Club Car Carryall 272 2005 Owner's manual

Brand: Club Car

Model: Carryall 272 2005

Category: Utility Vehicle

Type: Owner's manual

This manual is also suitable for

Carryall 472 2005

Owner’s Manual

An business

2005

Carryall 272 and 472

Vehicles

Gasoline

Carryall 272

Carryall 472

P. O. Box 204658

Augusta, Georgia 30917-4658 USA

Telephone 706-863-3000

Service Parts Fax 706-855-7413

www.clubcar.com

2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual Page 1

NOTICE

The Transportation and Utility Vehicle Limited Warranty appears on the last pages of this manual. No other

warranties, express or implied, are contained herein. Your authorized representative checked the vehicle

before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form.

Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the

use of the material in this manual.

This manual contains proprietary information that is protected by copyright. All rights are reserved. No part of

this manual may be photocopied, reproduced, or translated to another language without the written consent

of Club Car, Inc.

The information contained in this document is subject to change without notice.

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.

Club Car

and

Carryall

are registered

trademarks of Club Car, Inc.

This manual effective August 2, 2004.

Page 2 2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual

FOREWORD

Thank you for choosing Club Car, the name most widely recognized as the industry leader in vehicle efﬁciency

and long-lasting value. You have chosen the ﬁnest utility vehicle on the market. Please protect your investment

and ensure that your Club Car vehicle(s) provides years of reliable, superior performance by reading and fol-

lowing the maintenance instructions in this manual.

Your comfort and safety are important to us, so we urge you to read and follow the step-by-step operating

instructions and safety precautions in this manual. These instructions must be followed in order to avoid the

risk of severe personal injury. If you rent or loan your vehicle to others, we recommend that you ask them to

read this manual before they operate the vehicle.

Club Car products are backed by a customer support system designed to offer you fast, courteous service. In

the event that your Club Car vehicle needs repairs or service, we recommend that your local authorized Club

Car representative perform them. For the name and address of the Club Car representative nearest you,

logon to our web site at www.clubcar.com or call 1-800-ClubCar (258-2227). If you would prefer to write to us,

direct your letter to: Club Car, Attention: Marketing Services, P.O. Box 204658, Augusta, Georgia 30917-4658

USA. Your local authorized Club Car representative can also provide technical advice, parts, and service

manuals.

We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehi-

cle, please include the manual so that the next owner will have the important operating, safety, and mainte-

nance information it contains.

Below is a quick reference table of items that will help you maintain this vehicle. These parts can be purchased

from your authorized Club Car dealer.

REGULAR MAINTENANCE ITEMS PERIODIC MAINTENANCE ITEMS

Engine Oil Filter

(CCI P/N 1016467)

Battery

(CCI P/N 1012328)

Engine Air Filter

(CCI P/N 1015426)

Spark Plug

O.H.V. (CCI P/N 101881101)

Engine Fuel Filter

(CCI P/N 102003201)

Spring Tune-Up Kit

(CCI P/N 101611003)

Battery Terminal Protector Spray

(CCI P/N 1014305)

Dry Moly Lube

(CCI P/N 1012151)

2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual Page 3

TABLE OF CONTENTS

Vehicle Feature Identiﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Model Identiﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Seat Latch and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pre-Operation and Daily Safety Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Driving Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Bed Latch and Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Front Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Loading and Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Towing with the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Transporting on a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Periodic Service Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Periodic Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Fueling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Cleaning the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Subsequent Owner Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Vehicle Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Club Car

Limited Two Year Warranty for 2005 Transportation and Utility Vehicles . . . . . . . . . . . . . . . . . 42

Vehicle Feature Identification

Page 4 2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual

CARRYALL 272

YOUNG DRIVERS INCREASE

CHANCE OF DEATH

• Y

oung drivers may not be able to control vehicle.

• No drivers younger than 16 years old.

• Do not leave childern unattended on vehicle.

UNDER

WARNING

ROLLOVER OR FALLING OFF MAY

CAUSE DEATH

• Read operators manual and operating instructions.

• Remain seated and hold on to seat handle while moving.

• Drive slowly in turns and straight up and down slopes.

• Do not start vehicle until all occupants are seated.

• One (1) person per seat maximum.

• Operate from driver side only and not on public roads.

• Keep entire body inside vehicle while moving.

• Do not use differential lock on paved surfaces.

• Do not operate while under the influence of alcohol or drugs.

OFF ON

WARNING

STAY CLEAR

CRUSH AREA

CCI 101609401

• Vehicle rated capacity - 1200 lbs. on level surface only.

Weight to include passengers, cargo bed load, and

gross trailer weight. See Owner's Manual.

