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TROUBLESHOOTING AND ELECTRICAL SYSTEM

Test Procedures

Page 11-8

2005 FE290 Gasoline Vehicle Maintenance and Service Supplement

11

A

Index of Test Procedures, Continued:

18. Engine Kill Wire

19. Reverse Buzzer Limit Switch

20. Reverse Buzzer

21. Low Oil Warning Light

22. Oil Level Sensor

23. Neutral Lockout Cam

24. Battery Test (Under Load)

25. Fuel Level Sending Unit

26. Fuel Gauge

27. Hour Meter

TEST PROCEDURE 1 – BATTERY

See General Warning, Section 10, Page 10-1.

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DANGER

• Due to the danger of an exploding battery, wear a full face shield and rubber gloves when

working around a battery.

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

service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full
face shield and rubber gloves when working on or near batteries.

• Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or

clothing. Antidotes:

- External: Flush with water. Call a physician immediately.

- Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable

oil. Call a physician immediately.

- Eyes: Flush with water for 15 minutes. Call a physician immediately.

NOTE:

The battery must be properly maintained and fully charged in order to perform the following test
procedures. Battery maintenance procedures, including watering information and allowable min-
eral content, can be found in section 12 of this manual.

See Battery, Section 12, Page 12-28.

1. Place the neutral lockout cam in the SERVICE (MAINTENANCE) position, put the Forward/Reverse han-

dle in the NEUTRAL position, and chock the wheels.

2. Check for loose or corroded battery terminal connections. Remove the negative (–) cable first and clean,

tighten, and replace connections as necessary.

Hydrometer Test

A hydrometer (CCI P/N 1011478) measures the specific gravity. The greater the specific gravity, the greater
the state of charge of the battery. A fully charged battery should read between 1.250 and 1.280 at 80 °F (27
°C). Never add acid to the battery to obtain a higher specific gravity

(Figure 11-3, Page 11-9)

.

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CAUTION

• Do not allow battery acid from battery caps or hydrometer to drip onto the body. Battery acid

will cause permanent damage. Wash off immediately.

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Summary of Contents for 2005 FE290

Page 1: ...Club Car MANUAL NUMBER 102680409 EDITION CODE 1204B0205A FE290 GASOLINE VEHICLES 2005 MAINTENANCE SERVICE SUPPLEMENT ...

Page 2: ......

Page 3: ... and skills attempted service or repairs to the vehicle may render the vehicle unsafe For this reason Club Car advises that all repairs and or service be performed by an authorized Club Car distributor dealer representative or by a Club Car factory trained tech nician It is the policy of Club Car Inc to assist its distributors and dealers in continually updating their service knowl edge and facili...

Page 4: ...ts vehicles and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or proce dures will be forwarded to all Club Car and Carryall distributors dealers and will when applicable appear in future editions of this manual Club Car Inc reserves the right to change specifications and designs at any time without notice and without ...

Page 5: ...eneral Information 11 1 Troubleshooting Guide 11 1 Electrical System 11 7 Test Procedures 11 7 Index of Test Procedures 11 7 SECTION 12 ELECTRICAL COMPONENTS Starter Generator 12 1 Voltage Regulator 12 12 Key Switch 12 13 Solenoid 12 14 Fuse 12 15 Accelerator Pedal Limit Switch 12 15 Kill Limit Switch 12 16 Neutral Lockout Limit Switch 12 17 Neutral Lockout Cam 12 18 Reverse Warning Buzzer 12 19 R...

Page 6: ...se Cover Removal 13 4 Oil Level Sensor 13 5 Crankcase Cover Installation 13 6 Ignition Coil and Flywheel 13 7 Flywheel Installation 13 9 Engine Installation 13 9 Torque Specifications 13 11 Adjustments and Settings 13 11 SECTION 14 FUEL SYSTEM General Information 14 1 Carburetor 14 1 Main Jet Elevation Size Chart 14 2 Changing the Main Jet 14 2 Engine Control Linkage 14 5 General Information 14 5 ...

Page 7: ...l Filter Removal 14 17 Fuel Filter Installation 14 17 Fuel Pump 14 19 General Information 14 19 Fuel Pump Removal 14 19 Fuel Pump Disassembly 14 19 Fuel Pump Cleaning and Inspection 14 20 Fuel Pump Assembly 14 20 Fuel Pump Installation 14 21 Fuel Tank 14 22 General Information 14 22 Fuel Tank Removal 14 22 Fuel Tank Disposal 14 23 Fuel Tank Storage 14 23 Fuel Tank Installation 14 24 Fuel Lines 14 ...

Page 8: ...verse Shifter Cable Adjustment 16 22 SECTION 17 TORQUE CONVERTER General Information 17 1 Troubleshooting 17 1 Drive Belt 17 2 Drive Belt Removal 17 3 Drive Belt Installation 17 3 Drive Clutch 17 4 Drive Clutch Removal 17 4 Drive Clutch Cleaning and Inspection 17 5 Drive Clutch Disassembly 17 7 Inspection of Drive Clutch Parts 17 9 Drive Clutch Assembly 17 10 Drive Clutch Installation 17 12 Driven...

Page 9: ... area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison ý 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 Only trained technicians should service or repair the vehicle Anyone doing even simple repairs or service should have knowledge and e...

Page 10: ...nimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes If wires are removed or replaced make sure wiring and wire harness are properly routed and secu...

Page 11: ...Contact your local authorized Club Car distributor dealer to perform all repairs and semiannual and annual periodic service PERIODIC SERVICE SCHEDULE See General Warning on page 10 1 ý WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual and this supplement NOTE If the vehicle is constantly subjected to heavy use or severe operating conditions...

Page 12: ...d wash dirt from casing check electrolyte level See Battery Section 12 Page 12 28 Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Electrical wiring and connections Check for tightness and damage Brake system Check brake shoes replace if necessary See Section 6 Wheel Brake Assemblies in the ...

Page 13: ...Grade 2 Brake slides Dry Moly Lube CCI P N 1012151 Annually by trained technician only every 100 hours of operation or every 200 rounds for golf cars Check fill unitized transaxle to plug level 27 oz 0 8 liter 80 90 WT API class GL 3 or 80 90 WT AGMA class EP Gear Lube Inspect front wheel bearings Repack as necessary Not applicable for DS Chassis Lube EP NLGI Grade 2 First change 100 hours Additio...

Page 14: ...age 10 6 See following CAUTION ý CAUTION Do not remove dipstick while engine is running 2 Check oil level by fully inserting the dipstick into the oil filler tube and immediately removing it again 3 If the oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full level safe level NOTE Properly recycle or dispose of used oil in accordance with...

Page 15: ... be grounded If the pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation If the vehicle has an all weather enclosure installed the fuel tank must be properly vented as shown Figure 10 4 Page 10 6 To avoid the possibility of fire clean up any spilled fuel before operating the vehicle ý CAUTION To allow for expansion do not fill higher than one inch 2...

Page 16: ...seat bottom 2 The fuel tank is located on the passenger side of the vehicle Figure 10 4 Page 10 6 Remove fuel cap and fill the fuel tank with fresh unleaded fuel only See preceding CAUTION and NOTE 3 Replace fuel cap on tank Make sure cap is tightened securely 4 Replace seat bottom BATTERY For periodic battery maintenance see Battery Section 12 Page 12 28 ...

Page 17: ...de includes the symptom probable cause s and suggested checks The procedures used in making these checks can be found in the referenced sections in this supplement or the appropriate maintenance and ser vice manual TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine does not start easily Spark plug is partially fouled or in poor condition Section 13 FE290 Engine Spark plug wire is damage...

