XRT 1200 and XRT 1200 SE Illustrated Parts List Gasoline Vehicles

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Spencer Bradley
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1 XRT 1200 and XRT 1200 S Illustrated Parts List asoline Vehicles Manual Number dition Code 0907L0112K

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 2006 and 2007 XRT 1200 and XRT 1200 S vehicles. The manual is divided into sections. Note that there are two or three flags on the outside edge of each page. The first flag contains the section number of which that page is a part. The other flag (or flags) contains either the letter,, or, signifying that the page pertains to either the diesel, gasoline, or electric vehicle only. 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. Some item numbers have more than one part number because several configurations of a component are represented together on one spread. 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, Inc. 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, Inc. 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 2007 Club Car, Inc. Club Car and Precedent are registered trademarks of Club Car, inc. This manual effective July 26, XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

5 CONTNTS SCTION 1 BOY AN TRIM Front Body and Trim Front Seats Rear Seat and Support Structure XRT 1200 S Latch Plate and Prop Rod Tilt Bed, Hinge, and Latch XRT Cargo Box XRT Tilt Bed, Hinge, and Latch XRT 1200 S Cargo Box XRT 1200 S Tailgate Bracket (arlier Style) Rear Body Trim SCTION 2 WHLS AN TIRS Wheels and Tires SCTION 3 CALS ecals XRT 1200 Vehicles ecals XRT 1200 Vehicles, Continued ecals XRT 1200 S Vehicles ecals XRT 1200 S Vehicles, Continued SCTION 4 BRAK SYSTMS Front Brake Assembly Brake Assembly Rear Brake Assembly, Continued Master Cylinder Hydraulic Brake System Hand Park Brake Assembly SCTION 5 PAL ROUP Brake Pedal Assembly Accelerator Pedal Assembly asoline Vehicle Accelerator Rod SCTION 6 STRIN AN SUSPNSION Steering Column Steering ear Assembly XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1

6 CONTNTS Front Suspension Rear Suspension SCTION 7 LCTRICAL SYSTM Wiring XRT 1200 Vehicles Wiring XRT 1200 S Key-Start Vehicle Forward/Reverse Shifter Assembly Headlights XRT 1200S Forward/Reverse Shifter Assembly lectrical Component Box, Key-Start Vehicles lectrical Components, Front Body lectrical Components, ash Panel Starter/enerator Mounting Starter/enerator Assembly Model asoline Vehicles Battery SCTION 8 F400 NIN F400 ngine (Key-Start) Shrouds and Brackets F400 ngine (Key-Start) Ignition Components and Flywheel F400 ngine (Key-Start) Oil Circulation F400 ngine (Key-Start) Cylinder Head F400 ngine (Key-Start) Crankcase, Camshaft and Oil Sensor F400 ngine (Key-Start) Crankcase and Crankshaft ngine Mounting SCTION 9 FUL, INTAK, AN OVRNOR SYSTM Fuel System Fuel Tank with Fuel Level Sending Unit Carburetor Assembly, F400 ngine Carburetor Installation overnor and Accelerator Cables Air Box and Intake Hose SCTION 10 XHAUST SYSTM xhaust System, F400 ngine SCTION 11 TORQU CONVRTR rive Clutch Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

7 CONTNTS riven Clutch SCTION 12 UNITIZ TRANSAXL MC012C-BS00 Beginning With Serial Number MC012C3J0001 ear Cases, Brackets and uard MC012C-BS00 Beginning With Serial Number MC012C3J0001 F&R Transmission and ear MC012C-BS00 Beginning With Serial Number MC012C3J0001 Axle Carrier Assembly MC012C-BS00 Beginning With Serial Number MC012C3J0001 ifferential Lock and Axles Unitized Transaxle ifferential Lock Cable Assembly and Shifter SCTION 13 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 XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 3