• Maximum cargo load - 800 lbs. Weight to include cargo

bed load and gross trailer weight.

• Maximum trailer hitch tongue weight - 150 lbs.

• Cargo should be evenly spread over the floor of the

cargo bed as far forward as possible and secured.

• For vehicle stability, when fully loaded, drive slowly

and avoid stopping on or backing down steep hills.

• Avoid top heavy loads. See Owner's Manual.

• When driving on uneven terrain or down steep hills,

reduce speed and load.

VEHICLE

Read Owner's Manual

and warnings on dash. CCI 101960201

CCI 102046601

REDUCED STEERING

CONTROL MAY CAUSE

SERIOUS INJURY OR DEATH

Disengage differential lock on

paved surfaces.

WARNING

Riding in cargo bed

can cause severe injury

or death.

Do not ride in cargo bed.

WARNING

CCI 101553901

WARNING

ROLLOVER OR FALLING OFF MAY

CAUSE DEATH

• Read operators manual and operating instructions.

• Remain seated and hold on to seat handle while moving.

• Drive slowly in turns and straight up and down slopes.

• Do not start vehicle until all occupants are seated.

• Front seats: One (1) person per seat maximum.

• Operate from driver side only and not on public roads.

• Keep entire body inside vehicle while moving.

• Do not operate while under the influence of alcohol or drugs.

• Never attempt jumps. CCI 102029101

YOUNG DRIVERS INCREASE

CHANCE OF DEATH

• Young drivers may not be able to control vehicle.

• No drivers younger than 16 years old.

• Do not leave childern unattended on vehicle.

UNDER

WARNING

CCI 102044601

WARNING

Rotating Parts

CCI 102224001

• Read owner's manual and safety warnings located on dash panel prior to driving.

• Study and understand controls.

TO START ENGINE

• Place shift lever in “N”– Neutral position.

• Depress brake pedal.

• Turn key switch to “START” position and hold, activating the choke

as necessary, until engine starts.

TO OPERATE VEHICLE

• Make sure wheels are turned in desired direction.

• Be sure nothing is in your path.

• While vehicle is stopped, and the engine is at idle, select vehicle direction

by placing shift lever in desired position.

F – Forward N – Neutral R – Reverse (Buzzer will sound)

• Release hand brake.

• Slowly push accelerator pedal to increase speed.

• Engine must be at idle before moving shift lever.

TO STOP VEHICLE

• Release accelerator pedal and push brake pedal.

• After stopping, firmly set hand brake.

• Turn key to “OFF” position, remove key and place shift lever in

straight up neutral position when not in use.

CCI 102224301

OPERATING INSTRUCTIONS

OFF ON

OFF ON START

•

Read Owner's Manual and safety warnings located on dash panel prior to driving.

•

Study and understand controls.

•

To start engine:

– Place shift lever in “N”– Neutral position.

– Depress brake pedal.

– Turn key switch to “START” position and release.

•

To operate vehicle:

– Make sure wheels are turned in desired direction.

– Be sure nothing is in your path.

– While vehicle is stopped, select vehicle direction by placing

shift lever or switch in desired position.

F – Forward N – Neutral R – Reverse (Buzzer will sound)

– Park brake will release when accelerator pedal is pushed.

– Slowly push accelerator pedal to increase speed.

– Accelerator pedal must be released to shift vehicle to neutral.

•

To stop vehicle:

– Release accelerator pedal and push brake pedal.

– After stopping, firmly push park brake until it locks.

– Turn key to “OFF” position, remove key and place shift

lever in straight up neutral position when not in use.

CCI 1016932-01

OPERATING INSTRUCTIONS

VEHICLE LOADING DECAL

OPERATING

INSTRUCTIONS DECAL

DIFFERENTIAL

LOCK CONTROL

DECAL

BED LOAD

WARNING DECAL

DRIVER/PASSENGER WARNING

DECAL

UNDERAGE

WARNING DECAL

(UNDER SEAT

SUPPORT)

(ON TOP OF

FUEL TANK)

KEY SWITCH

FUEL SHUT-OFF

VALVE

(TOP OF PASSENGER SIDE FENDER)

ROTATING PARTS

DECAL

CRUSH AREA

DECAL

BED

LATCH

BRAKE

PEDAL

ACCELERATOR

PEDAL

LOW OIL

WARNING

LIGHT

SWITCH

SERIAL

NUMBER

FUEL GAUGE/

HOUR METER

Vehicle Feature Identification

2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual Page 5

CARRYALL 272

WARNING

Rotating parts

HOT

manifold & muffler

KEEP CLEAR

CCI 1019605-01

CAN CAUSE SEVERE INJURY

CCI 1019152-01

Negative frame ground. Can cause severe injury.