Page 18: ...oting and Electrical System Test Procedures 13 14 and 15 Ignition coil or RPM limiter failed Section 11 Troubleshooting and Electrical System Test Procedures 13 14 and 15 Engine flooded with fuel as result of excess choking Section 3 General Information in the appropriate maintenance and service manual See Choke Kill circuit grounded Section 11 Troubleshooting and Electrical System Test Procedures...

Page 19: ... System Rings are heavily worn low cylinder pressure Section 13 FE290 Engine Carburetor floods Inlet valve or seat is leaking dirty worn or damaged Section 14 Fuel System Float is damaged and filled with fuel Section 14 Fuel System Float needle valve not functioning properly Section 14 Fuel System Carburetor vent is clogged Section 14 Fuel System Starter fails to operate Neutral lockout cam is in ...

Page 20: ...kage is binding or is out of adjustment Section 16 Unitized Transaxle Idle RPM setting is set too high Section 14 Fuel System Insufficient low level of lubricant or wrong type of lubricant in transmission Section 16 Unitized Transaxle Internal gears are damaged or worn Section 16 Unitized Transaxle Synchronizer rings are worn damaged or jammed Section 16 Unitized Transaxle Excessive vehicle vibrat...

Page 21: ...isconnected Kill Wire on page 11 19 Accelerator pedal linkage out of adjustment causing engine kill limit switch to not operate Section 14 Fuel System Key switch failure Section 11 Troubleshooting and Electrical System Test Procedures 4 5 Carburetor is too lean check main and pilot jet sizes Section 14 Fuel System Carburetor throttle stop screw out of adjustment Section 14 Fuel System TROUBLESHOOT...

Page 22: ...ROUND Dashed lines indicate wiring present on Turf 1 Carryall 1 and Villager 4 vehicles only FRAME GROUND OIL LEVEL SENSOR ENGINE STARTER GENERATOR RPM LIMITER OIL LIGHT REVERSE BUZZER FUSE BLOCK VOLTAGE REGULATOR SOLENOID FUEL TANK FUEL GAUGE KEY SWITCH FORWARD REVERSE ASSEMBLY REVERSE BUZZER LIMIT SWITCH FRAME GROUND ORANGE B LACK WHITE WHITE WHITE BLACK BRAIDEDGROUNDWIRE BRAIDEDGROUNDWIRE YELLO...

Page 23: ... Hour Meter Circuit Utility vehicles Turf 1 Carryall 1 and Villager 4 have a combination fuel gauge hour meter Recognizing and understanding the function of each of these circuits will help to quickly isolate the source of an electrical problem Use the appropriate test procedure to correct the electrical problem See Test Proce dures on page 11 7 TEST PROCEDURES INDEX OF TEST PROCEDURES 1 Battery 2...

Page 24: ...es of milk or water Follow with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately NOTE The battery must be properly maintained and fully charged in order to perform the following test procedures Battery maintenance procedures including watering information and allowable min eral content can be found in section 12 of thi...

Page 25: ...so that the float rides free of the bottom but does not strike the bottom of the rubber bulb Remove the hydrometer from the cell and release the pressure from the bulb 6 Hold the hydrometer vertically ensuring that the float is not contacting the sides of the glass tube Hold the hydrometer at eye level and read the scale at the level of electrolyte Figure 11 3 Page 11 9 7 Record the reading 8 Retu...

Page 26: ...r than 1 225 the problem is not with the battery If the battery does not reach 12 4 volts or if the specific gravity of a cell is still less than 1 225 after charging replace the battery See following NOTE NOTE A fully charged battery that is in good condition should have a specific gravity of at least 1 225 in all cells and the difference in the specific gravity of any two cells should be less th...

Page 27: ...ailure Replace the fuse with a properly rated new one TEST PROCEDURE 3 GROUND CABLES See General Warning Section 10 Page 10 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Check the starter generator ground cable 2 1 Set the multimeter to 200 ohms Place the red probe on the A2 terminal of the starter generator ...

Page 28: ... Page 11 12 The reading should be continuity If the reading is incorrect ensure that terminal connections are clean and tight If the connections are good and the reading is incorrect repair or replace the cable TEST PROCEDURE 4 KEY SWITCH STARTER CIRCUIT See General Warning Section 10 Page 10 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General W...

Page 29: ... position the Forward Reverse handle in NEUTRAL and the accelerator pedal in the UP position the reading should be no continuity With the accelerator pedal pressed the reading should be continuity If readings are incorrect replace the switch TEST PROCEDURE 6 SOLENOID See General Warning Section 10 Page 10 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting...

Page 30: ...her reading is incorrect replace the solenoid 9 With the Forward Reverse handle still in NEUTRAL and the neutral lockout cam in the SERVICE MAIN TENANCE position set the multimeter to 20 volts DC and place the red probe on the large post that does not have wires connected to it Place the black probe on the vehicle frame Turn key switch to the ON position press accelerator pedal and listen for sole...

Page 31: ...the lobes on the cam are pressing the neutral lockout limit switch as the Forward Reverse handle is being shifted The limit switch should make an audible click as it is pressed If it does not check for wear on the cam lobes Be sure the cam snaps fully back into place If the cam lobes still do not activate the limit switch replace the cam TEST PROCEDURE 8 STARTER GENERATOR STARTER FUNCTION See Gene...

Page 32: ...hms place the red probe on the A1 terminal and the black probe on the A2 terminal The reading should be continuity If the reading is incorrect a possible open or poor contact in a brush assembly and or open armature windings may be the cause The starter generator will need to be removed from the vehicle and disassembled by a qualified technician See Starter Generator Removal Section 12 Page 12 1 6...

Page 33: ...EUTRAL position and chock the wheels 2 Ensure that the wires are connected correctly and are tight If they are not rewire or tighten as necessary 3 Disconnect the yellow wire from the DF terminal on the starter generator Cover the connector on the yel low wire to make sure the yellow wire will not short to ground Then using a jumper wire ground the DF terminal to the A2 terminal Figure 11 13 Page ...

Page 34: ...re 5 Turn the key switch to OFF killing the engine Using a multimeter set to 20 volts DC place the red probe on the large post of the solenoid with the red wire from the voltage regulator attached Place the black probe on the negative battery post Figure 11 14 Page 11 18 Turn the key switch to the ON position Press the accelerator to start the engine and run it at full governed speed If the readin...

Page 35: ...m in the SERVICE MAINTENANCE position turn the key switch to the ON position In a well ventilated area press the accelerator to start the engine 4 If the engine begins to run test the engine kill circuit for a shorted wire or other failed components in the engine kill circuit See Test Procedure 17 Key Switch Engine Kill Circuit on page 11 27 See fol lowing WARNING ý WARNING When the white black en...

Page 36: ...und 2 2 Turn the key switch to the ON position and crank the engine by pressing the accelerator There should be a strong blue spark between the probes of the spark gap tester If there is no spark or if the spark is a faint yellow or red color test components of the ignition circuit See Test Procedure 15 Ignition Coil on page 11 21 3 If the spark gap tester tool indicates a strong blue spark it is ...

Page 37: ...y in the vehicle and on the bench but fails to operate reliably replace the coil with a known good coil and operate the engine for several minutes to ensure that the coil functions at normal operating temperature If the new coil functions properly keep the new coil in the circuit Test Procedure 15A Ignition coil In Vehicle Test 1 Disconnect the battery cables as instructed See WARNING To avoid uni...