9 BOY AN TRIM 1

10 Club Car Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

11 ITM PART NO. SCRIPTION FRONT BOY AN TRIM Screw, Hex Washer Head 1/4-14 X Screw, 5/16-18 X 2.50 Hex Cap Screw, 1/4 X Hex-Head Screw, #12 X.50 Hex, Washer-Head Front Brushguard rill Assembly Support, Upper Cowl Support, Lower Fender Fender, Left Front Fender, Right Front Cowl, ark reen Cowl, ark ray Cowl, Red Cowl, White ashboard Panel, ash ecal, CC Nameplate, Utility Kit, ash Hardware (includes items 19 through 21) Screw, 1/4-20 X.75 Torx Pn Hd Cap, 1/4" Plastic Screw Head Washer, 1/4 Id Scalloped Plast Screw, 5/16-18 X 2.50 Hex Cap Floormat Rivet, Removable, Tuflok 1/4" Washer, 5/16 Type A Flat Rivet, 3/16 X.500 Alum Pop Washer, #10 Type A Flat Washer, 1/4 Type A Narrow Flat Lockwasher, 5/16 Split Screw, 5/16-18 X 1.25 Truss Hd Locknut, 5/16-18 Nylon Insert... 6 QTY 1 Note: The floormat is not illustrated XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1-3

12 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

13 ITM PART NO. SCRIPTION FRONT SATS Hinge Plate Washer, 5/16 Flat Body, Hinge Plate Screw, M8-125 X 22 Hex-Head Lockwasher, 8mm Split Screw, #10 Truss-Head Torx Cap, Corner Locknut, M Nylon Insert Pan, Seat Armrest, river Armrest, Passenger Console Cover Seat Support Assembly Seal Rivet, 1/4 X.438 Blind M VHB Tape Seat Holder Base Screw, 6m-1.00 X 10mm Hex Head Screw, 6m-1.00 X 35mm Hex Head /4-20 Threaded Insert Seat Holder Cup Radio/Beverage Holder Assembly Seat, Bucket, ray Washer, 1/4 Type A Narrow Flat Lockwasher, 1/4 Split Screw, 1/4-20 X 2.00 Hex-Head Cap Locknut, 5/16-18 Nylon Insert Screw, 1/4-20 X 0.75 Hex-Head Cap Screw, 5/16-18 X 2.25 Hex-Head Cap... 4 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1-5

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15 RAR SAT AN SUPPORT STRUCTUR XRT 1200 S ITM PART NO. SCRIPTION Barrel - Plastic Screw, #10 Truss-Head Torx Cap, Corner Seat Bottom Assembly, ray (includes items 5 through 12) Insert - Wood Strap, Utility Seat Bumper, Seat, Short Bumper, Seat, Long Vinyl Cover, Seat Bottom, ray Stiffener Screw, 1/4-20 X 0.75 Hex-Head Cap Washer, 1/4 Type A Narrow Flat Seat Support Panel Assembly Seat Back Assembly, ray (includes items 15 and 16) Cap, Seat Back Vinyl Seat Back-nstd Svc Locknut, 1/4-20 Hex Whiz Armrest Weldment, Passenger-Side Armrest Weldment, river-side Washer, Lock, xternal-tooth Carriage Bolt, 1/4-20 X Bolt, 5/16-18 X 0.75 Round-Head Locknut, 5/16-18 Hex Flange Trim, Seat Bottom Rear Trim, Seat Bottom Front Screw, 1/4-20 X 1.0 Truss-Head Machine... 4 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1-7

16 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

17 ITM PART NO. SCRIPTION LATCH PLAT AN PROP RO Bumper, Rubber Latch Plate, Tilt Bed Plate, Latch Support Latch Plate Shim Washer, Wave Locknut, 1/4-20 Hex Whiz Bolt, Carriage, 1/4-20 X Rod, Prop Track, Prop Rod Cotter Pin, 3/32 x 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... 4 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1-9

18 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

19 ITM PART NO. SCRIPTION TILT B, HIN, AN LATCH XRT Bushing, Steel Assembly, Tilt Bed (includes items 3 through 13) Bolt, Carriage, 5/16-18 X Tape, Vinyl Foam 1/8" x 3/4" * Latch Weld Assembly Plate, Floor Bed N/A Frame Assembly N/A xtension, Spring Latch Screw, 5/16-18 X 0.88 Torx Truss-Head rip, Tilt Latch Hand Locknut, 1/4-20 Hex Whiz Screw, 1/4-20 X Hex-Head Cap Locknut, 5/16-18 Nylon Insert Shim, Tilt Bed Pivot Bushing, Urethane Locknut, 5/16-18 Hex Flange Locknut, 3/8-16 Flanged imple xtra, Bracket, Hinge, Bed /8-16 X 3.5 Carr Blt r5 Zn Screw, Cap-hex Hd 3/8-16x Locknut, 3/8-16 Hex... 2 QTY 1 * Note: Item not shown XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1-11