Do not contact positive (+) battery post or cable to frame.

Disconnect negative battery lead first.

Excessive speed.

Can cause severe injury or death.

Do not tamper with engine governor adjustment.

MAXIMUM TONGUE

WEIGHT - 150 lbs.

CCI 1011553

NOTICE

WINCH CABLE FRACTURE COULD RESULT

IN SERIOUS INJURY OR DEATH.

•Do not use winch while persons are seated on the vehicle.

•Use remote operation switch for winch control.

•Stand to the side and away from the vehicle to operate winch.

•Read winch operator manual before operating winch.

WARNING

102231601

•

GASOLINE EXPLOSION / FIRE.

•

CAN CAUSE SEVERE INJURY OR DEATH.

•

NO SMOKING, SPARKS, OR OPEN FLAME.

•

STOP ENGINE, ALLOW TO COOL BEFORE REFUELING.

•

TURN FUEL VALVE ( ) ON DURING OPERATION.

( ) OFF DURING STORAGE OR TRANSPORT.

CCI 101547601

WARNING

INCORRECT WIRING COULD RESULT IN

SEVERE INJURY OR DEATH.

• Diode and solenoid connections must have correct polarity.

•Keep all persons clear of engine belts when making final

connections. CCI 102345901

WARNING

FNR

PARK BRAKE

RECEIVER

HITCH

WINCH CABLE

WARNING DECAL

DIODE

WIRING DECAL

FORWARD/REVERSE

HANDLE

CHOKE

BED LATCH

WARNING DECAL

(ON FRONT AND REAR

RECEIVER HITCHES)

FRAME GROUND AND

GOVERNOR WARNING DECAL

(ON FRAME)

ROTATING PARTS AND

HOT MANIFOLD DECAL

(ON STARTER/GENERATOR

AND ENGINE)

(ON SEAT SUPPORT PANEL)

GASOLINE WARNING DECAL

(ON PASSENGER SIDE

SEAT SUPPORT)

TRAILER HITCH

DECAL

(FOR VEHICLES WITH WINCH ACCESSORY)

(ON FRAME ABOVE DIODE)

Vehicle Feature Identification

Page 6 2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual

CARRYALL 472

UNDER

WARNING

OFF ON

WARNING

STAY CLEAR

CRUSH AREA

CCI 101609401

• Vehicle rated capacity - 1300 lbs. on level surface only.

Weight to include passengers, cargo bed load, and

gross trailer weight. See owner's manual.

• Maximum cargo load - 500 lbs. Weight to include cargo

bed load and gross trailer weight.

• Maximum trailer hitch tongue weight - 150 lbs.

• Cargo should be evenly spread over the floor of the

cargo bed as far forward as possible and secured.

• For vehicle stability, when fully loaded, drive slowly

and avoid stopping on or backing down steep hills.

• Avoid top heavy loads. See owner's manual.

• When driving on uneven terrain or down steep hills,

reduce speed and load.

VEHICLE

Read Owner's Manual

and warnings on dash. CCI 102274301

CCI 102046601

REDUCED STEERING

CONTROL MAY CAUSE

SERIOUS INJURY OR DEATH

Disengage differential lock on

paved surfaces.

WARNING

Riding in cargo bed

can cause severe injury

or death.

Do not ride in cargo bed.

WARNING

CCI 101553901

WARNING

ROLLOVER OR FALLING OFF MAY

CAUSE DEATH

• Read operators manual and operating instructions.

• Remain seated and hold on to seat handle while moving.

• Drive slowly in turns and straight up and down slopes.

• Do not start vehicle until all occupants are seated.

• Front seats: One (1) person per seat maximum.

• Operate from driver side only and not on public roads.

• Keep entire body inside vehicle while moving.

• Do not operate while under the influence of alcohol or drugs.

• Never attempt jumps. CCI 102029101

YOUNG DRIVERS INCREASE

CHANCE OF DEATH

• Young drivers may not be able to control vehicle.

• No drivers younger than 16 years old.

• Do not leave childern unattended on vehicle.

UNDER

WARNING

CCI 102044601

WARNING

Rotating Parts

CCI 102224001

• Read owner's manual and safety warnings located on dash panel prior to driving.

• Study and understand controls.

TO START ENGINE

• Place shift lever in “N”– Neutral position.

• Depress brake pedal.

• Turn key switch to “START” position and hold, activating the choke

as necessary, until engine starts.

TO OPERATE VEHICLE

• Make sure wheels are turned in desired direction.

• Be sure nothing is in your path.

