ 13-20
Oil Warning Light .............................................................................................................................. 13-20
Fuel Gauge/Hour Meter .................................................................................................................... 13-21
Fuel Level Sending Unit .................................................................................................................... 13-22
RPM Limiter ...................................................................................................................................... 13-23
Ignition Coil ....................................................................................................................................... 13-24
Oil Level Sensor ............................................................................................................................... 13-27
Headlights ......................................................................................................................................... 13-27
Voltage Limiter .................................................................................................................................. 13-28
Light Switch ...................................................................................................................................... 13-29
Battery .............................................................................................................................................. 13-30
Ground Cables .................................................................................................................................. 13-34
SECTION 14 – ELECTRICAL COMPONENTS: 850 GASOLINE VEHICLE
Starter/Generator .............................................................................................................................. 14-1
Voltage Regulator ............................................................................................................................. 14-11

Page viii 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Key Switch ....................................................................................................................................... 14-12
Solenoid ........................................................................................................................................... 14-14
Fuse ................................................................................................................................................. 14-14
Kill Limit Switch ................................................................................................................................ 14-15
Neutral Lockout Limit Switch ............................................................................................................ 14-16
Reverse Warning Buzzer ................................................................................................................. 14-18
Reverse Buzzer Limit Switch ........................................................................................................... 14-19
Low Oil Warning Light ...................................................................................................................... 14-20
Fuel Gauge/Hour Meter ................................................................................................................... 14-21
Fuel Level Sending Unit ................................................................................................................... 14-22
RPM Limiter ..................................................................................................................................... 14-22
Ignition Coil ...................................................................................................................................... 14-23
Oil Level Sensor ............................................................................................................................... 14-26
Headlights ........................................................................................................................................ 14-26
Voltage Limiter ................................................................................................................................. 14-28
Headlight Switch .............................................................................................................................. 14-29
Battery .............................................................................................................................................. 14-30
Ground Cables ................................................................................................................................. 14-34
SECTION 15 – ENGINE
General Information ......................................................................................................................... 15-1
Before Servicing ........................................................................................................................... 15-1
Engine Rotation ............................................................................................................................ 15-1
Spark Plug .................................................................................................................................... 15-1
Cylinder Head .................................................................................................................................. 15-3
General Information ...................................................................................................................... 15-3
Breather Valve (Reed Valve) ........................................................................................................ 15-3
Crankcase ........................................................................................................................................ 15-3
Engine Removal ........................................................................................................................... 15-3
Crankcase Cover Removal .......................................................................................................... 15-3
Oil Level Sensor ........................................................................................................................... 15-5
Crankcase Cover Installation ....................................................................................................... 15-5
Ignition Coil and Flywheel ................................................................................................................ 15-6
Flywheel Installation ......................................................................................................................... 15-8
Engine Installation ............................................................................................................................ 15-9
Torque Specifications ................................................................................................................... 15-10
Adjustments and Settings ............................................................................................................ 15-10
SECTION 16 – FUEL SYSTEM: GASOLINE VEHICLE
General Information ......................................................................................................................... 16-1