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21 ITM PART NO. SCRIPTION CARO BOX XRT Kit, Steel Box (includes items 2 through 25) Bolt, Carriage, 5/16-18 X Bumper, Rubber Washer, 1/4" Type B Flat Screw, 1/4-20 X 0.75 Torx Truss-Head Stud, Self-Clinching Flush Head Screw, 5/16-18 X 0.88 Torx Truss-Head Box Bed Tailgate Angle Locknut, 5/16-18 Hex Flange Front Panel Weldment Left Panel Weldment Right Panel Weldment Front Corner Cap Slam Latch Assembly, Tailgate (includes items 16 through 22) Hair Pin Clip Tether Assembly Spring Latch Left Spring Latch Right Washer, 1/4 Type A Narrow Flat Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X.625 Truss Hd Washer, Rubber, 3/ Washer, 1/4 Type A Narrow Flat Locknut, 1/4-20 Nylon Insert... 4 QTY 1 Note: leven each of items 2 and 25 are used to secure the floor plate to the bed frame and are not illustrated XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1-13

22 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

23 ITM PART NO. SCRIPTION TILT B, HIN, AN LATCH XRT 1200 S Bushing, Steel **** Assembly, Tilt Bed (includes items 3 through 13) Bolt, Carriage, 5/16-18 X Tape, Vinyl Foam 1/8" x 3/4" * N/A Plate, Floor, Carryall 1 Flat bed N/A Frame Assembly, Tilt Bed N/A xtension, Spring Latch Screw, 5/16-18 X 0.88 Torx Truss-Head rip, Tilt Latch Hand Locknut, 1/4-20 Hex Whiz Latch, Weld Asm, Fwd Bend Screw, 1/4-20 X Hex-Head Cap Locknut, 5/16-18 Nylon Insert Shim, Tilt Bed Pivot Bushing, Urethane Bed Seal Locknut, 5/16-18 Hex Flange Locknut, 3/8-16 Flanged imple xtra, Bracket, Hinge, Bed /8-16 X 3.5 Carr Blt r5 Zn Rivet, 3/16 X , Pop Locknut, 3/8-16 Hex Screw, 3/8-16 X Hex Cap... 2 QTY 1 **** Special order item available upon request. * Note: Item not shown XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1-15

24 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

25 ITM PART NO. SCRIPTION CARO BOX XRT 1200 S Kit, Cargo Box (includes items 2 through 37) Side Panel Assembly, Right-Hand (includes items 3 through 17) Barrel - Plastic Washer, 3/8 Flat Latch, Tailgate, Right-Hand N/A Side-Panel Weldment, Right-Hand Bushing, Snap-In Compression Spring Latch Tilt rip, Tilt Latch Hand Bushing, Nylon Kit, Tlgt Mtg Brkt, Ca Rh (includes items 12 through 16) Nut, 1/4-20 Hex N/A Asm, Tlgt, Mtg Brkt, Ca Rh Stud, 1/4 Self-clnchng Flush Washer, 1/4 Type A Narrow Flat Lockwasher, 1/4 Split Pin, 1/8 X 1.00 Split Roll Side Panel Assembly, Left-Hand (includes items 19 through 33) Barrel - Plastic Washer, 3/8 Flat Latch, Tailgate, Left-Hand N/A Side-Panel Weldment Bushing, Snap-In Compression Spring Latch Tilt rip, Tilt Latch Hand Bushing, Nylon Kit, Tlgt Mtg Brkt, Ca Lh (includes items 28 through 32) Nut, 1/4-20 Hex N/A Asm, Tlgt, Mtg Brkt, Ca Lh Stud, 1/4 Self-clnchng Flush Washer, 1/4 Type A Narrow Flat Lockwasher, 1/4 Split Pin, 1/8 X 1.00 Split Roll Assembly, Front Panel (includes items 35 and 36) N/A Front Panel Box ecal, Bed Load Warning Assembly, Tailgate (includes items 38 and 39) ecal, Logo, Tailgate N/A Tailgate Weldment... 1 QTY 1 Note: Additional components in kit are shown on the following two pages XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1-17

26 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

27 ITM PART NO. SCRIPTION TAILAT BRACKT (ARLIR STYL) Tailgate Mounting Bracket, Left-Hand Tailgate Mounting Bracket, Right-Hand Stud, Self-Clinching Flush Head Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Lockwasher, 5/16 Split... 4 QTY 1 Note: Additional components in kit are shown on the following two pages XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1-19