• While vehicle is stopped, and the engine is at idle, select vehicle direction

by placing shift lever in desired position.

F – Forward N – Neutral R – Reverse (Buzzer will sound)

• Release hand brake.

• Slowly push accelerator pedal to increase speed.

• Engine must be at idle before moving shift lever.

TO STOP VEHICLE

• Release accelerator pedal and push brake pedal.

• After stopping, firmly set hand brake.

• Turn key to “OFF” position, remove key and place shift lever in

straight up neutral position when not in use.

CCI 102224301

OPERATING INSTRUCTIONS

OFF ON START

FALLING OFF COULD RESULT

IN SEVERE INJURY OR DEATH

• Remain seated with entire body

inside vehicle and hold on to seat

handle or handrail at all times.

• Two (2) persons per bench seat maximum.

• One (1) person per bucket seat maximum.

• Do not leave children unattended on

vehicle at anytime.

• Never stand in front of or behind vehicle.

CCI 101705701

WARNING

VEHICLE LOADING DECAL

OPERATING INSTRUCTIONS DECAL

DIFFERENTIAL

LOCK CONTROL

DECAL

BED LOAD WARNING DECAL

DRIVER/PASSENGER WARNING

DECAL

UNDERAGE WARNING DECAL

(UNDER SEAT

SUPPORT)

(ON TOP OF

FUEL TANK)

KEY SWITCH

FUEL SHUT-OFF

VALVE

(TOP OF PASSENGER SIDE FENDER)

ROTATING PARTS DECAL

CRUSH

AREA DECAL

PASSENGER

WARNING DECAL

BED

LATCH

BRAKE PEDAL

ACCELERATOR

PEDAL

LOW OIL

WARNING

LIGHT

LIGHT SWITCH

SERIAL NUMBER

FUEL GAUGE/HOUR METER

Vehicle Feature Identification

2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual Page 7

CARRYALL 472

WARNING

Rotating parts

HOT

manifold & muffler

KEEP CLEAR

CCI 1019605-01

CAN CAUSE SEVERE INJURY

CCI 1019152-01

Negative frame ground. Can cause severe injury.

Do not contact positive (+) battery post or cable to frame.

Disconnect negative battery lead first.

Excessive speed.

Can cause severe injury or death.

Do not tamper with engine governor adjustment.

MAXIMUM TONGUE

WEIGHT - 150 lbs.

CCI 1011553

NOTICE

WINCH CABLE FRACTURE COULD RESULT

IN SERIOUS INJURY OR DEATH.

•Do not use winch while persons are seated on the vehicle.

•Use remote operation switch for winch control.

•Stand to the side and away from the vehicle to operate winch.

•Read winch operator manual before operating winch.

WARNING

102231601

•

GASOLINE EXPLOSION / FIRE.

•

CAN CAUSE SEVERE INJURY OR DEATH.

•

NO SMOKING, SPARKS, OR OPEN FLAME.

•

STOP ENGINE, ALLOW TO COOL BEFORE REFUELING.

•

TURN FUEL VALVE ( ) ON DURING OPERATION.

( ) OFF DURING STORAGE OR TRANSPORT.

CCI 101547601

WARNING

INCORRECT WIRING COULD RESULT IN

SEVERE INJURY OR DEATH.

• Diode and solenoid connections must have correct polarity.

•Keep all persons clear of engine belts when making final

connections. CCI 102345901

WARNING

FNR

PARK BRAKE

RECEIVER

HITCH

WINCH CABLE

WARNING DECAL

FORWARD/REVERSE

HANDLE

CHOKE

BED LATCH WARNING DECAL

DIODE

WIRING DECAL

(ON FRONT AND REAR

RECEIVER HITCHES)

FRAME GROUND AND

GOVERNOR WARNING DECAL

(ON FRAME)

ROTATING PARTS AND

HOT MANIFOLD DECAL

(ON STARTER/GENERATOR

AND ENGINE)

(ON SEAT SUPPORT PANEL)

GASOLINE WARNING DECAL

(ON PASSENGER SIDE

SEAT SUPPORT)

TRAILER HITCH

DECAL

(FOR VEHICLES WITH WINCH ACCESSORY)

(ON FRAME ABOVE DIODE)

!WARNING

Rotating Parts

Practice Safety

Page 8 2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual

Safety signs like you see above may at ﬁrst seem shocking, but their impact is mild

compared with the reality of severe personal injury.

Your safety and satisfaction are of the utmost importance to Club Car. That is why

before operating the vehicle, we urge you to review the information in this manual.

Understand and become familiar with the DANGER, WARNING and CAUTION state-

ments and procedures it contains, along with the safety decals that are afﬁxed to your

vehicle.