2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page ix
Carburetor ......................................................................................................................................... 16-1
Main Jet Elevation/Size Chart ....................................................................................................... 16-3
Changing the Main Jet .................................................................................................................. 16-3
Engine Control Linkage .................................................................................................................... 16-6
General Information ...................................................................................................................... 16-6
Accelerator Rod ............................................................................................................................ 16-7
Governor Cable ............................................................................................................................ 16-9
Accelerator Cable ......................................................................................................................... 16-10
Closed Throttle or Idle Adjustment ............................................................................................... 16-11
Engine RPM Adjustment ............................................................................................................... 16-12
Choke and Air Intake System ........................................................................................................... 16-12
Choke Button Removal ................................................................................................................. 16-12
Choke Button Installation .............................................................................................................. 16-12
Air Box Removal ........................................................................................................................... 16-13
Air Box Installation ........................................................................................................................ 16-13
Intake Duct Removal .................................................................................................................... 16-13
Intake Duct Installation ................................................................................................................. 16-14
Air Filter ........................................................................................................................................ 16-16
Fuel Filters ........................................................................................................................................ 16-17
Fuel Filter Removal ....................................................................................................................... 16-17
Fuel Filter Installation .................................................................................................................... 16-17
Fuel Pump ........................................................................................................................................ 16-19
General Information ...................................................................................................................... 16-19
Fuel Pump Removal ..................................................................................................................... 16-19
Fuel Pump Disassembly ............................................................................................................... 16-19
Fuel Pump Cleaning and Inspection ............................................................................................. 16-20
Fuel Pump Assembly .................................................................................................................... 16-20
Fuel Pump Installation .................................................................................................................. 16-21
Fuel Tank .......................................................................................................................................... 16-21
General Information ...................................................................................................................... 16-21
Fuel Tank Removal ....................................................................................................................... 16-22
Fuel Tank Disposal ....................................................................................................................... 16-23
Fuel Tank Storage ........................................................................................................................ 16-23
Fuel Tank Installation .................................................................................................................... 16-23
Fuel Lines ......................................................................................................................................... 16-25
Fuel Shut-Off Valve .......................................................................................................................... 16-25
Fueling Instructions ........................................................................................................................... 16-26

Page x 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
SECTION 17 – EXHAUST SYSTEM: GASOLINE VEHICLES
Muffler .............................................................................................................................................. 17-1
Muffler Removal ........................................................................................................................... 17-1
Muffler Installation ........................................................................................................................ 17-1
SECTION 18 – UNITIZED TRANSAXLE: 800/810 GASOLINE VEHICLES
General Information ......................................................................................................................... 18-1
Lubrication .................................................................................................................................... 18-2
Axle Shaft ......................................................................................................................................... 18-2
Axle Shaft and Oil Seal Removal ................................................................................................. 18-2
Axle Bearing ................................................................................................................................. 18-3
Axle Shaft Installation ................................................................................................................... 18-5
Unitized Transaxle Removal ............................................................................................................ 18-6
Unitized Transaxle Installation ......................................................................................................... 18-13
Forward/Reverse Shifter Cable ........................................................................................................ 18-19
Forward/Reverse Shifter Cable Removal ..................................................................................... 18-19
Forward/Reverse Shifter Cable Installation .................................................................................. 18-19
Forward/Reverse Shifter Cable Adjustment ................................................................................. 18-20
SECTION 19 – UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
General Information ......................................................................................................................... 19-1
Lubrication .................................................................................................................................... 19-2
Axle Shaft ......................................................................................................................................... 19-2
Axle Shaft and Oil Seal Removal ................................................................................................. 19-2
Axle Bearing ................................................................................................................................. 19-3
Axle Shaft Installation ................................................................................................................... 19-5
Unitized Transaxle Removal ............................................................................................................ 19-6
Unitized Transaxle Installation ......................................................................................................... 19-14
Forward/Reverse Shifter Cable ........................................................................................................ 19-19
Forward/Reverse Shifter Cable Removal ..................................................................................... 19-19
Forward/Reverse Shifter Cable Installation .................................................................................. 19-19
Forward/Reverse Shifter Cable Adjustment ................................................................................. 19-21
SECTION 20 – TORQUE CONVERTER: GASOLINE VEHICLE
General Information ......................................................................................................................... 20-1
Troubleshooting ............................................................................................................................... 20-1
Drive Belt .......................................................................................................................................... 20-2
Drive Belt Removal ....................................................................................................................... 20-2
Drive Belt Installation .................................................................................................................... 20-3