28 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

29 ITM PART NO. SCRIPTION RAR BOY TRIM Washer, 3/8 Flat Screw, 1/4 X Hex-Head Washer, 1/4" Type B Flat Tailskirt Side Step Bar (black) Side Step Bar (orange) Kit, Rear Receiver (includes items 8 through 13) Screw, 5/16-18 X 1.00 Hex Cap ecal, Trailer Hitch Rear Receiver Weld Asm Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Lockwasher, 5/16 Split Fender, Right Rear Fender, Left Rear Screw, 1/4-20 X 1.0 Hex-Head Cap Screw, 3/8-16 X 1.00 Hex-Head Cap Washer, 1/4 Type A Narrow Flat Lockwasher, 3/8 Split Locknut, 1/4-20 Nylon Insert QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 1-21

30 1

31 WHLS AN TIRS 2

32 2 1 TYPICAL 4 PLACS TYPICAL 4 PLACS ALL TRRAIN TRA TURF TRA IRCTION OF FORWAR ROTATION TRAKS MAX TRA Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

33 ITM PART NO. SCRIPTION WHLS AN TIRS Unf Lug Nut ray Tire Assembly, HAT Tread (includes items 3 through 5) Wheel Rim, ray Tire, HAT Valve Stem ray Tire Asm Traks Max II L (includes items 7 through 9) N/A Tire, Traks Max II L Wheel Rim 10" ray Valve Stem ray Tire Asm Traks Max II R (includes items 11 through 13) N/A Tire, Traks Max II L Wheel Rim 10" ray Valve Stem ray Tire Asm Turf Tread (includes items 15 through 17) Wheel Rim, ray N/A Tire, 23x Turf Trac R/s Valve Stem... 1 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 2-3

34 2

35 CALS 3

36 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

37 ITM PART NO. SCRIPTION CALS XRT 1200 VHICLS ecal, Bed Load Warning ecal, Crush Area Warning ecal, Off/On/Start ecal, Vehicle Loading ecal, ash Warning Underage Warning ecal ecal, ifferential Lock Warning ecal, Operating Instructions ecal, 400cc ecal, Xrt Passenger ecal, Xrt river... 1 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 3-3

38 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

39 ITM PART NO. SCRIPTION CALS XRT 1200 VHICLS, CONTINU ecal, Trailer Hitch ecal, asoline xplosion/fire Warning ecal, Frame round and overnor Warning ecal, Rotating Parts/Hot Manifold ecal, CC Nameplate, Utility ecal, Rotating Parts Warning ecal, Winch Cable Fracture Warning ecal, iode Safety... 1 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 3-5

40 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

41 ITM PART NO. SCRIPTION CALS XRT 1200 S VHICLS ecal, Bed Load Warning ecal, Crush Area Warning ecal, Warning ecal, Off/On/Start ecal, ash Warning Underage Warning ecal ecal, ifferential Lock Warning ecal, Operating Instructions ecal, Commercial Logo ecal, Loading, Coyote Str ecal, Side, Right-Hand XRT ecal, Side, Left-Hand XRT... 1 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 3-7

42 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

43 ITM PART NO. SCRIPTION CALS XRT 1200 S VHICLS, CONTINU ecal, Trailer Hitch ecal, asoline xplosion/fire Warning ecal, Frame round and overnor Warning ecal, Rotating Parts/Hot Manifold ecal, CC Nameplate, Utility ecal, Rotating Parts Warning ecal, Winch Cable Fracture Warning ecal, iode Safety... 1 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 3-9

44 3

45 BRAK SYSTMS 4

46 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

47 ITM PART NO. SCRIPTION FRONT BRAK ASSMBLY Unf Lug Nut Nut, 5/16-24 Hex Head Cone Washer, 5/16 Hardened Cluster, Front Brake (includes items 5 through 18) Backing Plate Asm Kit, Axle Adjuster (includes items 7 through 11) Adjuster Bolt, 1/4-28 UNF X Washer ust Cover N/A Washer, 1/4 Flat Kit, Axle Hardware (includes items 13 through 16) Bolt, Wheel Cylinder Spring, Shoe To Shoe, Lower Spring, Shoe To Shoe, Upper Shoe Hold own Shoe Kit, Axle Set Wheel Cylinder Assembly ia Assembly, Front Hub (includes item 20) Lug Stud Bolt, Banjo Copper Washer Screw, 5/16-24 X 1.0 Torx Hd... 8 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 4-3

