XRT800/XRT810 Illustrated Parts List

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1 XRT800/XRT810 Illustrated Parts List asoline and lectric Vehicles Manual Number dition Code 0508L0112K

3 USIN TH ILLUSTRAT PARTS LIST ý WARNIN This manual is to be used only for identification and ordering of service parts. Be sure to read and use the maintenance and service manual before attempting any vehicle repairs. This manual covers all XRT800 and XRT810 gasoline and electric vehicles. The manual is divided into 16 sections. Sections 1 through 15 pertain to the vehicles, and Section 16 pertains to tools that are used on all Club Car products. Note that there are flags on the outside edge of each page. The first flag contains the section number of which that page is a part. The other flags contain the letters or, signifying that the page pertains to either the gasoline vehicle, the electric vehicle, or both. Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table of Contents lists section numbers, and under them, the individual page titles and numbers to be found in that section. The index can be used to find specific parts and assemblies. The index is divided into numerical and alphabetical listings with the page numbers in italic text. There is a two-page spread for each individual page title in the Table of Contents. On the left-hand page is an illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon. The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding to the numbers on the illustration), part descriptions, and quantity of parts used. Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indented to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level 2 part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the part quantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. A part that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion of the vehicle illustrated on that particular spread. HOW TO ORR PARTS Replacement parts and accessories can be obtained from our network of authorized dealers and distributors. You can obtain the name and phone number of your closest authorized Club Car dealer or distributor by visiting our web site at and clicking on the istributor Search link or by calling our toll-free Service Parts and Technical Assistance hotline at (800) or (706) , extension P. O. Box Augusta, eorgia USA Telephone Service Parts Fax

4 NOT: This illustrated parts list 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 the parts used to service the vehicle. Any modification and/or significant change in specifications will be forwarded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of this illustrated parts list. Club Car, LLC. reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold. Copyright 2010 Club Car, LLC. Club Car and ArmorFlex are registered trademarks of Club Car, LLC. This manual effective October 1, XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

5 CONTNTS SCTION 1 BOY AN TRIM Front Body Canopy Support System Bumper XRT800 and XRT Brush uard HUV4210-X ash Box XRT800 and XRT love Box XRT810 and XRT Side Trim XRT800 and XRT Nerf Bar XRT810 and XRT Rear Body and Fender asoline Vehicle Rear Body and Fender lectric Vehicle Front Seat Bottom and Armrests Seat Back Cargo Bed Bed Hinge Access Panel and Heat Shield SCTION 2 WHLS AN TIRS Wheels and Tires Hubcap XRT810 and XRT SCTION 3 CALS Safety ecals asoline Vehicles Safety ecals asoline Vehicles, Continued Safety ecals asoline Vehicles, Continued Logo ecals asoline Vehicles Safety ecals lectric Vehicles Safety ecals lectric Vehicles, Continued Logo ecals SCTION 4 BRAK SYSTMS Rear Brake Assembly, Self-Adjusting Vehicle with 2-Wheel Brakes Brake Pedal Assembly Brake Cable, qualizer, and qualizer Rod Vehicles with Two-Wheel Brakes Accelerator Pedal asoline Vehicles Accelerator Pedal Assembly lectric Vehicles with MCOR Accelerator Rod asoline Vehicles XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1

6 CONTNTS SCTION 5 STRIN AN SUSPNSIONS Steering Column Steering Wheel Steering ear Assembly Front Suspension, Upper Front Suspension, Lower Front Spindles and Hubs Rear Suspension Steering ear Assembly SCTION 6 LCTRICAL SYSTM ASOLIN VHICLS Wiring asoline Vehicle Headlights lectrical Component Box asoline Vehicle lectrical Components, Front Body asoline Vehicle Starter/enerator Assembly Model asoline Vehicles F290 Starter/enerator Mounting asoline Vehicle F350 Starter/enerator Mounting asoline Vehicles Battery asoline Vehicle SCTION 7 F290 NIN F290 ngine Shrouds and Brackets F290 ngine Ignition Components and Flywheel F290 ngine Oil Circulation F290 ngine Cylinder Head F290 ngine Crankcase, Camshaft, and Oil Sensor F290 ngine Crankcase and Crankshaft F290 ngine Mounting SCTION 8 F350 NIN S27 F350 ngine Oil Circulation F350 ngine without ACR (Automatic Compression Release) Shrouds and Brackets AS26 F350 ngine Ignition Components and Flywheel AS26 F350 ngine Cylinder Head AS26 F350 ngine Crankcase and Crankshaft Oil Sensor AS26 F350 ngine Crankcase and Crankshaft F350 ngine Mounting Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