Page 38: ...plug and place the black probe on a clean unpainted surface of the engine or frame Figure 11 19 Page 11 22 3 2 If the resistance is between 6 0 11 0 k ohms the secondary coil and spark plug cap are within acceptable limits proceed to step 6 on page 11 24 If the resistance is not between 6 0 11 0 k ohms the spark plug cap and secondary coil must be tested independently from each other Figure 11 18 ...

Page 39: ...e three or four revolutions while gently pulling it off the wire Figure 11 21 Page 11 23 4 3 Using a multimeter set to 200 ohms place the red probe of the multimeter into the end of the spark plug cap that normally connects to the spark plug and place the black probe into the end of the cap with the internal screw Figure 11 22 Page 11 23 If there is no continuity the cap has failed and must be rep...

Page 40: ...oil Bench Test 1 Remove the coil from the engine See Ignition Coil Removal Section 12 Page 12 24 2 Using a multimeter set to 200 ohms measure the primary coil resistance 2 1 Place the black probe of the meter on the terminal on the ignition coil 1 and place the red probe on the core 2 Figure 11 24 Page 11 25 2 2 If the resistance is not between 0 6k 1 7k ohms replace the ignition coil 3 Using a mu...

Page 41: ...ceed to the next step with the spark plug cap still removed 5 Test the secondary coil separately from the spark plug cap 5 1 Using a multimeter set to 20k ohms place the red probe of the multimeter into the end of the spark plug wire and place the black probe on the core 2 Figure 11 26 Page 11 26 If the resistance is between 6 0k 11 0k ohms the secondary coil is within acceptable limits If the res...

Page 42: ...ion 10 Page 10 1 2 Check for proper wiring and tight connections 3 Disconnect wires from the limit switch and test the limit switch for continuity Place the red probe of the multimeter on the common COM terminal white black wire of the limit switch Place the black probe on the normally open NO terminal black wire of the limit switch Without the lever pressed the reading should be no continuity Pre...

Page 43: ...DURE 18 ENGINE KILL WIRE See General Warning Section 10 Page 10 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Disconnect white black wire bullet connector located at the engine RPM limiter Figure 11 15 Page 11 19 3 Connect red probe of multimeter to the male bullet terminal on the white black wire and connect...

Page 44: ... General Warning Section 10 Page 10 1 2 Remove the center dash assembly See Key Switch Removal Section 12 Page 12 13 3 Check for proper wiring and tight connections Using a multimeter individually check for continuity through each wire that connects to the reverse buzzer If the buzzer will not function when properly wired replace the buzzer See Reverse Warning Buzzer Removal Section 12 Page 12 19 ...

Page 45: ...n the cam lobes Be sure the cam has snapped fully back into place If the cam lobes still do not activate the limit switch replace the cam TEST PROCEDURE 24 BATTERY TEST UNDER LOAD See General Warning Section 10 Page 10 1 NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout cam in the SERVICE MAINTENANCE position put the Forward Reverse han dle in the NEU...

Page 46: ...gs in ohms should be obtained depending on the position of the float inside the fuel tank The resistance reading will vary according to the exact position of the float The chart below may be used as a guideline to determine if the fuel level sending unit is operating correctly Make sure the float is at the surface of the fuel in the tank 5 If the readings are within the specifications listed above...

Page 47: ...ace the black probe on the negative post of the battery Record the voltage reading 5 Set a multimeter to 20 volts DC and place the red probe of the multimeter on the 2 terminal of the fuel gauge hour meter with the blue wire Place the black probe on the 3 terminal of the fuel gauge hour meter with the black wire Figure 11 30 Page 11 31 6 Connect the battery cables positive cable first and tighten ...

Page 48: ...osition put the Forward Reverse han dle in the NEUTRAL position and chock the wheels 2 Turn the key switch to ON and record the current hour meter reading 3 Press and hold the accelerator pedal to run the engine for at least six minutes the meter records in six minute increments See following DANGER ý DANGER Do not operate vehicle in an enclosed area without proper ventilation The engine produces ...

Page 49: ...dure 10 Starter Generator Generator Function on page 11 17 Starter Generator Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove the access panel on a DS Golf Car or Villager 4 vehicle lift the cargo bed on a Turf or Carryall vehicle 3 Mark and disconnect the wires from the starter generator 1 Loosen t...

Page 50: ...ed or installed could damage the brushes Lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 12 6 Page 12 4 2 Remove brush covers 29 and 30 screws 25 and lock washers 26 brush springs 28 and brushes 27...

Page 51: ... Using a spring scale test brush spring tension If any spring has a tension less than 24 ounces 6 67 N replace all four springs Figure 12 5 Page 12 3 See following CAUTION ý CAUTION When checking brush spring tension do not push springs beyond the point they would normally be if there were new brushes installed Exerting excessive force or pushing brush springs beyond their normal maximum extension...

Page 52: ...down into the holders Position springs into the notches in the brushes Install the brush cover 30 that has the drain hole in it next to the A2 terminal Install the remaining three brush cov ers 29 in the openings in the commutator end cover 23 Figure 12 3 Page 12 2 Disassembly of the Starter Generator to Service the Armature Commutator 1 If the brushes are not removed contact between the brushes a...

Page 53: ... Page 12 5 2 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearings and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing Bear ings should be replaced if there is extensive wear or pitting on the balls or on the rolling surfaces Do not remove the bearings unless they are to be replaced Figure 12 7 Armature...

Page 54: ... screws from the housing Remove the four pole pieces from inside the housing Remove the field coils from the inside of the housing Figure 12 10 Page 12 7 See following NOTE NOTE Do not remove the insulators or the field coils unless an electrical test indicates that it is necessary Figure 12 10 Page 12 7 See Test Procedure 8 Section 11 Page 11 15 Visual Inspection of Armature Obvious defects can b...

Page 55: ...heck for loose or raised commutator bars Slight roughness of the commutator can be polished away with 400 grit or finer sandpaper See following CAUTION ý CAUTION Do not use emery cloth on the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes 2 Using a micrometer measure the outside diameter at two points...

Page 56: ...eter set on 200 ohms place the positive probe on the commutator bars and the neg ative probe on the armature core The reading should be no continuity If the reading is incorrect replace the armature and the two bearings Figure 12 12 Page 12 8 Figure 12 11 Inspect Commutator Figure 12 12 Armature Ground Test A2 A B B A1 1 1 1 A1 Measure each position in two places 90 apart COMMUTATOR ARMATURE ARMAT...

Page 57: ... washer lock washer and nut onto each threaded terminal on the outside of the housing Tighten nuts to 47 5 in lb 5 4 N m Figure 12 10 Page 12 7 ý CAUTION Route the field terminal wires so that they will not contact the armature 3 Install the four pole pieces into the housing Use the four screws to secure pole pieces to the inside of the housing to retain the field wires Tighten screws to 9 ft lb 1...

Page 58: ... the shaft Insert the shaft key 34 into the shaft Install the belt pulley 39 onto the shaft and install the lock washer 40 and M14 nut 41 Tighten the nut to 28 ft lb 38 0 N m Figure 12 7 Page 12 5 Starter Generator Installation 1 Install the green wire from the F1 terminal to the A1 terminal on the starter generator Figure 12 1 Page 12 1 Install a flat washer lock washer and nut onto each terminal...