48 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

49 ITM PART NO. SCRIPTION BRAK ASSMBLY rum without Center Hole, Brake Assembly, Brake Cluster LH (includes items 3 through 17) Backing Plate Asm Kit, Axle Adjuster (includes items 5 through 9) Adjuster Bolt, 1/4-28 UNF X Washer ust Cover N/A Washer, 1/4 Flat Kit, Axle Hardware (includes items 11 through 14) Bolt, Wheel Cylinder Spring, Shoe To Shoe, Lower Spring, Shoe To Shoe, Upper Shoe Hold own Shoe Kit, Axle Set Wheel Cylinder Assembly ia Park Brake Assembly, Left-Hand... 1 QTY 4 Note: Right-hand brake cluster components not shown XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 4-5

50 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

51 ITM PART NO. SCRIPTION RAR BRAK ASSMBLY, CONTINU Pin, Clevis, 5/16 X 3/ Unf Lug Nut Nut, 5/16-24 Hex Head Cone Washer, 5/16 Hardened Pin, Cotter, x Screw, 5/16-24 X 1.0 Torx Hd Brake rum Nut, Flange Washer - Axle Center Cap, Rubber Locking Cap, Nut Pin, Bow Tie Locking QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 4-7

52 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

53 ITM PART NO. SCRIPTION MASTR CYLINR Screw, 5/16-18 X 1.00 Hex Cap Spring, Brake Return Clevis Rod, qualizer, 13.30" Master Cylinder (includes items 6 through 9) Push Rod Pressure Switch Filler Cap Asm Master Cylinder Boot Support Leg Brace Asm Spacer Bell Crank Pin, Bow Tie Locking Pin, 3/8 X 1-5/16 Clevis Plug, 3/8 X Pin, Bow Tie X Pin, 1/2 X 2-1/2 Clevis Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert... 6 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 4-9

54 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

55 ITM PART NO. SCRIPTION HYRAULIC BRAK SYSTM Washer, 1/4 Flat Rivet, 3/16 iameter rive Hose, Hydraulic, Front Brake Line, Hydraulic Rear Brake Front Line, Hydraulic Rear Brake, Right-Hand Hose Flex Rear Line Hyd Rear Brake LS Bolt, Banjo Copper Washer Horse Shoe Clamp P-Clamp Washer, #10 Type A Flat Screw, 1/4-20 X 1.25 Hex-Head Cap Locknut, 1/4-20 Nylon Insert... 1 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 4-11

56 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

57 ITM PART NO. SCRIPTION HAN PARK BRAK ASSMBLY Pin, Clevis, 5/16 X 3/ Washer, 3/8 Flat Spring, Brake Return Screw, #7-19 X Phillips Pan-Head Tap Hanger, Brake Cable Park Brake Cable Clip Park Brake Boot Cable, Long Parking Brake qualizer Nut, 5/16-24 Hex Cone Nut, 5/16-24 Hex Pulley Kit (includes items 13 through 16) Locknut, #10-24 Nylon Insert Screw, #10-24 X 3/4 Socket-Head Pulley, 2-Inch Flat Mount Washer, #10 Type A Flat Cable, Park Brake Pin, Bow Tie Locking Lever, Box Shield, Boot Screw, Cap-hex Hd 3/8-16x Locknut, 3/8-16 Hex... 2 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 4-13

58 4

59 PAL ROUP 5

60 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

61 ITM PART NO. SCRIPTION BRAK PAL ASSMBLY Screw, 5/16-18 X 2.50 Hex Cap Package, Brake Mounting Block Rod, qualizer, 13.30" Assembly, Brake Pedal (includes items 5 through 9) Bumper, Rubber Pad, Hydraulic Brake Pedal N/A Brake Pedal Weld Asm Nut, 1/4-20 Hex Screw, #10-16 Type AB, Sheet Metal Pin, Bow Tie Locking Pin, 3/8 X 1-5/16 Clevis Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert... 4 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 5-3

62 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

63 ACCLRATOR PAL ASSMBLY ASOLIN VHICL ITM PART NO. SCRIPTION 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 XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 5-5

64 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

65 ITM PART NO. SCRIPTION ACCLRATOR RO Rod, Accelerator (includes items 2 through 4) Nut, 1/4-28 Hex Jam Joint, Ball N/A Accelerator Rod... 1 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 5-7