Take time to understand the language of safety. It is a language that can save your life.

PROPOSITION 65 – STATE OF CALIFORNIA

∆

WARNING

This product contains or emits chemicals or substances that have been determined by the state of

California to cause cancer and birth defects or other reproductive harm.

Safety Details

2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual Page 9

SAFETY DETAILS

∆

WARNING

•This owner’s manual should be read completely before attempting to drive or service the

vehicle. Failure to follow the instructions in this manual could result in property damage,

severe personal injury, or death.

It is important to note that some vital statements throughout this manual and on the decals afﬁxed to the vehi-

cle are preceded by the words DANGER, WARNING, or CAUTION. For your protection, we recommend that

you take special notice of these safety precautions. Safety precautions are essential and must be followed.

If any of the operation or safety decals on the vehicle become damaged, have been removed, or cannot be

easily read, they should be replaced immediately to avoid possible property damage, personal injury, or

death. Contact your Club Car dealer.

∆

DANGER

•A DANGER indicates an immediate hazard that will result in severe personal injury or death.

∆

WARNING

•A WARNING indicates an immediate hazard that could result in severe personal injury or

death.

∆

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 situation that potentially could result

in property damage.

Figure 1 Battery Cable Removal

FRONT

OF VEHICLE

AS SEEN FROM

PASSENGER SIDE

OF VEHICLE

Remove

negative

cable first.

DISCONNECT BATTERY CABLES

BEFORE WORKING ON VEHICLE

General Warnings

Page 10 2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual

GENERAL WARNINGS

The following safety statements listed must be heeded whenever the vehicle is being operated, repaired, or

serviced. Vehicle feature identiﬁcation information is also included beginning on page 4. Other speciﬁc safety

statements appear throughout this manual and on the vehicle.

∆

DANGER

•Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and

service area. Ventilate when charging or using in an enclosed space. Wear a full face shield

and rubber gloves when working on or near batteries.

•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.

•A Club Car vehicle will not provide protection from lightning, ﬂying objects, or other storm-

related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek

shelter in accordance with applicable safety guidelines for your location.

∆

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.

• Do not leave children unattended on vehicle.

•Prior to leaving the vehicle unattended or servicing the vehicle, set the park brake, place the

Forward/Reverse handle in the NEUTRAL position, turn the key switch to the OFF position,

and remove the key. Chock the wheels when servicing the vehicle.

•Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle

performance, severe personal injury, or death.

•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.

•Check the vehicle for proper location of all vehicle safety and operation decals and make sure

they are in place and are easy to read.

•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.

•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.

•To avoid unintentionally starting the vehicle:

- Disconnect battery cables, negative (–) cable ﬁrst (Figure 1).

- 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.

General Information

2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual Page 11

∆

WARNING

•Wear safety glasses or approved eye protection when servicing the vehicle. 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.

•Use insulated tools when working near batteries or electrical connections. Use extreme

caution to avoid shorting of components or wiring.

GENERAL INFORMATION

This manual is designed to include information on both the Carryall 272 and the Carryall 472. Both are key-

start vehicles. They start and operate similar to an automobile. Each has a feature that allows the engine to

run at idle or advanced RPM using the accelerator pedal when the Forward/Reverse handle is in the NEU-

TRAL position.

All operating procedures, maintenance, and regular servicing are identical to both vehicles unless otherwise

noted. If any of these differ between vehicles, it will be noted for that speciﬁc procedure.

MODEL IDENTIFICATION

The serial number of your Club Car vehicle is printed on a bar code decal mounted on the frame directly

above the accelerator pedal (Example: QG0501-583947)

(Figure 2)

. There is also a second serial number

decal mounted on the front body frame behind the instrument panel. The instrument panel must be removed

to view this decal.

See following NOTE.

NOTE:

Have the vehicle serial number available when ordering parts or making inquiries.

Figure 2 Serial Number

SERIAL NUMBER

AD0501-583947

P O BOX 204658

AUGUSTA GA 30917

Club Car R

Controls and Indicators

Page 12 2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual

CONTROLS AND INDICATORS

See General Warnings on page 10.

∆

WARNING

•Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls

and operating procedures.

•Do not tamper with the governor. Doing so will void the warranty, as well as damage the

engine and other components, and could result in property damage, personal injury, or death

due to unsafe speeds.

• Do not shift the Forward/Reverse handle while the vehicle is in motion.

•Engine must be at idle before shifting the Forward/Reverse handle. Failure to do so may result

in injury to inattentive passengers and (or) damage to the vehicle.

•To help avoid injury to an inattentive passenger or damage to the vehicle, always bring the

vehicle to a full stop before shifting the Forward/Reverse handle.