Page 59: ...round the pulley 10 on the end of the starter generator 5 Position a pry bar 13 between the top of the starter generator mounting bracket 2 and the underside of the starter generator by passing the pry bar under the exhaust header 6 While holding the pry bar measure the belt tension using a Krikit gauge 1 available at NAPA Auto Parts stores or equivalent Proper tension for a new starter generator ...

Page 60: ...gure 12 15 Page 12 12 5 Remove the voltage regulator mounting screw 4 and remove the voltage regulator 5 Voltage Regulator Installation 1 Position the voltage regulator 5 in the electrical component box and install the mounting screw 4 Figure 12 15 Page 12 12 Tighten screw to 23 in lb 2 6 N m 2 Connect voltage regulator red wire 1 to the solenoid and connect the yellow wire 2 bullet connector 3 Co...

Page 61: ...g in General Warning Section 10 Page 10 1 2 Remove the center dash panel 2 1 Remove the plastic cap 1 covering the mounting screw 2 on each side of the center dash panel Figure 12 16 Page 12 13 2 2 Loosen but do not remove the screw 2 on each side of the center dash panel 3 2 3 Insert screwdriver at the top center of the dash between dash and cowl brace Gently pry center dash out slightly from und...

Page 62: ...305 to minimize corrosion SOLENOID See General Warning Section 10 Page 10 1 Testing the Solenoid See Test Procedure 6 Section 11 Page 11 13 Solenoid Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove electrical component box cover Figure 12 26 Page 12 25 3 Disconnect all the wires from the solenoid 4 ...

Page 63: ...termine the cause of the failure and make necessary repairs before installing a new fuse Use the appropriately rated fuse if a fuse with a higher amp rating is used damage to the vehicle electrical system may occur 2 Install the snap on electrical box cover by pressing down firmly on all corners and install the screw tight ening to 18 in lb 2 0 N m 3 Connect battery cables positive cable first and...

Page 64: ...al limit switch Figure 12 17 Page 12 16 3 Press the accelerator pedal to make sure that the switch is being actuated when the pedal is released 4 Install the snap on electrical box cover by pressing down firmly on all corners and install the screw tight ening to 18 in lb 2 0 N m 5 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 N m See Figure 10 1 Section 10 Page 10...

Page 65: ...ivated when the pedal is released 5 Install snap on electrical component box cover 1 Be sure to press down firmly all corners Install screw 20 and tighten to 18 in lb 2 N m 6 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 N m See Figure 10 1 Section 10 Page 10 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion NEUTRAL LOCKO...

Page 66: ...e everyone is clear of the vehicle Turn the key switch ON The engine should not crank when pressing the accelerator If the engine does crank turn the key switch OFF and re adjust the shift linkage 5 Test drive the vehicle in both forward and reverse for proper operation NEUTRAL LOCKOUT CAM See General Warning Section 10 Page 10 1 If the cam lobes have worn to the point where they will no longer ac...

Page 67: ...10 Page 10 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion REVERSE WARNING BUZZER See General Warning Section 10 Page 10 1 Testing the Reverse Warning Buzzer See Test Procedure 20 Section 11 Page 11 28 Reverse Warning Buzzer Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 ...

Page 68: ...ting in General Warning Section 10 Page 10 1 2 Disconnect the wires from the reverse buzzer limit switch 4 located on the back of the Forward Reverse assembly Figure 12 18 Page 12 18 3 Remove the nuts 2 and washers 6 from the neutral lockout limit switch 5 and slide the neutral lockout limit switch off of the screws Do not disconnect the wires 4 Remove the spacers 9 from the reverse buzzer limit s...

Page 69: ... wires from the low oil warning light 11 Figure 12 21 Page 12 21 Do not allow wires to touch 4 Press the retaining tabs and remove the low oil warning light from the center dash Low Oil Warning Light Installation 1 Push a new unit into hole in dash until plastic tabs engage dash Figure 12 21 Page 12 21 2 Connect yellow wire from the key switch and yellow wire from the oil level sensor to the low o...

Page 70: ...e engine is running When the hour meter is recording the hourglass icon at the left of the field blinks slowly Fuel Gauge Hour Meter Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove the center dash panel See Key Switch Removal on page 12 13 3 Disconnect the wires from the fuel gauge hour meter Figur...

Page 71: ...The fuel level sending unit is an integral part of the fuel tank and should never be removed Thoroughly test the fuel level sending unit before replacing the fuel tank Testing the Fuel Level Sending Unit See Test Procedure 25 Section 11 Page 11 30 RPM LIMITER See General Warning Section 10 Page 10 1 Testing the RPM Limiter See Test Procedure 14 Section 11 Page 11 20 RPM Limiter Removal 1 Disconnec...

Page 72: ...and Test Procedure 15 Page 11 21 Ignition Coil Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Disconnect spark plug wire from the spark plug See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 3 Remove the governor guard 1 Figure 12 24 Page 12 25 4 Remove the muffler See...

Page 73: ...remaining four bolts 10 attaching the fan housing as shown Figure 12 26 Page 12 25 then while opening the housing detach the spark plug wire grommet 4 from the housing Figure 12 28 Page 12 26 9 Disconnect the 18 gauge black wire 12 from the spade terminal on the ignition coil 11 and remove the coil by removing two bolts 10 Figure 12 27 Page 12 25 Figure 12 24 Governor Guard Removal Figure 12 25 St...

Page 74: ...ark plug wire with water to make gasket removal and installation easier 4 Remove the grommet 4 from the old spark plug wire Clean the grommet and place it on the new spark plug wire 5 5 Install the protector tube onto the new wire 6 Slide the gasket onto the end of the new spark plug wire 7 Install the cap on the new coil spark plug wire by rotating it clockwise three or four revolutions while app...

Page 75: ...re the wire harness to the stiffener with a wire tie Place the wire tie through the lower hole at the back of the stiffener Figure 12 25 Page 12 25 ý CAUTION Make sure wire harness is routed and secured away from the muffler 18 Install the muffler See Muffler Installation Section 15 Page 15 1 19 Place the governor guard 1 onto the throttle bracket and the 2 ended bolt Install the two Torx screws 4...

Page 76: ... amp rating at 32 F 0 C 500 CCA at 0 F 17 8 C and a reserve capacity of at least 105 minutes The group 70 clas sification indicates battery size 8 1 4 inches W x 6 1 2 inches D x 7 1 4 inches H 21 0 cm W x 16 5cm D x 18 4 cm H It is important to use the proper size to ensure that the battery clamp will fit correctly Testing the Battery See Test Procedure 1 Section 11 Page 11 8 Preventive Maintenan...

Page 77: ...he plate to become permanently inactive Check the water level more frequently in hot weather or when the battery becomes old Vibration Damage The battery hold down clamp should always be tight enough to keep the battery from bouncing Battery life may be severely shortened if the clamp is too loose Excessive vibration shortens the life of the battery It may also cause acid to leak out of the vent c...

Page 78: ... lifting carrying or installing battery The battery acid could cause severe personal injury when accidentally coming in contact with the skin or eyes and could damage clothing Charging the Battery See General Warning Section 10 Page 10 1 Also see DANGER on page 12 28 1 Charge the battery using an automotive type 12 volt battery charger Follow all warnings and procedures supplied by the battery cha...

Page 79: ...014305 to minimize corrosion Battery Storage See General Warning Section 10 Page 10 1 See also DANGER on page 12 28 1 Keep the battery clean and free of corrosion See Preventive Maintenance on page 12 28 2 The battery cables should be disconnected from the battery so the battery can be connected to the charger The battery can be left in the vehicle 3 Fully charge the battery prior to storage 4 Sto...