66 5

67 STRIN AN SUSPNSION 6

68 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

69 ITM PART NO. SCRIPTION STRIN COLUMN Plate, Scorecard Wheel, Steering Screw, #12-14 X Nut, 5/8-18 Nylon Insert Jam Yoke Assembly (includes items 6 and 7) Bolt, Hex-Head, 8mm X Lockwasher, 5/16 Split Steering Column (includes items 9 through 17) Washer, I X 1.19 O Ring, Internal Retaining Wedge, Molded Seat, Plastic Bearing Bearing, Ball Ring, Retaining Spring, Steering Shaft Shaft Steering Column Column Weld Assy, Steering (includes items 18 through 20) N/A Column Mtg Bracket N/A Steering Column N/A Steering Bracket Brace Boot, Steering Column Round Screw, 3/8-16 X 1.00 Hex-Head Cap Washer, 3/8 Type A Flat Locknut, 3/8-16 Hex... 4 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 6-3

70 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

71 ITM PART NO. SCRIPTION STRIN AR ASSMBLY Locknut, 3/8-16 impled Rack and Pinion Steering ear (includes items 3 through 18) Bellows, Long Nut, 12mm Hex Rack Screw Locknut Snap Ring Seal, Steering Pinion ust Bearing, Ball Support Yoke Rack uide Pressure Spring Ring, Stop, C-Type Inner Ball Joint Asm N/A Pinion, Steering N/A Bearing, Lower Pinion N/A Screw, Rack uide N/A Housing, Steering ear N/A Rack, Steering Tie Wrap, 8" Nylon nd, Tie Rod M12 X 1.25 Rh rag Link Locknut, M Nylon Pin, Cotter Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat... 4 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 6-5

72 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

73 ITM PART NO. SCRIPTION FRONT SUSPNSION Washer, 1/2 Type A Flat Bearing, Thrust Screw, 5/16-18 X 1.00 Hex Cap Unf Lug Nut Locknut, 7/16-14 Nylon Hex Screw, 3/8-16 X 2.75 Hx Hd Cap Washer, Od Wave Pin, Cotter, x Locknut, 1/2-20 Nylon Insert Shock Tower ust Cover Bearing, Tapered Nut, Slotted Hex Jam Assembly, Spindle, RH Assembly, Spindle, LH Suspension Mtg Plate Shock Absorber, Coil Over Seal, ual-lip Screw, 7/16-14 X 2.50 Hex Cap Assembly, Front Hub (includes item 21) Lug Stud King Pin Bolt Assembly Right A-arm Asm (includes items 24 through 28) Fitting, 1/4-28 Thread-Forming rease Bushing, Urethane Sleeve, A-Arm Bushing, Flanged Bronze Bushing, Bronze Spindle Left A-Arm Asm (includes items 30 through 34) Fitting, 1/4-28 Thread-Forming rease Bushing, Urethane Sleeve, A-Arm Bushing, Flanged Bronze Bushing, Bronze Spindle Screw, 1/2-20 X 5.0 Hex Cap Steering Stop Mtg Plate Bolt, 3/8-16 X 4.50 Hex Head Locknut, 5/16-18 Nylon Insert Locknut, 3/8-16 Hex... 8 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 6-7

74 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

75 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 Compression Mount Bushing, Urethane Hanger, Brake Cable Spring, Rear Leaf Spacer 0.38 I X O Locknut 7/16-14 Flange imple Screw, 3/8-16 X 3.50 Hex Cap Stud Mount Shackle, Rear Spring -gas U-Bolt Reinforced Spring Pad Shock Absorber, Rear Bolt, 3/8-16 X 4.50 Hex Head Washer, 3/8 Type B Flat Locknut, 3/8-16 Hex... 6 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 6-9

76 6

77 LCTRICAL SYSTM 7

78 18_R(W7) 7 NO NC COM 1 18_OR(W23) 16_BLK(W32) FULTANK SNIN UNIT HA LIHT RIHT LIHT SWITCH OIL LIHT WORK LIHT SWITCH 18_YL(W4) 18_YL(W33) BLACK OIL SNIN UNIT FRAM ROUN AT SAT SUPPORT BLU FNR LIMIT SWITCHS FUL/HOUR RVRS BUZZR 2 COM NO 16_BLU(W42) 16_BLK(W47) 16_BLU(W43) MTR UA 18_BLU(W41) 18_WHT(W40) 18_YL(W54) 18_YL(W8) FRONT POS (+) N (-) 18_BLU(W15) 18_BLK(W11) 18_R_WHT_STP(W6) 18_RN(W14) HA LIHT LFT 16_BLK(W13) 18_BLK(W16) 18_BLK(W49) S L B M 18_WHT_BLK(W18) INITION KILL 14_BLU(W12) 16_BRN(W44) 18_OR(W39) VOLTA RULATOR 18_YL(W26) (-) VOLTA LIMITR (+) 16_BLK_WHT_STP(W48) P/N _YL(W10) 18_BLK(W34) 18_BLK(W35) CNTR ASH PANL ASSMBLY 18_BLK(W50) FUS BLOCK 18_BLK(W55) 16_BLK(W19) 16_BLK(W9) 18_RN_WHT(W17) Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