•To help avoid unintentionally starting or rolling the vehicle, set the park brake, place the

Forward/Reverse handle in the NEUTRAL position, turn the key switch to the OFF position,

and remove the key when leaving the vehicle.

•With the differential lock engaged, vehicle turning functions are greatly reduced. To prevent

loss of vehicle control when differential lock is engaged, do not operate vehicle at speeds

greater than half throttle and use caution when attempting to turn the vehicle.

KEY SWITCH

The key switch is mounted on the instrument panel to the right of the steering column

(Figure 3)

. It has three

positions: OFF, ON, and START. To start the vehicle, place the Forward/Reverse handle in the NEUTRAL

position and turn the key past the ON position to the START position and hold until the engine is running

smoothly. Release the key and it will return to the ON position and the engine should idle.The engine will con-

tinue to idle until the key is turned to the OFF position.

See following WARNING, CAUTION and NOTE.

∆

WARNING

•Moving parts! Keep clear of the engine compartment while the engine is running.

Figure 3 Key Switch

OFF ON START

Controls and Indicators

2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual Page 13

CAUTION

•Do not “rev” the engine for long periods of time while the Forward/Reverse handle is in the

NEUTRAL position. Failure to heed this caution could result in damage to the unitized

transaxle.

•Do not shift the Forward/Reverse handle while the accelerator pedal is pressed. Shift the

handle only when the vehicle is at a complete stop. Failure to heed this caution could result in

damage to the unitized transaxle.

NOTE:

The key can be removed only when the key switch is in the OFF position.

FORWARD/REVERSE CONTROL

The Forward/Reverse handle is located on the seat support panel

(Figure 4)

. The handle has three distinct

positions:

(FORWARD),

(NEUTRAL), and

(REVERSE). Rotate the handle towards the driver (FOR-

WARD) to operate the vehicle in the forward direction, or towards the passenger (REVERSE) to operate the

vehicle in reverse. The engine can be started only when the handle is in the straight up position (NEUTRAL).

The engine must be at idle before shifting the Forward/Reverse handle.

See WARNING and CAUTION on

page 12.

Club Car vehicles operate at a reduced speed in reverse. The reverse buzzer will sound as a warning when

the Forward/Reverse handle is in the REVERSE position.

ACCELERATOR PEDAL

The accelerator pedal is the pedal on the right, with the word GO molded into it

(Figure 5)

With the engine running and the Forward/Reverse handle in the FORWARD or REVERSE position, vehicle

speed will increase as the accelerator pedal is pressed. When the accelerator pedal is released, it will return

to the original position and the engine will idle.

See WARNING and CAUTION on page 12.

Figure 4 Forward/Reverse Handle

FNR

Controls and Indicators

Page 14 2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual

BRAKE PEDAL

The brake pedal is the large pedal on the left with the word STOP molded into it

(Figure 5)

. To slow or stop the

vehicle, press the brake pedal

(Figure 6).

PARK BRAKE

The park brake handle is located between the driver and passenger seats. To engage the park brake, ﬁrst

apply pressure to the brake pedal, then pull up on the park brake handle until handle latches into place. To dis-

engage, pull up on the handle and press the button on the end of the handle. Push handle down.

See follow-

ing WARNING.

∆

WARNING

•The park brake has multiple locking positions and should be ﬁrmly locked to prevent vehicle

from rolling.

CHOKE

The choke is located on the seat support panel below and to the left of the driver’s left knee. If the vehicle is

hard to start in cool or cold temperatures, activate choke: Pull the choke handle out to activate. Release the

handle when the engine begins to run smoothly (Figure 7).

Figure 5 Accelerator and Brake Pedals Figure 6 Brake Pedal

Figure 7 Choke Figure 8 Differential Lock

WARNING

Controls and Indicators

2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual Page 15

DIFFERENTIAL LOCK

The differential lock is used to provide better traction at the rear wheels when necessary. Engaging the differ-

ential lock will transfer power to both rear wheels simultaneously (Figure 8).

∆ WARNING

•With the differential lock engaged, vehicle turning functions are greatly reduced. To prevent

loss of vehicle control when differential lock is engaged, do not operate vehicle at speeds

greater than half throttle and use caution when attempting to turn the vehicle.

• Disengage differential lock on paved surfaces.

1. To engage the differential lock, slow the vehicle to no more than half throttle and pull differential lock han-

dle toward the back of the vehicle. The differential lock will engage when power to both rear wheels is

required.