Page 80: ...ehicle is equipped with a starter generator The generator is not designed to charge a dead battery If the vehicle battery has become discharged it must be charged using a properly rated automotive type charger ý WARNING Do not jump start a dead battery using another battery and jumper cables GROUND CABLES See General Warning Section 10 Page 10 1 Testing the Ground Cables See Test Procedure 3 Secti...

Page 81: ...ormation for removing and replacing the FE290 engine For complete instruction on engine disassembly repair rebuilding and reassembly see the Engines and Drivetrain Components Repair and Rebuild Manual CCI P N 102396501 BEFORE SERVICING Carefully read the applicable information and instructions before beginning engine service Diagrams DAN GER WARNING CAUTION and NOTE statements and detailed descrip...

Page 82: ...bridging between the electrode and base The electrode should not be eroded Black color excessive carbon and or a wet plug indicates that the fuel is too rich White burned or melted elec trodes indicate the fuel is too lean or pre igniting Oily deposits on the plug electrode are an indication of worn rings valve guides cylinder wall etc Also examine the spark plug wire Remove rubber boot and inspec...

Page 83: ...ATION Test cylinder compression using a standard compression tester Low compression would normally indicate a problem in the cylinder assembly such as defective rings gaskets etc At a cranking speed of 550 600 rpm the compression should be 156 185 psi See Engines and Drivetrain Components Repair and Rebuild Manual for inspection and repair BREATHER VALVE REED VALVE General Information The function...

Page 84: ...ms 1 2 5 and 6 Figure 13 4 Page 13 5 6 Lift engine from the mounting plate 7 Remove crankcase oil drain plug and filler tube Tip the engine slightly to allow all of the oil to drain from the crankcase Dispose of engine oil properly CRANKCASE COVER REMOVAL 1 Remove yellow jumper wire 11 from cord connector 12 Figure 13 2 Page 13 4 2 Remove nuts and clamps at two ended bolts 1 and 2 Figure 13 3 Page...

Page 85: ...kcase Cover Removal on page 13 4 2 Disconnect the oil level sensor wire 2 from the cord connection 1 Figure 13 5 Page 13 6 3 Remove the screw 3 from the wire clamp 4 4 Remove the two mounting screws from the inside of the crankcase cover and remove the oil level sensor and bracket 5 If necessary remove the three screws 7 that hold the sensor to the bracket 5 Figure 13 4 Engine Mounting Plate TYPIC...

Page 86: ...stall and tighten crankcase cover bolts as instructed Failure to do so could cause the cover to become warped 1 Clean the gasket surfaces on the crankcase cover to fit a new gasket during installation and inspect the oil seal for wear and damage 2 Install crankcase cover Using HANDS ONLY seat cover completely against the crankcase If the cover will not seat the camshaft is not installed correctly ...

Page 87: ... three screws and remove the remaining four screws attaching the flywheel housing as shown then remove the housing Figure 13 7 Page 13 7 2 Disconnect the ignition coil 1 from its primary lead wire at the connector 2 Remove the two bolts 3 and take out the ignition coil Figure 13 8 Page 13 7 Figure 13 6 Crankcase Cover Installation Figure 13 7 Flywheel Housing Figure 13 8 Ignition Coil 3 5 8 1 6 4 ...

Page 88: ...t place screwdriver or pry bar in the fan blades 4 Remove the flywheel with a puller CCI P N 1016627 5 Remove the flywheel key from its groove Flywheel Installation See Flywheel Installation on page 13 9 Ignition Coil Inspection and Repair See Test Procedure 15 Section 11 Page 11 21 Ignition Coil Installation 1 Installation is the reverse of removal 2 While tightening the two bolts 3 use a bronze ...

Page 89: ...e fan blades Use a strap wrench to hold flywheel Do not place screwdriver or pry bar between fan blades 3 Install the fan housing and tighten the screws to 90 in lbs 10 N m ENGINE INSTALLATION See General Warning Section 10 Page 10 1 1 Place engine onto engine mounting plate and tighten the mounting hardware 1 2 and 5 to 13 ft lb 17 7 N m Tighten nuts 6 to 17 ft lb 23 1 N m Figure 13 4 Page 13 5 2...

Page 90: ...an with cloth Figure 13 12 Page 13 10 9 2 Reinsert dip stick until fully seated 9 3 Oil must be in the SAFE LEVEL range ý CAUTION Do not overfill with oil 10 Install a new or cleaned spark plug gapped to 0 027 0 031 inch 0 686 0 787 mm and connect plug wire to plug 11 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 N m See Figure 10 1 Section 10 Page 10 3 Coat termi...

Page 91: ...bracket to block bolts M8 200 in lb 23 N m Oil drain plug M14 20 ft lb 27 1 N m Fan housing screws M6 90 in lb 10 N m Fan shroud screws M6 25 in lb 2 8 N m Bolts marked with 4 when used with nuts M8 M6 M5 130 in lb 15 N m 50 in lb 5 9 N m 30 in lb 3 4 N m ITEM LIMITS Spark plug gap standard 0 027 to 0 031 in 0 69 to 0 79 mm Ignition coil air gap standard 0 012 in 0 304 mm Compression pressure min ...

Page 92: ...13 13 A ...

Page 93: ... Section 13 Page 13 2 Air filter element See Air Filter on page 14 16 Fuel filters See Fuel Filters on page 14 16 Choke and air intake system for restriction of air flow See Choke and Air Intake System on page 14 12 Fuel pump See Fuel Pump on page 14 19 Fuel lines from fuel tank to filter to pump to filter to carburetor See Fuel Lines on page 14 25 Exhaust system for restrictions See Section 15 Ex...

Page 94: ... 14 1 Page 14 3 When removing the carburetor body the throttle return spring 11 must be disconnected Note its proper orientation so that it can be replaced in the same orientation The carburetor must be kept upright during removal 2 Position the carburetor with the drain screw 11 over a catch basin Figure 14 2 Page 14 4 3 Turn the carburetor bowl drain screw counterclockwise two or three turns and...

Page 95: ...in the carburetor body when the fuel bowl is removed Figure 14 2 Page 14 4 During normal operation the fuel bowl retains the float pivot pin 6 Make sure that the float pivot pin does not fall out of the carburetor body after the fuel bowl is removed Figure 14 1 Carburetor Installation 1 2 3 4 13 15 12 30 21 26 10 21 8 7 5 11 19 TYPICAL 2 PLACES 18 22 23 14 16 17 ...

Page 96: ...t part 8 Install the new main jet and tighten it to 12 in lb 1 4 N m See following CAUTION and NOTE ý CAUTION Do not remove the valve spring assembly from the float assembly Doing so will damage the spring Figure 14 2 Changing the Main Jet Drain carburetor over a catch basin by turning bowl drain screw 11 counterclockwise 2 to 3 turns STEPS 2 AND 3 STEP 4 A Mark carburetor and corresponding positi...

Page 97: ...en to the throttle bracket 4 just before positioning the carburetor and securing it to the engine Figure 14 1 Page 14 3 12 2 Install the intake pipe gasket 16 check for proper orientation and intake pipe 17 12 3 Install the carburetor retaining nuts 19 and tighten them to 50 in lb 5 7 N m 13 Connect fuel supply line 26 and tighten screw clamp to 9 in lb 1 0 N m if equipped Figure 14 1 Page 14 3 14...