2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page xi
Drive Clutch ...................................................................................................................................... 20-4
Drive Clutch Removal ................................................................................................................... 20-4
Drive Clutch Cleaning and Inspection ...........................................................................................20-5
Drive Clutch Disassembly ............................................................................................................. 20-7
Inspection of Drive Clutch Parts ................................................................................................... 20-9
Drive Clutch Assembly .................................................................................................................. 20-10
Drive Clutch Installation ................................................................................................................ 20-12
Driven Clutch .................................................................................................................................... 20-12
Driven Clutch Removal ................................................................................................................. 20-12
Driven Clutch Disassembly ........................................................................................................... 20-12
Driven Clutch Inspection ............................................................................................................... 20-13
Driven Clutch Assembly ................................................................................................................ 20-13
Driven Clutch Installation .............................................................................................................. 20-16
SECTION 21 – ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE
General Information .......................................................................................................................... 21-1
Wiring Diagram ................................................................................................................................. 21-2
Troubleshooting ................................................................................................................................ 21-4
Troubleshooting the Vehicle with the Diagnostic Handset ............................................................ 21-4
Troubleshooting Guide 1 .............................................................................................................. 21-5
Troubleshooting Guide 2 .............................................................................................................. 21-8
Test Procedures ............................................................................................................................... 21-10
Index of Test Procedures .............................................................................................................. 21-10
Communication Display Module (CDM) ............................................................................................ 21-33
Using the CDM to Retrieve Data from the Onboard Computer .................................................... 21-34
CDM Troubleshooting Guide ........................................................................................................ 21-35
SECTION 22 – IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS
Plugging the Handset into the Vehicle .............................................................................................. 22-1
Introductory Display .......................................................................................................................... 22-2
Menu Navigation ............................................................................................................................... 22-2
Monitor Menu .................................................................................................................................... 22-4
Faults Menu ...................................................................................................................................... 22-6
Functions Menu ................................................................................................................................ 22-11
Get Settings From Controller ........................................................................................................ 22-11
Write Settings to Controller ........................................................................................................... 22-12
Reset All Settings ......................................................................................................................... 22-13
Information ........................................................................................................................................ 22-14

Page xii 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Programmer Setup ........................................................................................................................... 22-14
Program ....................................................................................................................................... 22-14
Faults ........................................................................................................................................... 22-14
Information ................................................................................................................................... 22-15
IQDM and IQDM-P Handset Troubleshooting .................................................................................. 22-16
Test Procedures ............................................................................................................................... 22-17
Index of Test Procedures ............................................................................................................. 22-17
SECTION 23 – ELECTRICAL COMPONENTS: ELECTRIC VEHICLE
Key Switch – 800 and 810 ............................................................................................................... 23-1
Key Switch – 850 ............................................................................................................................. 23-2
Forward/Reverse Switch – 800 and 810 .......................................................................................... 23-4
Forward/Reverse Rocker Switch – 850 ............................................................................................23-6
Tow/Run Switch ............................................................................................................................... 23-7
Motor Controller Output Regulator (MCOR) ..................................................................................... 23-8
Reverse Buzzer ................................................................................................................................ 23-9
Solenoid ........................................................................................................................................... 23-10
Onboard Computer (OBC) ............................................................................................................... 23-11
Solid State Speed Controller ............................................................................................................ 23-13
Charger Receptacle ......................................................................................................................... 23-15
Receptacle Fuse Link ................................................................................................................... 23-16
Battery Warning Light ....................................................................................................................... 23-17
SECTION 24 – BATTERIES: ELECTRIC VEHICLES
General Information ......................................................................................................................... 24-1
Battery Troubleshooting Chart ......................................................................................................... 24-2
Battery Testing ................................................................................................................................. 24-3
Battery Charger Test .................................................................................................................... 24-3
On-Charge Voltage Test .............................................................................................................. 24-3
Hydrometer Test ........................................................................................................................... 24-3
Discharge Test ............................................................................................................................. 24-5
Battery Troubleshooting Examples .............................................................................................. 24-7
Battery Replacement ........................................................................................................................ 24-8
Battery Care ..................................................................................................................................... 24-9
Preventive Maintenance ............................................................................................................... 24-9
Self-Discharge .............................................................................................................................. 24-10
Electrolyte Level ........................................................................................................................... 24-10
Mineral Content ............................................................................................................................ 24-11
Vibration Damage ......................................................................................................................... 24-11