2. To disengage the differential lock, come to a complete stop, then push lever toward front of vehicle.

LOW OIL WARNING LIGHT

The vehicle is equipped with a low oil warning light, located on the instrument panel just to the right of the

steering column and key switch (Figure 9). If the warning light comes on, oil should be checked and added to

the engine as necessary before continuing to use the vehicle. The vehicle should never be driven when the

low oil warning light remains on. If the warning light goes on and off, the vehicle may be driven, but oil should

be added at the ﬁrst opportunity. If the oil level is correct and the warning light stays on, have a trained tech-

nician check the vehicle. See following CAUTION.

CAUTION

•Failure to add oil immediately when the low oil warning light stays on may result in permanent

engine damage.

Figure 9 Low Oil Warning Light

OFF ON START

Seat Latch and Adjustment

Page 16 2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual

FUEL GAUGE/HOUR METER

A fuel gauge and hour meter are housed together at the lower left corner of the instrument panel. The fuel

gauge operates when the key switch is in the ON position, and allows the operator to monitor the fuel level in

the vehicle. The hour meter operates only when the engine is running, and should be used only by trained

technicians to track vehicle usage and determine when periodic service procedures are required. See Peri-

odic Service Schedule on page 28.

HEADLIGHT CONTROL

The headlight control is located on the front instrument panel between the fuel gauge/hour meter and steering

column. Pull the headlight control knob out to turn the headlights on and push the knob in to turn the head-

lights off.

NOTE: Using the headlights for extended periods of time without the engine running, or with the engine

idling, will discharge the battery.

SEAT LATCH AND ADJUSTMENT

•Carryall 272:

The seats are hinged to allow easy access to the engine compartment. A latch at the rear of each seat

bottom keeps the seat from moving on its hinges while the vehicle is in operation. To disengage the

latch, grasp the seat back and pull ﬁrmly in a forward/upward direction until the latch releases. To

engage the seat latch, push down ﬁrmly on the seat back until the seat locks into place. See following

WARNING.

•Carryall 472:

The front seats are hinged to allow easy access to the fuel tank and master cylinder. A latch at the rear

of each seat bottom keeps the seat from moving on its hinges while the vehicle is in operation. To dis-

engage the latch, grasp the seat back and pull ﬁrmly in a forward/upward direction until the latch

releases. To engage the seat latch, push down ﬁrmly on the seat back until the seat locks into place.

The rear bench seat has a removable bottom cushion, which allows for access to the battery and

engine oil check. To remove the bottom cushion, locate the pull tab at the center of the back edge and

pull forward and up. When replacing the cushion, set the plastic strip on the underside front edge

immediately behind the frame front edge, and gently push the back edge of the cushion down into posi-

tion. See following WARNING.

The bucket seats on both vehicles are adjustable and can be moved forward or backward to accommodate the

driver or passenger. To adjust a seat:

1. Remove the seat from the vehicle.

2. Remove the four bolts and washers from the bottom of the seat mounting plate.

3. Align the mounting plate holes with holes in the seat to achieve the desired seat position.

4. Install washers and bolts and tighten to 96 in-lb (10.8 N·m).

5. Reinstall seat in vehicle.

∆ WARNING

• Make sure seat hinges and latch are securely engaged before operating vehicle.

Pre-Operation and Daily Safety Checklist

2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual Page 17

PRE-OPERATION AND DAILY SAFETY CHECKLIST

Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving

your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect

each vehicle to ensure that it is in proper working condition before accepting delivery.

Use the following checklist as a guide to inspect the vehicle. This checklist should be used daily to ensure that

the vehicle is in proper working condition and in conjunction with the Periodic Service Schedule on page 29.

Any problems should be corrected by a Club Car distributor/dealer or a trained technician.

• General: All the parts should be in place and properly installed. Be sure that all nuts, bolts, and screws

are tight. Check hose clamps for tight ﬁt and the starter belt for tightness.

•Safety and information decals: Check to ensure that all safety and information decals are in place.

See pages 4 through 7.

• Tires: Check for proper tire pressure. Visually inspect tires for wear, damage, and proper inﬂation on a

daily basis. See Vehicle Speciﬁcations on page 40.

• Battery: Before using vehicle for the ﬁrst time, check electrolyte to ensure it is at the proper level

(Figure 30, Page 37). Check battery posts. Wires should be tight and free of corrosion and battery

should be fully charged.

• Engine: Check for proper engine oil level. See Engine Oil on page 31.

• Fuel: Check fuel level. See Fueling Instructions on page 35. Check fuel tank, lines, fuel cap, pump,

fuel ﬁlters, and carburetor for fuel leakage on a daily basis.

• Exhaust system: Check for leaks.

• Hydraulic brakes: Check ﬂuid level. See Master Cylinder on page 31.