7 CONTNTS SCTION 9 AS11 F350 NIN AS11 F350 ngine without ACR (Automatic Compression Release) Shrouds and Brackets AS11 F350 ngine Ignition Components and Flywheel F350 ngine Oil Circulation AS11 F350 ngine Cylinder Head AS11 F350 ngine without ACR Crankcase, Camshaft, and Oil Sensor AS11 F350 ngine Crankcase and Crankshaft F350 ngine Mounting SCTION 10 FUL, INTAK, AN OVRNOR SYSTMS Fuel System Fuel Tank with Fuel Level Sending Unit Carburetor Assembly F Carburetor Assembly F Carburetor Installation F Carburetor Installation F overnor and Accelerator Cables Intake uct, Choke, and Air Box Assembly Carburetor Assembly F350 S Carburetor Installation F350 S SCTION 11 XHAUST SYSTM xhaust System F290 ngine xhaust System F350 ngine SCTION 12 TORQU CONVRTR rive Clutch rive Belt F rive Belt F riven Clutch SCTION 13 TRANSAXL AN FNR SHIFTR- ASOLIN VHICL Transaxle asoline Vehicles, ear Cases and Brackets Transaxle asoline Vehicles, Transmission and ear Reduction Transaxle asoline Vehicles, ifferential and Axles Forward/Reverse Shifter Assembly asoline Vehicles Forward/Reverse Shifter Cable asoline Vehicles ifferential uard XRT XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 3

8 CONTNTS SCTION 14 LCTRICAL SYSTM LCTRIC VHICLS Wiring lectric Vehicle Headlights lectrical Components, Front Body lectric Vehicle Motor Controller Output Regulator (MCOR) Forward/Reverse Switch, Tow/Run Switch Battery Charger Receptacle Batteries, lectric Vehicle OBC, Controller, and Solenoid lectric Vehicle Reverse Buzzer SCTION 15 LCTRIC MOTOR Motor (Model 5BC59JBS6365A) Motor (Model J4-4001) lectric Vehicle Motor (Model J8-4001A) lectric Vehicle SCTION 16 TRANSAXL LCTRIC VHICLS Transaxle lectric Vehicles ifferential uard SCTION 17 BATTRY CHARR Powerrive 3 Battery Charger, omestic Powerrive 2 Battery Charger (Model 22110), omestic Powerrive Battery Charger (Model 17930), omestic Powerrive Battery Charger (Model 18780), xport Powerrive Battery Charger (Model 20310), uropean SCTION 18 MAINTNANC AN SRVIC TOOLS Maintenance and Service Tools Maintenance and Service Tools, Continued Maintenance and Service Tools, Continued Maintenance and Service Tools, Continued Maintenance and Service Tools, Continued SCTION i INX Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

9 BOY AN TRIM 1

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11 ITM PART NO. SCRIPTION FRONT BOY Floormat Screw, 1/4-20 X 0.75 Hex-Head Cap Screw, 1/4-20 X.75 Torx Pn Hd Cap, 1/4" Plastic Screw Head Washer, 1/4 Id Scalloped Plast ash Cowl, Red Cowl, reen Cowl, Camouflage (Husqvarna) Cowl, Classic Blue Cowl, XRT- Black Cowl, XRT- Camo Hard Wood H (Standard camo for XRT850) N/A Cowl, XRT- Camo Max4 H Cowl, XRT- Silver Support, Upper Cowl Object Holder Cowl Cover, river-side Cowl Cover, Passenger-Side Rivet Clip, ash Push Pin, Black Rivet, Removable, Tuflok 1/4" Washer, 1/4 Type A Narrow Flat Locknut, 1/4-20 Nylon Insert... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-3

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13 ITM PART NO. SCRIPTION CANOPY SUPPORT SYSTM Screw, 5/16-18 X 3/4 Hex-Head with Patch Asm, Brace, Canopy, Tube, Xrt Washer, 5/16 Type A Flat... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-5

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15 ITM PART NO. SCRIPTION BUMPR XRT800 AN XRT Screw, M8 X 1.25 X 30 Tri, Blk Bolt, Flange Head, M X Lock Nut, Flg M8 X 1.25 Nylon Bumper, Cast... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-7

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17 ITM PART NO. SCRIPTION BRUSH UAR HUV4210-X Kit, Brush uard (includes items 2 through 6) Screw, M8 X 1.25 X 30 Tri, Blk Bolt, Flange Head, M X Lock Nut, Flg M8 X 1.25 Nylon uard, Brush N/A Instr, Brush uard... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-9

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19 ITM PART NO. SCRIPTION ASH BOX XRT800 AN XRT Box, ash Rivet... 4 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-11

