2003 Club Car Turf / 2 / 6 / Carryall 1 / 2 / 6 / Plus / XRT Gas Electric Golf Car Service Manual

Description

This Official 2003 Club Car Turf/Carryall Turf 1, Turf 2, Turf 2 XRT, Turf 6, Carryall 1, Carryall 2, Carryall 2 Plus, Carryall 2 XRT, Carryall 6 Gas and Electric Golf Car Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2003 Turf/Carryall Turf 1, Turf 2, Turf 2 XRT, Turf 6, Carryall 1, Carryall 2, Carryall 2 Plus, Carryall 2 XRT, Carryall 6 Gas and Electric Golf Carts.

This manual provides detailed information for the maintenance and repair of Turf and Carryall vehicles and should be used in conjunction with the appropriate maintenance and service supplement:
2003 PowerDrive System 48 Vehicle Maintenance and Service Supplement, (covers motor and electrical), Item # 102318805
2003 FE290 Gasoline Vehicle Maintenance and Service Supplement (covers engine and electrical), Item # 102318807
2003 FE350 Gasoline Vehicle Maintenance and Service Supplement (covers engine and electrical), Item # 102318808

Table of Contents

SECTION 1 – SAFETY
General Warning

SECTION 2 – VEHICLE SPECIFICATIONS

SECTION 3 – GENERAL INFORMATION
General Information
Serial Number Identification
Storage – Gasoline Vehicle
Preparing the Gasoline Vehicle for Extended Storage
Returning the Stored Gasoline Vehicle to Service
Storage – Electric Vehicle
Preparing the Electric Vehicle for Extended Storage
Returning the Stored Electric Vehicle to Service

SECTION 4 – BODY AND TRIM
Cleaning the Vehicle
Front Body Repair
Stress Lines or Streaks
Minor Impact Damage/Deformations
Minor Scratches and Surface Blemishes
Small Scratches That Cannot Be Buffed Out
Touch-up Paint Color Chart;
Gouges, Punctures, Tears, Large Scratches, and Abrasions
Front Body
Front Body Removal
Front Body Installation
Tilt Bed – Turf 1, 2, Carryall 1, 2 and 2 Plus
Tilt Bed Removal
Tilt Bed Installation
Flat Bed – Turf 6 and Carryall 6
Flat Bed Removal
Flat Bed Installation
Flat Bed Trim – Turf 6 and Carryall 6
Flat Bed Trim Removal
Flat Bed Trim Installation
Access Door-Turf 6 and Carryall 6
Access Door Removal
Access Door Installation
Side Door – Turf 6 and Carryall 6
Side Door Removal :
Side Door Installation
Rear Fender
Rear Fender Removal
Rear Fender Installation
Trailer Hitch (Optional on Some Models)
Trailer Hitch Removal
Trailer Hitch Installation
Tailskirt
Tailskirt Removal
Tailskirt Installation
Floor Mat
Front Floor Mat Removal
Front Floor Mat Installation
Rear Floor Mat Removal – Turf 6 and Carryall 6 Only
Rear Floor Mat Installation – Turf 6 and Carryall 6 Only
Bumper
Bumper Removal
Bumper Installation

SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Brake Pedal and Park Brake
Brake Pedal Removal
Brake Pedal Installation
Park Brake Removal
Park Brake Installation
Accelerator Pedal – Gasoline Vehicles
Accelerator Pedal Removal – Gasoline Vehicles
Accelerator Pedal Installation – Gasoline Vehicles
Accelerator Pedal – Electric Vehicles
Accelerator Pedal Removal – Electric Vehicles
Accelerator Pedal Installation – Electric Vehicles
Pedal Group Adjustment – Gasoline Vehicles
Pedal Group Adjustment – Electric Vehicles

SECTION 6 – WHEEL BRAKE ASSEMBLIES
General Information
Brake Shoe Removal
Brake Assembly Cleaning (Self-Adjusting Brakes)
Brake Shoe Installation (Self-Adjusting Brakes)
Brake Adjustment (Self-Adjusting Brakes)
Brake Assembly Cleaning (Manually-Adjusted Brakes)
Brake Shoe Installation (Manually-Adjusted Brakes):
Brake Adjustment (Manually-Adjusted Brakes)
Brake Cluster Adjustment
Brake Cable Equalization
Final Brake Cluster Adjustment
Test Drive Vehicle,
Brake Cluster Removal and Installation
Rear Brake Cluster Removal
Rear Brake Cluster Installation
Front Brake Cluster Removal
Front Brake Cluster Installation
Front Brake Cables
Front Brake Cable Removal
Front Brake Cable Installation ■
Rear Brake Cables
Rear Brake Cable Removal
Rear Brake Cable Installation

SECTION 7 – STEERING AND FRONT SUSPENSION
General Information
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Disassembly
Steering Column Assembly
Steering Column Installation
Steering Adjustment
Rack and Pinion
Rack and Pinion Removal
Rack and Pinion Disassembly
Rack and Pinion Assembly
Rack and Pinion Installation
Tie Rod and Drag Link
Tie Rod and Drag Link Removal
Tie Rod and Drag Link Installation
Front Suspension •
Lubrication
Wheel Alignment
Front Suspension Components
Leaf Spring Removal
Leaf Spring Installation
Kingpin and Steering Spindle Removal
Kingpin and Steering Spindle Installation
Delta A-Plate Removal
Delta A-Plate Installation
Shock Absorber Removal
Shock Absorber Installation
Front Wheel Bearings and Hubs
Front Wheel Free Play Inspection
Front Wheel Bearings and Hub Removal
Front Wheel Bearings and Hub Installation

SECTION 8 – WHEELS AND TIRES
General Information
Wheels
Wheel Removal
Wheel Installation
Tires
Tire Removal
Tire Repair
Tire Installation

SECTION 9 – REAR SUSPENSION
General Information
Shock Absorbers
Shock Absorber Inspection and Removal
Shock Absorber Installation
Multi-Leaf Springs
Multi-Leaf Spring Removal
Multi-Leaf Spring Installation
Snubber
Snubber Removal
Snubber Installation
Stabilizer Bar
Stabilizer Bar Removal
Stabilizer Bar Installation
Jounce Bumpers
Jounce Bumper Removal
Jounce Bumper Installation

SECTION i – INDEX