Page 98: ...lug Accelerator Rod Removal 1 Raise the front of the vehicle Place chocks at the rear wheels and lift the front of the vehicle with a chain hoist or floor jack Place jack stands under the round frame cross tube to support the vehicle See pre ceding DANGER See also WARNING Lift only one end of the vehicle in General Warning Section 10 Page 10 1 2 Remove the accelerator rod by disconnecting the ball...

Page 99: ...length of the accelerator rod so the indicated cam edge is parallel with the edge of the electrical component box as shown Figure 14 5 Page 14 7 ý CAUTION Be sure that approximately an equal number of threads are exposed at each end of the accelerator rod 6 Install the accelerator rod on the bell crank ball joint on the electrical component box Figure 14 6 Page 14 8 See following CAUTION ý CAUTION...

Page 100: ...les positive cable first and tighten hardware to 12 ft lb 16 N m See Figure 10 1 Section 10 Page 10 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion GOVERNOR CABLE Governor Cable Removal 1 Turn the key switch to the OFF position and remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect the battery cable...

Page 101: ... box screw and cover and loosen the accelerator cable housing retaining nuts Figure 14 4 Page 14 7 or Figure 14 5 Page 14 7 2 Disconnect the accelerator cable 1 from cam 17 in the electrical box Figure 14 7 Page 14 10 3 Disconnect the spring 16 from the engine governor arm 4 Remove the accelerator cable from the accelerator cable bracket 5 Remove the cable assembly from the vehicle Accelerator Cab...

Page 102: ...ne Control Linkage Page 14 10 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement 14 A Figure 14 7 Governor and Accelerator Cables 6 14 11 12 10 15 17 13 1 2 2 6 16 5 3 4 TYPICAL 2 PLACES CARBURETOR THROTTLE ...

Page 103: ...arbon monoxide which is an odorless deadly poison 1 If the governor is adjusted proceed to step 2 otherwise adjust the governor See Governor Cable Installation and Adjustment on page 14 9 2 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 N m See Figure 10 1 Section 10 Page 10 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosio...

Page 104: ... the carburetor and an air duct that provides the engine with air from outside the engine compart ment Clean cool air is drawn through the choke assembly and into the air cleaner intake This feature increases engine horsepower and extends air filter life The choke system aids in starting the engine in cold weather When starting a cold engine the spring loaded choke cover is pushed in by hand This ...

Page 105: ...be sure the intake seal 14 is seated correctly Figure 14 10 Page 14 14 The seal fits tightly onto the bottom side of the air box If seal is not in place moisture will enter the air intake system 2 Place the air box assembly into vehicle and install three flat washers 22 and screws 23 from underside of air box mounting plate into air box Figure 14 10 Page 14 14 Tighten to 33 in lb 3 7 N m 3 Place h...

Page 106: ...asoline Vehicle Maintenance and Service Supplement 14 A Figure 14 10 Air Intake and Choke Assemblies TYPICAL 2 PLACES 1 2 3 TYPICAL 3 PLACES 17 20 21 19 22 15 15 16 5 17 18 6 11 4 12 13 10 9 8 14 TYPICAL 3 PLACES 23 24 7 25 26 27 27 REFERENCE CARBURETOR 26 31 27 30 ...

Page 107: ... that may still be adhered to the air duct shield or frame 3 2 Place a new strip of double sided tape on the air duct shield Do not remove backing from exposed side of tape 3 3 Secure the bottom of the air duct shield to the floorboard with a rivet 31 3 4 Remove the backing from the tape and secure top of air duct shield to frame 4 Install air box See Air Box Installation on page 14 13 5 Install s...

Page 108: ...aught between lid and air box Close the lid 6 Fasten wire latches 3 Make sure latches securely engage the bottom half of the box See following CAUTION ý CAUTION Engine damage will occur if the air box cover is not properly secured If air box is extremely dirty remove air box from vehicle and clean thoroughly Use only Club Car replacement air filters CCI P N 1015426 The use of other air filters cou...

Page 109: ...ter and plug the fuel lines 3 and 4 Figure 14 11 Page 14 18 FUEL FILTER INSTALLATION ý CAUTION Fuel filters are marked with flow direction arrows Make sure that filters are installed with arrows pointing in the direction of fuel flow from tank to carburetor 1 Install the primary fuel filter 17 in the fuel line Use new clamps 16 Figure 14 11 Page 14 18 2 Install the secondary fuel filter 22 in the ...

Page 110: ...0 in 33 0 cm 2 5 in 6 4 cm 22 0 in 55 9 cm 17 0 in 43 2 cm 17 0 in 43 2 cm LENGTH DS Villager 4 Total 48 5 in 123 2 cm 39 0 in 99 1 cm Solid Color Clear 2 0 in 5 1 cm 6 0 in 15 2 cm 17 0 in 33 0 cm 2 5 in 6 4 cm 22 0 in 55 9 cm 17 0 in 43 2 cm 17 0 in 43 2 cm LENGTH Turf 1 CA 1 44 5 in 113 0 cm 39 0 in 99 1 cm 16 15 14 19 18 13 6 5 12 11 NO 7 IMPULSE LINE NO 1 FUEL LINE NO 5 CARBURETOR AIR VENT TU...

Page 111: ...nk to the closed OFF position Figure 14 16 Page 14 26 4 Remove hardware attaching the fuel pump 24 and lift the fuel pump out of the engine compartment Figure 14 11 Page 14 18 5 Remove the clamp and impulse line 7 from fuel pump 6 Disconnect the fuel lines 2 and 3 from the pump and plug them to prevent fuel leakage See following WARNING ý WARNING Carefully drain any fuel remaining in the pump into...

Page 112: ... 32 and 33 and all gaskets and diaphragms for damage Figure 14 12 Page 14 20 3 If a valve assembly is damaged the rubber retaining plug 33 and valve assembly must be replaced FUEL PUMP ASSEMBLY 1 Install the fuel gasket 35 and diaphragm 34 on the back cover 36 Figure 14 12 Page 14 20 2 Install the valve assembly in the pumping chamber 30 See following CAUTION ý CAUTION If the valve assembly is not...

Page 113: ...condary fuel filter Figure 14 11 Page 14 18 3 Connect the impulse line 7 to the bottom nipple on the fuel pump Use a new clamp 16 4 Install the fuel pump For DS or Villager 4 vehicles install the fuel pump on the frame and tighten the mounting bolts 26 and lock nuts 25 to 60 in lb 6 8 N m Figure 14 11 Page 14 18 For Carryall vehicles install the fuel pump onto the mounting bracket with two thread ...

Page 114: ...ning in the car buretor fuel pump and fuel lines is used up and the engine stalls Figure 14 16 Page 14 26 4 Turn the key switch to the OFF position and remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 5 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 6 Return the neutral lo...

Page 115: ...d or kept as a spare 2 In a well ventilated area flush the fuel tank with water to remove any remaining fuel 3 In a well ventilated area set the tank upside down so that the water can drain out of it To make sure that the tank dries completely allow the tank to sit for 24 hours See following CAUTION ý CAUTION Dispose of wastewater and fuel tank in accordance with local state and federal laws and o...

Page 116: ... 23 8 Add fuel to the tank 9 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 N m See Figure 10 1 Section 10 Page 10 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 10 Ensure that the wheels are chocked the Forward Reverse handle is in the NEUTRAL position and that the neutral lockout cam is in the SERVICE MAINTENANCE posi...