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21 ITM PART NO. SCRIPTION LOV BOX XRT810 AN XRT Bumper, Rubber love Box Rivet love Box Lock / Key Kit (includes item 5) N/A Asm, love Box Lock / Key (includes items 6 through 8) N/A Key N/A Lock N/A Nut... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-13

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23 ITM PART NO. SCRIPTION SI TRIM XRT800 AN XRT Bumper, Side Trim Screw, #8-18 x 0.375, Hex-Head Washer... 8 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-15

24 1 ITMS 2 THROUH Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

25 ITM PART NO. SCRIPTION NRF BAR XRT810 AN XRT Kit, Nerf Bar (black) (includes items 2 through 7) Washer, 3/8 Flat Tape, Non-skid Nerf Bar Assy, river Nerf Bar Assy, Passngr Screw, 3/8-16 X 1.00 Hex-Head Cap Locknut, 3/8-16 Hex... 6 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-17

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27 ITM PART NO. SCRIPTION RAR BOY AN FNR ASOLIN VHICL Body Kick Plate Body, Hinge Plate Washer, 1/4" Type B Flat Body Support Weldment Cable Retainer Wear Pad Fender, river Side (includes item 8) U-Nut, 1/ Fender, Passenger Side (includes item 10) U-Nut, 1/ Body, Rear, as, Red Body, Rear, as, Orange Body, Rear, as, reen Body, Rear, as, Classic Blue Body, Rear, as, Olive reen Washer, 1/4 Type A Narrow Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine... 6 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-19

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29 ITM PART NO. SCRIPTION RAR BOY AN FNR LCTRIC VHICL Body Kick Plate Body, Hinge Plate Washer, 1/4" Type B Flat Body Support Weldment Cable Retainer Wear Pad Fender, river Side (includes item 8) U-Nut, 1/ Fender, Passenger Side (includes item 10) U-Nut, 1/ Body, Rear, lectric, Red Body, Rear, lectric, Orange Body, Rear, lectric, reen Body, Rear, lectric, Olive reen Washer, 1/4 Type A Narrow Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine... 6 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-21

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31 ITM PART NO. SCRIPTION FRONT SAT BOTTOM AN ARMRSTS Insert - Wood Hinge Plate Screw, 1/4-20 X 1.50 Hex-Head Cap Screw, 1/4-20 X 0.75 Hex-Head Cap Seat Bottom Assembly, Buff (includes items 6 through 9) N/A Plywood Assy Vinyl Cover Seat Btm - Buffsvc N/A Foam, Seat asket, Seat Seat Bottom Assembly, White (includes items 11 through 14) N/A Plywood Assy Vinyl Cover, Seat Bottom, White N/A Foam, Seat asket, Seat Seat Bottom Assembly, Black (includes items 16 through 19) N/A Plywood Assy Vinyl Cover, Seat Bottom, Black N/A Foam, Seat asket, Seat Seat Bottom Assembly, ray (includes items 21 through 24) N/A Plywood Assy Vinyl Cover, Seat Bottom, ray N/A Foam, Seat asket, Seat Hip Restraint, rvr Side Hip Restraint, Pass Side Washer, 1/4 Type A Narrow Flat... 8 QTY 1 Note: Sub-components contained in items 10, 15, and 20 are the same as those shown for item 5, except for the vinyl seat covers XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-23

32 TYPICAL 2 PLACS 4 8 TYPICAL 2 PLACS TYPICAL 2 PLACS TYPICAL 2 PLACS TYPICAL 2 PLACS 1 TYPICAL 2 PLACS TYPICAL 2 PLACS ON ACH SI OF VHICL 15 TYPICAL 2 PLACS TYPICAL 2 PLACS Items Items TYPICAL 2 PLACS through through Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

33 ITM PART NO. SCRIPTION SAT BACK Washer, 1/4 Flat Body Spacer Screw, 5/16-18 X 1.25 Thrd Frm Screw - M6 X 1.0 X 30 Sems Service Backrest Asm, Beige Service Backrest Asm, White Service Backrest Asm, ray Screw, M6 Hex Plug, Square mm Weldment, Bed Support Seat Support, Cross Brace Seat Support W/striker, rv (includes items 13 through 16) Seat Support, river-side Striker Plate Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Support, Seat, Right (passenger) (includes items 18 through 21) Seat Support, Passenger-Side Striker Plate Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Washer, 5/16 Type A Flat Screw, 1/4-20 X 2.00 Hex-Head Cap Locknut, 5/16-18 Nylon Insert Locknut, 1/4-20 Nylon Insert Screw, 5/16-18 X 1.75 Hex-Head Cap... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-25