2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page xiii
Battery Charger ................................................................................................................................ 24-12
Charging Batteries ........................................................................................................................ 24-12
Plug and Receptacle ..................................................................................................................... 24-13
Receptacle Fuse Link ................................................................................................................... 24-14
Charger Shuts Off After 16 Hours ................................................................................................. 24-14
Deep-Discharge ............................................................................................................................ 24-14
Early Excessive Discharging ........................................................................................................ 24-15
Incoming AC Service .................................................................................................................... 24-15
Fleet Rotation ............................................................................................................................... 24-15
Numbering Vehicles and Chargers ............................................................................................... 24-15
Battery Storage ................................................................................................................................. 24-15
Charging a Battery Pack that has Low Voltage ................................................................................ 24-16
SECTION 25 – BATTERY CHARGER: ELECTRIC VEHICLE
Refer to the appropriate Battery Charger Maintenance and Service Manual.
SECTION 26 – MOTOR (MODEL 5BC59JBS6390)
General Information .......................................................................................................................... 26-1
Motor Identification ........................................................................................................................... 26-1
External Motor Testing ...................................................................................................................... 26-1
Motor ................................................................................................................................................. 26-2
Motor Component Testing and Inspection ........................................................................................ 26-5
Armature ....................................................................................................................................... 26-5
Field Windings Inspection ............................................................................................................. 26-6
Motor Components ....................................................................................................................... 26-6
Bearing Inspection ........................................................................................................................ 26-7
Bearing Removal .......................................................................................................................... 26-7
Bearing Installation ....................................................................................................................... 26-7
Speed Sensor Magnet Inspection .................................................................................................26-9
Speed Sensor Magnet Removal ................................................................................................... 26-9
Speed Sensor Magnet Installation ................................................................................................ 26-9
Reconditioning the Motor .................................................................................................................. 26-9
Motor Assembly ................................................................................................................................ 26-10
Motor Installation .............................................................................................................................. 26-12
Motor Speed Sensor ......................................................................................................................... 26-15
SECTION 27 – MOTOR (MODEL EJ4-4001)
General Information .......................................................................................................................... 27-1
Motor Identification ........................................................................................................................... 27-1
External Motor Testing ...................................................................................................................... 27-1

Page xiv 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Motor ................................................................................................................................................ 27-2
Motor Removal ............................................................................................................................. 27-2
Motor Disassembly ....................................................................................................................... 27-4
Motor Component Testing and Inspection ....................................................................................... 27-6
Armature Inspection and Testing ................................................................................................. 27-6
Motor Frame and Field Windings Inspection ................................................................................ 27-7
Motor Brush, Spring, and Terminal Insulator Inspection .............................................................. 27-8
Reconditioning the Motor ................................................................................................................. 27-11
Motor Assembly ............................................................................................................................... 27-11
Motor Installation .............................................................................................................................. 27-13
SECTION 28 – TRANSAXLE (TYPE G): ELECTRIC VEHICLE
Transaxle Identification .................................................................................................................... 28-1
Lubrication ........................................................................................................................................ 28-1
Axle Bearing and Shaft .................................................................................................................... 28-1
Axle Shaft ..................................................................................................................................... 28-1
Axle Bearing ................................................................................................................................. 28-4
Transaxle ......................................................................................................................................... 28-5
Transaxle Removal ...................................................................................................................... 28-5
Transaxle Disassembly, Inspection, and Assembly ......................................................................... 28-7
Transaxle Disassembly and Inspection ........................................................................................ 28-7
Transaxle Assembly ..................................................................................................................... 28-9
Transaxle Installation ....................................................................................................................... 28-10
SECTION 29 – IQ DISPLAY MODULE (IQDM-P) PROGRAMMING
Plugging the Handset into the Vehicle ............................................................................................. 29-1
Program Menu ................................................................................................................................. 29-2
Speed Setting ............................................................................................................................... 29-2
Fast Accel .................................................................................................................................... 29-3
Pedal Up Mode ............................................................................................................................ 29-3
Speed Cal .................................................................................................................................... 29-3
Code A, Code B, and Code C ...................................................................................................... 29-3
SECTION i – INDEX