Page 117: ... has an arrow indicating fuel flow direction Figure 14 11 Page 14 18 Fuel line no 2 runs directly from the primary fuel filter to the fuel inlet of the fuel pump Fuel line no 3 runs directly from the fuel outlet of the fuel pump to the secondary fuel filter Figure 14 11 Page 14 18 The secondary fuel filter has an arrow indicating fuel flow direction and is identical to the primary fuel filter Fuel...

Page 118: ...ce procedures Fully Open Position The valve s open position differs from standard valve configurations For the valve to be fully open it must be turned approximately 120 from the closed OFF position until it cannot be turned any further Figure 14 17 Page 14 26 If the valve becomes partially closed Figure 14 18 Page 14 26 the engine will not run properly due to fuel starvation Figure 14 16 Closed F...

Page 119: ...er clamp 6 from the muffler bracket 2 6 Remove the muffler 1 from the vehicle MUFFLER INSTALLATION NOTE Any time the muffler is removed from the vehicle install a new muffler clamp 6 CCI P N 1017689 and muffler gasket 12 CCI P N 1015330 Figure 15 1 Page 15 2 1 Place a new gasket 12 on the cylinder block exhaust stud bolts 2 Loosely secure muffler 1 to muffler bracket 2 with clamp 6 3 Attach muffle...

Page 120: ... Reverse handle in the NEUTRAL position and the neutral lockout cam in the SER VICE MAINTENANCE position Start the engine and check for exhaust leaks and proper engine oper ation See following DANGER ý DANGER Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 11 After checking the exhaust and engine ...

Page 121: ...ears to one of three shift positions FOR WARD F NEUTRAL N or REVERSE R Figure 16 1 Page 16 2 Bring the vehicle to a complete stop before changing FORWARD or REVERSE direction Neutral Lockout During normal vehicle operation the neutral lockout feature prevents the engine from running when the For ward Reverse handle is in the NEUTRAL position If a vehicle is started in FORWARD or REVERSE and then s...

Page 122: ...raining lubricant remove both plugs to allow the lubricant to drain faster Clean and reinstall the drain plug and gasket before filling the transaxle with new lubricant Use a funnel when filling the transaxle through the lubricant level indicator hole Fill with 27 oz 0 8 liter 80 90 WT API class GL or 80 90 WT AGMA class 5 EP gear lubricant or until lubricant begins to run out of the level indicat...

Page 123: ... key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 3 Loosen the lug nuts on the wheel to be removed 4 Place chocks at the front wheels and lift the rear of the vehicle with a floor jack Then place jack stands under the axle tubes to sup...

Page 124: ...liers 0 047 inch tip to remove the retaining ring 74 Place a bearing puller wedge attachment CCI P N 1012812 on the axle shaft between the wheel mounting flange and the bearing Figure 16 6 Page 16 5 See also Figure 16 7 Page 16 7 See following CAUTION ý CAUTION Do not tighten the bearing puller wedge attachment against the axle shaft This could damage the axle shaft when pressing the bearing and c...

Page 125: ...e and Service Supplement Page 16 5 16 A Figure 16 6 Differential Gear Case Axle Tubes 74 73 70 71 ClubCar REFERENCE PASSENGER SIDE CASE 74 73 70 68 69 78 77 76 79 87 86 90 89 85 91 84 82 89 85 88 81 80 79 77 78 75 69 67 70 71 73 74 REFERENCE DRIVER SIDE CASE 83 72 71 72 ...

Page 126: ...e bearing was removed from the shaft replace it with a new one Do not tighten the bearing puller wedge attachment against the axle shaft This could damage the axle shaft when the bearing and collar are pressed on 7 Use external snap ring pliers 0 047 in tip to install collar retaining ring 74 Figure 16 6 Page 16 5 AXLE SHAFT INSTALLATION 1 Clean bearing and seal seats in axle tube 75 or 76 Figure ...

Page 127: ...xle assembly and other components Loss of vehicle control could result in severe personal injury or death UNITIZED TRANSAXLE REMOVAL See General Warning Section 10 Page 10 1 1 Turn the key switch to the OFF position and remove the key and place the Forward Reverse handle in the NEUTRAL position 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General W...

Page 128: ... 8 4 2 Disconnect the air intake hose from the carburetor Figure 16 10 Page 16 8 4 3 Disconnect impulse line from fuel pump Figure 16 11 Page 16 8 4 4 Loosen the hose clamp and then disconnect the fuel line from the carburetor To prevent spilling fuel the disconnected end of the line can be plugged with a 1 4 inch bolt Figure 16 12 Page 16 8 Figure 16 9 Fuel Vent Tube Figure 16 10 Air Intake Hose ...

Page 129: ...ble to shifter cable mounting bracket Then disconnect the shifter cable rod end from the shifter arm on the unitized transaxle and remove the cable from the cable mounting bracket Figure 16 15 Page 16 9 4 8 Mark for identification and then disconnect the 6 gauge white wire F2 post 6 gauge black ground wire A2 post and 16 gauge yellow wire DF post from starter generator Figure 16 16 Page 16 9 Figur...

Page 130: ...10 4 11 Cut away the wire ties securing the engine kill wire at the lower right front of the engine below the exhaust header the wire harness at the governor cable bracket and the wire harness to the plate beneath the muffler 5 Disconnect the brake cables 5 1 Remove bow tie pins 1 brake cable clevis pins 2 and E clips 3 Figure 16 19 Page 16 10 5 2 Remove the cable from the cable support bracket Fi...

Page 131: ...nough to relieve tension from leaf springs then remove the bolts securing the leaf springs to the shackles Figure 16 22 Page 16 11 9 Remove the bolts securing the leaf springs to their front mounts Figure 16 23 Page 16 11 Figure 16 20 Shock Absorbers Figure 16 21 Floor Jack Figure 16 22 Rear Shackles Figure 16 23 Spring Retainer Bolts Clu bCa r Club Car LIFTING POSITION FOR TURF 1 AND CARRYALL 1 P...

Page 132: ...jack stands to support the vehicle Figure 16 25 Page 16 12 12 Pull the floor jack from beneath the vehicle and move it away 13 Carefully lift the snubber out of the snubber bracket in the vehicle frame and lower it to the floor Figure 16 26 Page 16 12 The powertrain should be completely disconnected from the vehicle and resting on the floor 14 Grasp the ends of the leaf springs at the rear of the ...

Page 133: ...n drive and driven clutch and pull up on belt to force the driven clutch sheaves apart Roll the belt counterclockwise while pulling it off driven clutch Figure 16 29 Page 16 13 17 Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle Figure 16 30 Page 16 13 18 Loosen but do not remove the governor arm retaining bolt 1 Figure 16 31 Page 16 13 Remove the go...

Page 134: ...celerator cable should remain attached to the governor arm 22 Remove the six bolts mounting the unitized transaxle to the engine 22 1 Remove four transaxle mounting bolts and flat washers one at each corner of the transaxle mount ing plate Figure 16 34 Page 16 14 22 2 Remove two middle transaxle mounting nuts from the engine block studs Figure 16 34 Page 16 14 23 Remove leaf springs wheels and bra...

Page 135: ... FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 15 16 A Figure 16 35 Transaxle Gear Casing and Brackets 30 29 ClubCar 3 4 9 6 5 7 8 10 17 18 19 16 11 12 13 21 22 20 31 14 15 23 24 28 27 25 26 1 2 REFERENCE FORWARD REVERSE SHIFTER 32 ...