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35 ITM PART NO. SCRIPTION CARO B Lanyard, Tailgate Bolt Lanyard Tailgate Bed Assembly (includes items 5 through 17) Locknut, 3/8-16 impled Pushnut, 3/ N/A xtension, Spring Latch N/A Washer, 3/8 Flat Type A N/A Bed N/A Support, Latch Link N/A Pin, Support N/A Rod, Long Link N/A Rod, Bed Lift, Short Bent N/A Catch, Tilt Bed N/A Bearing, Bronze, 1/2x9/ Screw, 1/4-20 X 1.0 Hex-Head Cap Screw, 3/8-16 X 1.00 Hex-Head Cap Kit, Plastic Bed Box Latch (includes items 19 through 22) Screw, Hex Washer Head 1/4-14 X Washer, 5/16 Type B Flat Spring, Tilt Latch 3.4 Lb/in Instr, Bed Box Field Kit... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-27

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37 ITM PART NO. SCRIPTION B HIN Bumper, Rubber Bushing, Steel Bushing, Urethane Locknut, 1/4-20 Hex Whiz Locknut, 3/8-16 Flanged imple Screw, M8X1.25X30, Hex Rue Ring - 1/2" Hinge, Roto Bed Support, Hinge Stiffener, Bed Support Bushing, Steel Pin, Clevis, 3/ Screw, 3/8-16 X 1.00 Hex-Head Cap Washer, 1/4 Type A Narrow Flat Washer, 3/8 Type A Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Screw, 3/8-16 X Hex Cap... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-29

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39 ITM PART NO. SCRIPTION ACCSS PANL AN HAT SHIL 1 N/A Access Panel - Black, Cut Shield, Heat ecal, Rotating Parts/Hot Manifold... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 1-31

40 1

41 WHLS AN TIRS 2

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43 ITM PART NO. SCRIPTION WHLS AN TIRS Unf Lug Nut Tire Assembly, All Trail II (includes items 3 through 5) Wheel Rim, ray Tire, Unmounted, All Trail II Valve Stem... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 2-3

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45 ITM PART NO. SCRIPTION QTY HUBCAP XRT810 AN XRT Wheel Cover, Chrome lite XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 2-5

46 2

47 CALS 3

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49 ITM PART NO. SCRIPTION SAFTY CALS ASOLIN VHICLS ecal, Crush Warning, river-side ecal, Crush Warning, Passenger-Side ecal, Maintenance... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 3-3

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51 SAFTY CALS ASOLIN VHICLS, CONTINU ITM PART NO. SCRIPTION ecal, asoline xplosion/fire Warning ecal, Frame round and overnor Warning ecal, Rotating Parts/Hot Manifold... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 3-5

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53 SAFTY CALS ASOLIN VHICLS, CONTINU ITM PART NO. SCRIPTION ecal, Warning, Instrument Panel ecal, Warning, Instrument Panel ecal, Operating Instructions, Instrument Panel... 1 Note: Item 2 is for use on vehicles equipped with a 12-volt accessory outlet. QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 3-7

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55 ITM PART NO. SCRIPTION LOO CALS ASOLIN VHICLS ecal, Club Car ecal, 800 rv ecal, 800 Pass ecal, 810 rv ecal, 810 Pass... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 3-9

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57 ITM PART NO. SCRIPTION SAFTY CALS LCTRIC VHICLS ecal, Tow/Run Switch Warning ecal, Component Cover ecal, Maintenance... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 3-11

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59 ITM PART NO. SCRIPTION SAFTY CALS LCTRIC VHICLS, CONTINU ecal, Warning, Instrument Panel ecal, Warning, Instrument Panel ecal, Operating Instructions, Instrument Panel ecal, Crush Warning, river-side ecal, Crush Warning, Passenger-Side... 1 QTY 3 Note: Item 2 is for use on vehicles equipped with a 12-volt accessory outlet XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 3-13

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61 ITM PART NO. SCRIPTION LOO CALS ecal, Club Car ecal, 800, rv ecal, 800, Pass ecal, 810, rv ecal, 810, Pass... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 3-15