79 R WORK LIHTS ON LIHT BAR BLU 1 7 BLU R BLU - + R 3 BATTRY YLLOW BROWN BLACK NIN BAR 10_NON_INSUL(W27) 2 6_BLK(W29) OPTIONAL TALL LIHT 6_R(W28) 5 SOLNOI WHIT R 18_R(W24) 18_YL(W2) STARTR NRTOR 6_WHT(W1) F2 A1 6_BLK(W3) A2 F F1 6_RN_HIH_TMP(W31) 18_YL(W21) 18_BLK(W38) 18_BRN(W45) 18_BLK(W53) 18_BRN(W52) BLACK BROWN WHIT 18_R(W25) 18_R(W36) 18_WHT(W20) OPTIONAL 4 10_R(W30) 18_R(W37) UNR ASH 16_BLK(W5) TALL LIHT LCTRICAL COMPONNT BOX NO COM 18_BRN(W22) BRAK LIHT PRSSUR SWITCH XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-3

80 7 See previous two pages for illustration. Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

81 ITM PART NO. SCRIPTION WIRIN XRT 1200 VHICLS Wire Assy, #6 Black Wire Assembly #6 Red Wire Assembly, #10, Uninsulated Wire Assy, #10 Red Wire Assy, #6 reen Asm, Wire Harness... 1 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-5

82 BLU BLU BLACK BROWN 7 PASSNR SI HALIHT BLU BLACK HALIHT IO FRAM ROUN RIVR SI HALIHT BLACK BLACK SONIC WL BLACK BLU BLACK BLACK/WHIT BLACK YLLOW BLACK RVRS BUZZR R/WHIT BLU BLU SONIC WL BLU YLLOW WHIT/BLACK BLU BLU BLU YLLOW R SONIC WL L M B YLLOW S KY SWITCH OIL LIHT LIHT SWITCH ORAN BLU BLACK BLU YLLOW R YLLOW WHIT/BLACK ORAN WHIT 4 FUL AU/ HOUR MTR ORAN BLU WHIT/BLACK YLLOW R YLLOW BLU BLACK BLU MASTR CYLINR RN/WHIT YLLOW WHIT R RN/WHIT Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

83 R YLLOW YLLOW 7 R/WHIT SONIC WL FORWAR / RVRS LVR RVRS BUZZR LIMIT SWITCH ORAN BLACK 2 1 LOCKOUT CAM LIMIT SWITCH RN BLU ORAN RN WHIT IO FUL TANK IO R R R R SOLNOI BLACK ORAN FRAM ROUN ORAN BLU YLLOW R/WHIT VOLTA RULATOR BLACK RN/WHIT SONIC WL BLACK YLLOW YLLOW R YLLOW FUS BLOCK 4 YLLOW R RPM LIMITR WHIT BRAI ROUN BLACK A1 WHIT / BLACK A2 F2 WHIT F F1 RN NIN 3 STARTR / NRATOR OIL LVL SNSOR R YLLOW BLU BLU BLACK RN/WHIT WHIT/BLACK SONIC WL BROWN BROWN R/WHIT FRAM ROUN WHIT/BLACK BLACK SONIC WL 1 R/WHIT BLACK BLACK BLACK R/WHIT BLACK WHIT 5 YLLOW YLLOW RAR RVRS BUZZR YLLOW WHIT BLACK R BROWN BROWN YLLOW BLACK BLACK OPTIONAL TAIL LIHT BATTRY 2 WHIT BROWN BLACK OPTIONAL TAIL LIHT XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-7

84 7 See previous two pages for illustration. Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

85 ITM PART NO. SCRIPTION WIRIN XRT 1200 S KY-START VHICL Wire Assy, #6 Black Wire Assembly #6 Red Wire Assembly, #10, Uninsulated Wire Assy, #10 Red Wire Assy, #6 reen Asm, Wire Harness - Stretch... 1 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-9

