Target Audience:
Owners and technicians of 2004 Club Car Carryall, Turf, and XRT utility vehicles.
Vendor Offering:
GearHead Manuals specializes in instant downloadable PDF repair manuals for a wide range of vehicles and equipment.
Download Method:
Instant download after payment, no ZIP files, plain PDF.
Support:
Lifetime Protection Policy for lost or damaged downloads.
Ease Of Use:
Printable pages, accessible on smart devices for on-the-spot repairs.
Covered Models:
2004 Club Car Turf 1, Turf 2, Turf 2 XRT, Turf 6, Carryall 1, Carryall 2, Carryall 2 Plus, Carryall 2 XRT, Carryall 6
Estimated Page Count:
Not specified, but comprehensive coverage implies several hundred pages.
Type:
Repair, Service, and Shop Manual
Engine Systems:
Engine removal/installation, fuel system, lubrication, cooling system, engine specifications, intake & exhaust.
Drivetrain Systems:
Transmission, drive chain & sprockets.
Chassis Systems:
Steering system, shocks.
Electrical Systems:
Complete electrical system diagnostics and repair.
Bodywork:
Body work and cosmetic repairs.
Maintenance Procedures:
Routine maintenance, lubrication schedules, fluid checks and changes.
Repair Procedures:
Engine repair, transmission service, steering adjustments, electrical component replacement.
Troubleshooting Procedures:
Advanced troubleshooting guides for common and complex issues.
Depth:
Comprehensive, covering diagnostics, repair, and maintenance from basic to advanced levels.
Engine Type:
Varies by model and powertrain. Likely 4-cycle gasoline engines (e.g., Kawasaki engines commonly used by Club Car) and electric motor systems.
Horsepower Range:
Typically in the 8-25 HP range for gasoline models, with electric models focusing on torque and efficiency.
Fuel Type:
Gasoline (for gasoline models)
Carburetion:
Likely carbureted fuel delivery for gasoline engines.
Oil Type:
Specific SAE viscosity grade (e.g., SAE 30 or 10W-30) and API service classification will be detailed in the manual.
Cooling Method:
Air-cooled or liquid-cooled, depending on the specific engine model.
Transmission Type:
Continuously Variable Transmission (CVT) with belt drive is standard for most Club Car utility vehicles of this era.
Optional Features:
No common optional transmissions for this model range; CVT is the primary system.
Drive System:
Typically rear-wheel drive (RWD) via differential and drive axles.
Gear Ratios:
CVT inherently provides a wide range of effective gear ratios; specific ratios for high/low range may be detailed.
Overall Length:
Varies by model, typically ranging from 90 to 120 inches.
Overall Width:
Typically around 45-50 inches.
Overall Height:
Typically around 70-75 inches (with roof).
Curb Weight:
Varies significantly between gasoline and electric models, typically 800-1200 lbs.
Bed Capacity:
Varies by model, with models like Carryall 6 having larger cargo beds. Payload capacities typically 500-1000 lbs.
Crash Test Ratings:
N/A (Utility vehicles are not typically subjected to automotive crash testing standards).
Braking System:
Hydraulic drum brakes on rear axle, possibly front disc brakes on some higher-spec models. Parking brake mechanism.
Occupant Protection:
Roll bar (ROPS - Roll Over Protective Structure) is a standard safety feature on most utility vehicles of this era.
Lighting:
Headlights, taillights, brake lights, and turn signals (depending on model configuration).
Oil Change:
Typically every 50-100 operating hours or annually, detailed in the manual.
Air Filter Replacement:
As needed based on operating conditions, or at specified intervals (e.g., every 100-200 hours).
Spark Plug Replacement:
Typically every 500-1000 operating hours for gasoline engines.
Belt Inspection Replacement:
Regular inspection for wear and tension, replacement based on wear or manufacturer recommendation (e.g., every 500-1000 hours).
Engine Oil Viscosity:
Specific SAE grade (e.g., SAE 30, 10W-30) and API classification as per engine manufacturer recommendations.
Transmission Fluid:
Specific type and grade for the CVT and differential, detailed in the manual. May include specific gear oil or CVT fluid.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid for the braking system.
Coolant Type:
For liquid-cooled engines, specific ethylene glycol-based coolant mixture (e.g., 50/50).
Common Wear Items:
Drive belts, brake pads/shoes, wheel bearings, tie rod ends, and suspension bushings are common wear items in utility vehicles.
Electrical Problems:
Battery issues, starter solenoid failures, and corroded connections can occur due to environmental exposure.
Engine Specific:
Carburetor adjustments or cleaning, and exhaust system leaks can be issues on older gasoline engines.
Club Car Legacy:
Club Car has a long-standing reputation for producing durable and reliable golf and utility vehicles since 1958.
Carryall Series Evolution:
The Carryall series has been a workhorse for Club Car, evolving from basic utility carts to more versatile, multi-purpose vehicles like the XRT line.
Manufacturing Location:
Club Car vehicles are typically manufactured in the United States.