62 3

63 BRAK SYSTMS 4

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65 RAR BRAK ASSMBLY, SLF-AJUSTIN VHICL WITH 2- WHL BRAKS ITM PART NO. SCRIPTION Nut, 5/16-24 Hex Head Cone Bolt, Brake Cluster Mounting rum without Center Hole, Brake Asm, Brake Cluster, Mech, rvr (includes items 5 through 17) Lever Assembly, Self-Adjusting Brake, Right (Passenger) Adj Mechanism, S.A. Brakes, Right (Passenger) Package, Brake Shoe, Self-Adjusting Plate, Washer, Brake, Self-Adjusting Back Plate, Rh Kit, Shoe Retainer (includes items 11 and 12) Pin Spring, Shoe, Clamp Package Brake Spring Self Adj (includes items 14 and 15) Brake Spring Self Adj Spring Brake Cover, ust Brake Block Asm, Brake Cluster, Mech, Pass (includes items 19 through 31) Lever Assembly, Self-Adjusting Brake, Left Adjusting Mechanism, Self-Adjusting Brake, Left Package, Brake Shoe, Self-Adjusting Plate, Washer, Brake, Self-Adjusting Back Plate, Lh Kit, Shoe Retainer (includes items 25 and 26) Pin Spring, Shoe, Clamp Package Brake Spring Self Adj (includes items 28 and 29) Brake Spring Self Adj Spring Brake Cover, ust Brake Block... 1 QTY 4 Note: river-side brake cluster not shown. Components have a similar appearance to passenger-side brake cluster components XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 4-3

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67 ITM PART NO. SCRIPTION BRAK PAL ASSMBLY Bumper, Rubber Screw, 5/16-18 X 2.50 Hex Cap Hill Brake Spacer Spring, Hill Brake Torsion Package, Brake Mounting Block Kit, Hill Brake Pedal (includes items 7 through 11) Pad, Hill Brake Pushnut, 3/ N/A Hill Brake Weld Assembly Bushing, Nylon Screw, #10-16 Type AB, Sheet Metal Kit, Hill Brake Latch (includes items 13 through 19) Sleeve, Hill Brake Rod Pushnut, 3/ Ball Joint, 1/ N/A Rod, Hill Brake Pin, Cotter, 7/64 x 1/2 Stainless-Steel N/A Pawl, Hill Brake Ratchet Assembly Brake Pedal Kit (includes items 21 through 23) Pad, Brake Pedal N/A Weldment, Brake Pedal 4wb Std Screw, #10-16 Type AB, Sheet Metal Pin, Bow Tie Locking Pin, 3/8 X 1-5/16 Clevis Nut, 1/4-20 Hex Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert... 4 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 4-5

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69 BRAK CABL, QUALIZR, AN QUALIZR RO VHICLS WITH TWO-WHL BRAKS ITM PART NO. SCRIPTION Spring, Brake Return Rod, qualizer, 8.91" qualizer Bracket Brake Cable Kit (includes items 5 through 8) Pin, Clevis, 5/16 X 3/ Clip, 1/ N/A Cable, Brake, 41" Cotter Pin, 3/32 x Kit, Field P-clamp, Brake Line (includes items 10 through 12) Screw, 3/8-16 X 3.50 Hex Cap P-clamp, Brake Line N/A Instr Fd. P-clamp, Brake Line Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Locknut, 5/16-18 Nylon Insert Locknut, 3/8-16 Hex... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 4-7

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71 ITM PART NO. SCRIPTION ACCLRATOR PAL ASOLIN VHICLS Accelerator Bracket and Bearing Assembly Washer, 1/4 Flat Washer, 1/4 Flat Cup, Spring Bumper, Spring Return Bearing, Pivot Support Sub Asm, Accelerator Pedal (includes items 8 through 10) Pad, Accelerator Pedal N/A Accelerator Pedal Weldment Screw, #10-16 Type AB, Sheet Metal Spring, Accelerator Return Retainer, Spring Stud, 1/4-28 X 1.35 Ball Screw, 1/4-20 X Hex Cap Kit, Accelerator Pivot Rod Assembly (includes items 16 through 18) Spacer Assembly (includes item 17) Spacer, Accelerator N/A Pivot Rod Weldment Washer, 5/16 Type A Flat Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat Locknut, 5/16-18 Nylon Insert Locknut, 1/4-20 Nylon Insert Locknut, 1/4-28 Nylon Insert Locknut, 3/8-16 Hex... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 4-9

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73 ITM PART NO. SCRIPTION ACCLRATOR PAL ASSMBLY LCTRIC VHICLS WITH MCOR Accelerator Bracket and Bearing Assembly Washer, 1/4 Flat Washer, 1/4 Flat Cup, Spring Bumper, Spring Return Bearing, Pivot Support Sub Asm, Accelerator Pedal (includes items 8 through 10) Pad, Accelerator Pedal N/A Accelerator Pedal Weldment Screw, #10-16 Type AB, Sheet Metal Spring, Accelerator Return Retainer, Spring Screw, 1/4-20 X Hex Cap Screw, 1/4-20 X Flange Kit, Accelerator Pivot Rod Assembly (includes items 16 through 18) Spacer Assembly (includes item 17) Spacer, Accelerator N/A Pivot Rod Weldment Washer, 5/16 Type A Flat Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat Locknut, 5/16-18 Nylon Insert Locknut, 1/4-20 Nylon Insert Locknut, 1/4-28 Nylon Insert Locknut, 3/8-16 Hex... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 4-11