PERFORMANCE INSPECTION

After you have familiarized yourself with the vehicle controls and have read and understood the driving

instructions, take the vehicle for a test drive.

Use the following checklist as a guide to inspect the vehicle and check daily for proper operation. Any prob-

lems should be corrected by a Club Car distributor/dealer or a trained technician.

• Forward/Reverse shifter: Check for proper operation. See Controls and Indicators on page 12.

• Brakes: Be sure the brakes function properly. When brake pedal is fully pressed under moderate pres-

sure, it should not go more than halfway to the ﬂoorboard, and vehicle should come to a smooth,

straight stop. If the brake pedal goes more than halfway to the ﬂoorboard, or if the vehicle swerves or

fails to stop, have the brake system checked and adjusted as required. When brake pedal is fully

pressed under heavy pressure, pedal should feel ﬁrm and foot pad should be a minimum of 2 inches

(5.1 cm) from ﬂoorboard. Brake adjustment must be maintained so the brake pedal cannot be pressed

to the ﬂoorboard under any circumstance.

•Park brake: Apply moderate pressure to park brake handle. Tension should increase as the handle is

pulled. When latched, the park brake should lock the wheels and hold the vehicle stationary (on an

incline of 20% or less).

•Reverse buzzer: The reverse buzzer should sound as a warning when the Forward/Reverse handle is

in the REVERSE position.

• Steering: The vehicle should be easy to steer and should not have any play in the steering wheel.

• Accelerator: After starting the engine with the key switch and placing the Forward/Reverse handle in

the FORWARD position, the vehicle should accelerate smoothly to full speed as the accelerator pedal

Driving Instructions

Page 18 2005 Carryall 272/ Carryall 472 Gasoline Vehicle Owner’s Manual

is pressed. When the pedal is released it should return to the original position and the engine should

idle. Club Car vehicles operate at reduced speed in reverse.

•Governor: Check maximum vehicle speed. It should operate in forward at 17-19 mph (27-31 km/h) on

a level surface.

•Differential lock cable: With the wheels at rest, pull the differential lock handle toward the rear of the

vehicle (locked position). The differential lock arm at the other end of the cable should move approxi-

mately one-half inch (12.7 mm) downward. When the differential lock handle is placed back into the

unlocked position, the differential lock arm should move approximately one-half inch (12.7 mm)

upward.

• General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle’s ride and perfor-

mance. Have a Club Car dealer or a trained technician investigate anything unusual.

DRIVING INSTRUCTIONS

∆ WARNING

• Only licensed drivers should be allowed to drive the vehicle.

•Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls

and operating procedures.

• No one under the age of 16 years should be allowed to drive the vehicle.

• No more than one person per bucket seat at one time, or two persons per bench seat.

• Do not allow riders in the cargo bed.

• For night use, the vehicle must be equipped with headlights, taillights, and reﬂectors.

• The vehicle is not specially equipped for handicapped persons:

-Be sure all persons can properly operate the vehicle prior to allowing them to drive the

vehicle.

-Be sure all passengers are capable of securing themselves in a vehicle before allowing

them to ride in one.

• Do not shift the Forward/Reverse handle while the vehicle is in motion.

•Stop the vehicle before shifting the Forward/Reverse handle. Engine must be at idle before

shifting the Forward/Reverse handle. Failure to do so may result in injury to inattentive

passengers and (or) damage to the vehicle.

•To help avoid being struck, do not stand in front of or behind the vehicle.

• Do not leave children unattended on vehicle.

• Operate the vehicle from the driver seat only.

•To help prevent falls from the vehicle, remain seated and hold onto seat handles at all times.

Driver should keep both hands on the steering wheel when the vehicle is in motion.

•To help prevent the possibility of serious injury, keep entire body inside vehicle.

•To help prevent vehicle from overturning, drive slowly in turns.

•To help prevent vehicle from overturning, drive slowly straight up and down slopes. Avoid

driving the vehicle on slopes exceeding 20% incline.

•Avoid stopping a loaded vehicle on a hill. If a loaded vehicle must be stopped on a hill, avoid

sudden starts or rolling backwards and stopping suddenly. Failure to heed this warning could

result in the vehicle overturning.

•To help avoid possible injury to inattentive passengers and (or) damage to the vehicle, avoid

sudden starts, sudden stops and abrupt turns.

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Club Car Carryall 272 2005 Owner's manual

Brand: Club Car

Model: Carryall 272 2005

Category: Utility Vehicle

Type: Owner's manual

This manual is also suitable for

Carryall 472 2005

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Club Car Carryall 272 2005 Owner's manual

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Club Car Carryall 272 2005 Owner's manual

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