86 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

87 ITM PART NO. SCRIPTION FORWAR/RVRS SHIFTR ASSMBLY Screw, 1/4 X Hex-Head Handle, FNR Screw, #8-32 X 0.63 Machine Cable, Shifter (includes items 5 and 6) Joint, #10-32 Ball Nut, #10-32 Hex Washer, Wave Assembly, FNR Shifter (includes items 9 through 25) Stud, 1/4-28 X Ball Washer, #4 Flat Screw, #4-40 Machine FNR Bell Crank Weldment Ring, 0.338" Internal Retaining Spring, FNR Cam Pin, 1/8 X 1/2 Roll Neutral Lockout Cam Kit (includes item 17) Washer, 0.38" I elrin Flat Bushing, Secondary Weight, Split Washer, #4 Nylon Flat Switch, Limit FNR Shifter Base Assembly, Switch, Limit Nut, #4-40 Hex Machine Lockwasher, #4 Split Locknut, 1/4-28 Nylon Insert Bracket, Shifter Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 0.75 Truss-Head Machine... 4 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-11

88 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

89 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 XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-13

90 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

91 XRT 1200S FORWAR/RVRS SHIFTR ASSMBLY ITM PART NO. SCRIPTION Screw, 1/4 X Hex-Head Handle, FNR Screw, #8-32 X 0.63 Machine Washer, Wave Cable, FNR Shifter (includes items 6 through 8) Joint, #10-32 Ball Cable, Transmission Shifter Nut, #10-32 Hex Assembly, FNR Shifter (includes items 10 through 26) Stud, 1/4-28 X Ball Washer, #4 Flat Screw, #4-40 Machine FNR Bell Crank Weldment Ring, 0.338" Internal Retaining Spring, FNR Cam Pin, 1/8 X 1/2 Roll Neutral Lockout Cam Kit (includes item 18) Washer, 0.38" I elrin Flat Bushing, Secondary Weight, Split Washer, #4 Nylon Flat Switch, Limit FNR Shifter Base Assembly, Switch, Limit Nut, #4-40 Hex Machine Lockwasher, #4 Split Locknut, 1/4-28 Nylon Insert Bracket, Shifter Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 0.75 Truss-Head Machine... 4 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-15

92 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

93 LCTRICAL COMPONNT BOX, KY-START VHICLS ITM PART NO. SCRIPTION Stud, 1/4-28 X Ball Fuse, 10-Amp Ring, 0.338" Internal Retaining Solenoid, 12-Volt Washer, 0.38" I elrin Flat 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 Voltage Regulator Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Locknut, 5/16-18 Nylon Insert Bolt, Carriage, 5/16-18 X Nut, #10-32 Hex Locknut, 1/4-28 Nylon Insert... 1 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-17

94 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

95 ITM PART NO. SCRIPTION LCTRICAL COMPONNTS, FRONT BOY Screw, #10-32 X 1.25 Rd Hd Mch Lockwasher, #10 Split Kit, Reverse Buzzer (includes items 4 through 12) Locknut, #6-32 Whiz Washer, #4 Flat Screw, #6-32 X 1/2 Hex Washer-Head Screw, #4-24 X 0.33 Pan-Head Machine Buzzer, Reverse (9-48 VC) Wire Assembly Black # Screw, #4-40 X 0.75 Round-Head Machine Nut, #4-40 Hex Machine Lockwasher, #4 Split Limiter, Voltage Kit, iode (includes items 15 through 17) Locknut, 5/16-18 Hex Flange iode Assembly Thermal Pad Washer, #10 Type A Flat Nut, #10-32 Hex Tie Wrap, 11" Nylon... 4 QTY 7 Note: Not all components of the reverse buzzer kit are used in all applications XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-19

96 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

97 ITM PART NO. SCRIPTION LCTRICAL COMPONNTS, ASH PANL 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 Switch Tie Wrap, 8" Nylon... 3 QTY XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-21

98 Page XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List

99 ITM PART NO. SCRIPTION STARTR/NRATOR MOUNTIN 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 XRT 1200 and XRT 1200 S asoline Vehicles Illustrated Parts List Page 7-23

Transportation Vehicles Illustrated Parts List

2004-2005 Transportation Vehicles Illustrated Parts List Villager 4, Villager 6, Villager 8, TransPorter 4, and TransPorter 6 asoline and lectric Vehicles Manual Number 02397503 dition Code 0805U02T USIN