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75 ITM PART NO. SCRIPTION ACCLRATOR RO ASOLIN VHICLS Rod, Accelerator (includes items 2 through 4) Nut, 1/4-28 Hex Jam Joint, Ball N/A Accelerator Rod... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 4-13

76 4

77 STRIN AN SUSPNSIONS 5

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79 ITM PART NO. SCRIPTION STRIN COLUMN Washer, 5/16 Type B Flat Washer, 5/16 Flat Screw, 5/16-18 X 0.75 Thread-Forming Screw, 3/8-16 X 7.00 Hex Cap Screw, 5/16-18 Thrd Forming Steering Shaft Assembly (includes items 7 through 15) Washer, I X 1.19 O Ring, Internal Retaining Wedge, Molded Seat, Plastic Bearing Bearing, Ball Ring, Retaining Spring, Steering Shaft Column, Aluminum Steering Shaft Steering Column Tube Cover, Steering Column Kit, Steering Column Mounting Bracket (includes items 18 and 19) N/A Bracket, RH Steering Column Mount N/A Bracket, LH Steering column mount Boot, Steering Column Round Shaft, Intermediate Steering (includes items 22 and 23) Bolt, Hex-Head, 8mm X Lockwasher, 5/16 Split Washer, 3/8 Type A Flat Locknut, 3/8-16 Hex... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 5-3

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81 ITM PART NO. SCRIPTION STRIN WHL Nut, 5/8-18 Nylon Insert Jam Steering Wheel, Spline Wheel Center... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 5-5

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83 ITM PART NO. SCRIPTION STRIN AR ASSMBLY Link, Rack and Pinion rag Nut, 12mm Hex Steering ear Assembly (without yoke) (includes items 4 through 23) Bellows, Long Rack Screw Locknut Snap Ring Seal, Steering Pinion ust Bearing, Ball Stop Washer Stop Ring, C-Type Support Yoke Rack uide Pressure Spring Ring, Stop, C-Type Bellows, Short ust Seal Retaining Ring Inner Ball Joint Asm Washer, Tab N/A Box, Steering ear N/A Bearing, Lower Pinion N/A Pinion, Steering N/A Screw, Rack uide N/A Rack, Steering Tie Wrap, 8" Nylon Cotter Pin, 3/32 x Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat Ball Joint, Left (includes items 28 through 31) Socket, LH Vertical Seal, Vertical Socket ust Fitting, 1/4-28 Thread-Forming rease Nut, 3/8-24 UNF Hex Nut, 1/2-20 Hex, Left-Hand Thread Locknut, 3/8-16 Hex... 3 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 5-7

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85 ITM PART NO. SCRIPTION FRONT SUSPNSION, UPPR Locknut, 3/8-16 impled Tie Rod Sub-Assembly, elta A-Plate (includes items 4 through 7) Bushing, Urethane Sleeve, elta Inner Sleeve, elta Outer elta A-Plate elta Shock and ear Support Assembly A-Plate Strap Shock Absorber, Front, Common Cotter Pin, 3/32 x Nut, 1/2-20 Hex Screw, 3/8-16 X 2.25 Hx Hd Cap Ball Joint, Right-Hand (includes items 15 through 18) Socket, RH Vertical Seal, Vertical Socket ust Fitting, 1/4-28 Thread-Forming rease Nut, 3/8-24 UNF Hex Ball Joint, Left (includes items 20 through 23) Socket, LH Vertical Seal, Vertical Socket ust Fitting, 1/4-28 Thread-Forming rease Nut, 3/8-24 UNF Hex Nut, 1/2-20 Hex, Left-Hand Thread Locknut, 3/8-16 Hex Bolt, 3/8-16 X 1.75 Hex... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 5-9

86 Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

87 ITM PART NO. SCRIPTION FRONT SUSPNSION, LOWR Plate, Spring Mount Bearing, Thrust Plate, Front Spring Retainer Clevis, elta Upper King Pin Assembly Screw, 3/8-16 X 2.75 Hx Hd Cap Washer, Od Wave Locknut, 1/2-20 Nylon Insert Support, Brush uard Screw, 3/8-16 X 5.50 Hx Hd Cap ccentric Bolt Common N/A Spring Asm, Front, 1 Leaf (includes items 13 through 15) Bushing, Steel Bushing, Urethane N/A Spring, Front, 1 Leaf Lockwasher, 3/8 Split Nut, Hex 3/ Locknut, 3/8-16 Hex Screw, 3/8-16 X Hex Cap... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 5-11