2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 1-1
1
SECTION 1 – SAFETY
To ensure the safety of those servicing these vehicles, and to protect the vehicles from possible damage
resulting from improper service or maintenance, the procedures in this manual must be followed.
It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAU-
TION. These special statements relate to specific safety issues, and must be read, understood, and heeded
before proceeding with procedures. There are statements labeled NOTE, which provide other essential ser-
vice or maintenance information.
ý DANGER
• A DANGER indicates an immediate hazard that will result in severe personal injury or death.
ý WARNING
• A WARNING indicates an immediate hazard that could result in severe personal injury or
death.
ý CAUTION
• A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could
result in minor personal injury.
CAUTION
• A CAUTION without the safety alert symbol indicates a potentially hazardous situation that
could result in property damage.
GENERAL WARNING
The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser-
viced. Service technicians should become familiar with these general safety statements. Also, other specific
safety statements appear throughout this manual and on the vehicle.
ý DANGER
• Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full
face shield and rubber gloves when working on or near batteries.
• Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or
clothing. Antidotes:
- External: Flush with water. Call a physician immediately.
- Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
- Eyes: Flush with water for 15 minutes. Call a physician immediately.
• Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the
vehicle and service area. Service only in a well-ventilated area.
• Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine
produces carbon monoxide, which is an odorless, deadly poison.

SAFETY General Warning
Page 1-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
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ý WARNING
• Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and
CAUTION statements in this manual as well as those on the vehicle.
• Only trained technicians should service or repair the vehicle. Anyone doing even simple
repairs or service should have knowledge and experience in electrical and mechanical repair.
The appropriate instructions must be used when performing maintenance, service, or
accessory installation.
• Prior to servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF,
remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Chock the
wheels when servicing the vehicle.
Gasoline vehicles only:
• To avoid unintentionally starting the vehicle:
- Disconnect battery cables, negative (–) cable first (Figure 1-1, Page 1-3).
- Disconnect the spark plug wire from the spark plug.
• Frame ground – Do not allow tools or other metal objects to contact frame when
disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch
the vehicle frame, engine, or any other metal component.
Electric vehicles only:
• Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries.
• To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figure 1-2,
Page 1-3).
• After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge.
All vehicles:
• Wear safety glasses or approved eye protection when servicing the vehicle or battery charger.
Wear a full face shield and rubber gloves when working on or near batteries.
• Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the
vehicle.
• Moving parts! Do not attempt to service the vehicle while it is running.
• Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning
could result in severe burns.
• Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
• Check the vehicle owner’s manual for proper location of all vehicle safety and operation
decals and make sure they are in place and are easy to read.
• Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
• Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic
floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold
vehicle in raised position. Use approved jack stands of proper weight capacity to support the
vehicle and chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
• If wires are removed or replaced, make sure wiring and wire harness are properly routed and
secured. Failure to properly route and secure wiring could result in vehicle malfunction,
property damage, personal injury, or death.
WARNING CONTINUED ON NEXT PAGE...

SAFETY General Warning
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 1-3
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ý WARNING
• For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle.
If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is
raised. Do not close bed until all persons are clear of cargo bed area. Keep hands clear of all
crush areas. Do not drop cargo bed; lower gently and keep entire body clear. Failure to heed
this warning could result in severe personal injury or death.
• Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance, severe personal injury, or death.
• Do not leave children unattended on vehicle.
Figure 1-1 Gasoline Vehicle Figure 1-2 IQ System Electric Vehicle
(Viewed from passenger side of vehicle)
1. Remove negative battery cable.
2. Remove positive battery cable.
Connect battery cables in reverse order.
(Viewed from driver side of vehicle)
1. Place TOW/RUN Switch in TOW before disconnecting or
connecting battery cables.
2. Remove negative battery cable.
3. Remove positive battery cable.
Connect battery cables in reverse order.
1
2
1
2
3
4
3
2
1
(–)
(+)

1