88 Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

89 ITM PART NO. SCRIPTION FRONT SPINLS AN HUBS 1 N/A Replacement Kit, Front Hub (includes items 2 through 4) Cap, Front Hub Hex Nut, Locking Flange, M14x N/A Asm, Front Hub, Bb, Long Stud (includes items 5 through 8) N/A Bearing, Ball, N/A Spacer, Bearing, Front Hub, Pm Lug Stud, 1/2-20 Unf, N/A Front Hub, Ball Brg, Long Stud N/A Asm, Hub And Spindle, Left-Hand xt (includes items 10 through 15) Front Hub Assembly, Ball Bearing (includes items 11 and 12) Lug Stud, 1/2-20 UNF, 4037 Stl N/A Hub, Front Cap, Front Hub Hex Nut, Locking Flange, M14x Asm, Spindle, LH, xt (includes items 16 through 19) Fitting, 1/4-28 Thread-Forming rease N/A Subasm, Spindle, LH, xt Bushing, Flanged Bronze Bushing, Bronze Spindle N/A Asm, Hub And Spindle, Right-Hand xt (includes items 21 through 26) Front Hub Assembly, Ball Bearing (includes items 22 and 23) Lug Stud, 1/2-20 UNF, 4037 Stl N/A Hub, Front Cap, Front Hub Hex Nut, Locking Flange, M14x Asm, Spindle, RH, xt (includes items 27 through 30) Fitting, 1/4-28 Thread-Forming rease N/A Subasm, Spindle, RH, xt Bushing, Flanged Bronze Bushing, Bronze Spindle... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 5-13

90 5 Items 3 through 2 Items 8 through Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

91 ITM PART NO. SCRIPTION RAR SUSPNSION Nut, 3/8-24 Hex Kit, Shock Absorber Cushion (includes items 3 and 4) Cushion, Shock Absorber Retainer, Shock Absorber Cushion Bushing, Steel Shackle, Rear Spring Shock Absorber Kit (includes items 8 through 10) Cushion, Shock Absorber Retainer, Shock Absorber Cushion Shock Absorber Rear Prv Spd Bumper Mount, Angled Locknut, 7/16-14 Nylon Hex Spring Retainer Rear Leaf Spring Spacer, Overload Bumper U-Bolt Bushing, Urethane Bumper, Jounce Bracket, Left-Hand Bracket, Right Locknut, 3/8-16 Hex Screw, 3/8-16 X Hex Cap... 6 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 5-15

92 Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

93 ITM PART NO. SCRIPTION STRIN AR ASSMBLY Nut, 12mm Hex nd, Tie Rod, M12 X 1.25, Lh Nut - Hex Locking, M12 X Asm, Steering Rack And Pinion (includes items 5 through 24) Bellows, Long Rack Screw Locknut Snap Ring Seal, Steering Pinion ust Bearing, Ball Stop Washer Stop Ring, C-Type Support Yoke Rack uide Pressure Spring Ring, Stop, C-Type Bellows, Short ust Seal Retaining Ring Inner Ball Joint Asm Washer, Tab N/A Box, Steering ear N/A Bearing, Lower Pinion N/A Pinion, Steering N/A Screw, Rack uide N/A Rack, Steering Tie Wrap, 8" Nylon Link, rag, Male Thd Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat Nut, 1/2-20 Hex, Left-Hand Thread Locknut, 3/8-16 Hex... 3 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 5-17

94 5

95 LCTRICAL SYSTM ASOLIN VHICLS 6

96 Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

97 XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 6-3

98 6 See previous two pages for illustration. Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

99 ITM PART NO. SCRIPTION QTY WIRIN ASOLIN VHICL Wire Harness, asoline Vehicle XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 6-5

100 Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

101 ITM PART NO. SCRIPTION HALIHTS Headlight Assembly, river-side Single Beam (includes items 2 through 10) Screw, #10-16 Hex-Head Hi-Lo Headlight Bezel, Left Nut, #10-24 Stainless-Steel Hex Machine Turn Signal Lens Assy Mounting Bracket Retainer, Headlight Connector Harness Assembly, Headlight Bulb, Headlight Lens, Headlight Headlight Assy, Passenger-Side Single Beam (includes items 12 through 20) Screw, #10-16 Hex-Head Hi-Lo Headlight Bezel, Right Nut, #10-24 Stainless-Steel Hex Machine Turn Signal Lens Assy Mounting Bracket Retainer, Headlight Connector Harness Assembly, Headlight Bulb, Headlight Lens, Headlight... 1 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 6-7

102 through Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

103 LCTRICAL COMPONNT BOX ASOLIN VHICL ITM PART NO. SCRIPTION Screw, #12-16 X Hi-Lo Locknut, 5/16-18 Hex Flange N/A Assembly, lectrical Component Box (includes items 4 through 27) Stud, 1/4-28 X Ball Fuse, 10-Amp Ring, 0.338" Internal Retaining Solenoid, 12-Volt Washer, 0.38" I elrin Flat Wire Assembly #6 Red Bushing, Secondary Weight, Split iode Bell Crank and Shaft Assembly Box, lectrical Component Cover, lectric Box Cam, lectric Box Bolt, Carriage, 5/16-18 X Wire Assy, #10 Red Fuse Block Screw, #12-16 X Hi-Lo Fuse, 20-Amp Screw, 1/4-15 X 1.50 Hi-lo Hex iode Assembly Voltage Regulator Nut, 5/16-18 Hex Nut, #10-32 Hex Locknut, 1/4-28 Nylon Insert Tie Wrap, 8" Nylon Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert Bolt, Carriage, 5/16-18 X QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 6-9

104 Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

105 LCTRICAL COMPONNTS, FRONT BOY ASOLIN VHICL ITM PART NO. SCRIPTION Lockwasher, M Knob, Light Switch Light, Oil auge, Fuel/Hour, with Bracket (includes items 5 and 6) Bracket, Fuel auge/hour Meter N/A auge, Fuel/Hour Nut, M Key Switch 12v Key Start Key Set Spacer, Keyswitch Nut, Key Switch Switch, Light Receptacle, Accessory Panel, Instrument Panel, Instrument (with 12-Volt Accessory Outlet Cutout) Rivet, Removable, Tuflok 1/4"... 7 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 6-11

106 Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

107 ITM PART NO. SCRIPTION STARTR/NRATOR ASSMBLY MOL ASOLIN VHICLS Starter/enerator (cw) (includes items 2 through 33) Bearing, Output Shaft Ball Key, Starter/enerator Bearing, Ball Brush Holder Assembly (cw) (includes item 6) Brush Spring Set Brush and Screw Set (cw) Front Bracket Retainer Armature Field Coil Housing Pole Set Screw Set Field Stator Coil Assembly F Insulator Set F Insulator A Connector (cw) Screw and Mold Assembly Brush Connector Assembly (cw) Cover Set (includes items 21 and 22) Brush Inspection Port Cover Brush Port Cover w/rain Rear Bracket (cw) Nut and Screw Set (includes items 25 through 29) Brush Holder Asm Screw N/A Washer, M5 Flat N/A Washer, M14 Lock N/A Nut, Hex, M14 x N/A Screw, M5 x 0.8 x 18mm Nut and Washer Set Nut and Washer Set Through Bolt Set Spacer Armature Asm Conversion Kit (includes items 35 through 38) Key, Starter/enerator Pulley, Starter/enerator Armature Spacer... 1 QTY 6 Note: Item 36 will ONLY fit Model Starter/enerator XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 6-13

108 Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

109 F290 STARTR/NRATOR MOUNTIN ASOLIN VHICL ITM PART NO. SCRIPTION Screw, M8-125 X 22 Hex-Head Bracket, Starter/enerator Mounting (F290) Bolt, Carriage, 5/ Screw, M X 18mm Torx Bracket, Starter/enerator Adjustment Wire Assy, #6 reen V-Belt Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Screw, Cap-hex Hd 3/8-16x Lockwasher, 5/16 Split Locknut, 3/8-16 Hex... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 6-15

110 Page XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List

111 F350 STARTR/NRATOR MOUNTIN ASOLIN VHICLS ITM PART NO. SCRIPTION Screw, M8-125 X 22 Hex-Head Bracket, Starter/enerator Mounting Bolt, Carriage, 5/ Screw, M X 18mm Torx Bracket, Starter/enerator Adjustment Wire Assy, #6 reen V-Belt Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Screw, Cap-hex Hd 3/8-16x Lockwasher, 5/16 Split Locknut, 3/8-16 Hex... 2 QTY XRT800/XRT810 asoline and lectric Vehicle Illustrated Parts List Page 6-17

2009 XRT800/XRT810 Illustrated Parts List Gasoline and Electric Vehicles

2009 XRT800/XRT810 Illustrated Parts List asoline and lectric Vehicles Manual Number 103472613 dition Code 05080310F USIN TH ILLUSTRAT PARTS LIST ý WARNIN This manual is to be used only for identification