Page 136: ...acket on transaxle case Tighten the mounting screws to 134 in lb 15 1 N m Figure 16 33 Page 16 14 7 Install the governor cable bracket on transaxle case Tighten the mounting screws to 134 in lb 15 1 N m Figure 16 32 Page 16 14 8 Install governor lever arm on governor shaft Figure 16 37 Page 16 16 8 1 With the governor lever arm loose on the governor shaft turn the governor arm shaft counterclock w...

Page 137: ...t the vehi cle Figure 16 40 Page 16 17 Make sure the vehicle is stable on the jack then remove the jack stands 14 After the jack stands are removed lower the vehicle to approximately its normal height Position the leaf springs in the front spring mounts and install the bolts and lock nuts Tighten to 15 ft lb 20 3 N m 15 Adjust the vehicle height with the floor jack to position the leaf springs for...

Page 138: ...t of the engine Figure 16 43 Page 16 18 19 Install three wire ties to secure the engine kill wire to the accelerator cable where they both route together on the passenger side of the engine 20 Connect the oil level sensor wire 18 gauge yellow to the jumper wire Figure 16 44 Page 16 18 21 Connect the 6 gauge white wire to the F2 post the 6 gauge black ground wire to the A2 post and tighten both wir...

Page 139: ...he mounting nuts to 22 ft lb 29 8 N m Connect shifter cable rod end to the shifter arm Figure 16 46 Page 16 19 24 Attach the ground wire to the mounting screw on the oil filler tube mounting bracket and tighten to 50 in lb 5 7 N m Figure 16 47 Page 16 19 25 Connect accelerator cable to actuator cam in the electrical box Position the accelerator cable in the mounting slot in the wall of the electri...

Page 140: ...igure 16 51 Page 16 20 29 Connect carburetor vent tube to carburetor and secure with hose clamp Figure 16 52 Page 16 20 30 Install transaxle drain plug and tighten to 21 ft lb 28 5 N m 31 Fill transaxle with 27 oz 0 8 liter 80 90 Wt API class GL 3 or 80 90 WT AGMA class EP gear lube Install and tighten the level indicator hole plug to 21 ft lb 28 5 N m 32 Ensure that all wiring is secured properly...

Page 141: ... key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 3 Remove the ball joint socket 2 from the Forward Reverse shifter assembly ball stud 3 Figure 16 54 Page 16 23 4 Remove the ball joint socket 10 from the shifter arm ball stud 11 on the...

Page 142: ...ss is properly routed and secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or death FORWARD REVERSE SHIFTER CABLE ADJUSTMENT With the shifter lever of the unitized transaxle in the NEUTRAL position Figure 16 54 Page 16 23 the For ward Reverse handle 9 should be straight up For minor adjustments the nut 1 may be loosened and the...

Page 143: ...Forward Reverse handle 9 Figure 16 54 Page 16 23 in the NEUTRAL position the shift lever of the transaxle will also be in the NEUTRAL position Figure 16 55 Page 16 23 Retighten nuts at the transaxle to 22 ft lb 29 8 N m retighten nuts at the Forward Reverse assembly to 43 in lb 4 9 N m Figure 16 54 Forward Reverse Shifter Cable Figure 16 55 Forward Reverse Positions ClubCar C O M N C N O 11 10 8 9...

Page 144: ...16 16 A ...

Page 145: ...At governed top speed the ratio of drive clutch to driven clutch is 0 92 to 1 On steep grades or when the vehicle is heavily loaded higher torques are achieved through the use of a torque sensing ramp device on the driven clutch This device overcomes the force of the centrifugal weights to close the driven clutch and open the drive clutch thus increasing axle torque with little or no change in eng...

Page 146: ...ing Section 10 Page 10 1 The drive belt should be inspected semiannually for wear and or glazing If it is excessively worn frayed or glazed replace the belt As the drive belt wears the engine RPM will increase to compensate for the change in torque converter ratio This will keep the vehicle s maximum ground speed correct See Section 2 Vehicle Specifications in the appropriate maintenance and servi...

Page 147: ... counterclock wise Figure 17 2 Page 17 3 See following CAUTION ý CAUTION Make sure fingers are not underneath the belt when rolling the belt off the driven clutch 4 Remove the belt from the drive clutch DRIVE BELT INSTALLATION 1 Position the new belt on the drive clutch then start the belt over the top of the driven clutch 2 With the belt started onto the driven clutch rotate the driven clutch cou...

Page 148: ...starter generator mounting and adjusting hardware and then remove the starter belt See WARNING Moving parts Do not in General Warning Section 10 Page 10 1 Figure 17 3 Loosen Retaining Bolt Figure 17 4 Drive Clutch Removal WAR NING Use Club Car clutch holder while tightening or loosening drive clutch retaining bolt CLUTCH HOLDER Hook clutch holder on boss of pully located behind drive clutch push d...

Page 149: ...mounting bolt has left hand threads The crankshaft has left hand threads at the clutch mounting hole 5 Lubricate the threaded portion of the clutch puller tool with a light oil and thread the clutch puller tool into the clutch retaining bolt hole 6 Use a 1 2 inch drive air wrench to tighten the clutch puller tool The drive clutch will come free of the crankshaft Figure 17 4 Page 17 4 7 Support the...

Page 150: ...E CONVERTER Drive Clutch Page 17 6 2005 FE 290 Gasoline Vehicle Maintenance and Service Supplement 17 A Figure 17 5 Drive Clutch Assembly 2 1 3 13 4 5 6 7 11 12 12 16 15 14 22 20 21 17 19 TYPICAL 3 PLACES 10 ...

Page 151: ... center bolt of the Drive Clutch Hub Puller CCI P N 1014497 into clutch until the stop nut touches the clutch then back the bolt out one half turn Figure 17 7 Page 17 7 2 3 Thread the three small bolts of the puller into corresponding holes in the clutch Tighten bolts evenly making sure the face of the puller plate is parallel to the face of the clutch Figure 17 7 Page 17 7 2 4 Unscrew the puller ...

Page 152: ...ns of the wave washer and of the primary and secondary weights to one another Figures 17 10 and 17 11 Page 17 8 Remove the plastic washers weights and wave washer from the pin Retain all parts Figure 17 8 Drive Button Mounting Figure 17 9 Weight Position Figure 17 10 Install Pin and Washer Figure 17 11 Install Secondary Weight Remove these items from ribs 10 24 SCREW FLAT WASHER DRIVE BUTTON DRIVE...

Page 153: ...ure 17 5 Page 17 6 See also Figure 17 13 Page 17 9 Discard the rings INSPECTION OF DRIVE CLUTCH PARTS 1 Inspect the idler bearing 6 for smooth rotation or seal damage Figure 17 5 Page 17 6 See follow ing NOTE NOTE It is normal for a small amount of grease to be present at the edge of seal 2 Inspect the bore of the moveable face assembly 14 for scarring or wear The moveable face assembly must be re...

Page 154: ...d face assembly 7 ý CAUTION To avoid damaging the spiral back up rings be very careful when installing the moveable face 6 1 Rotate the moveable face assembly clockwise while installing it onto the shaft 6 2 Install the retaining ring 3 Figure 17 5 Page 17 6 7 Install the primary weights on the mounting pins Figure 17 10 Page 17 8 8 Install a wave washer on each mounting pin Make sure that the con...

Page 155: ... o clock position as shown Figure 17 15 Page 17 11 14 Compress each take up spring and install the drive button over the rib and take up spring Figure 17 8 Page 17 8 15 Install a no 10 24 button retaining screw with flat washer through each button and into the rib Tighten the screws to 34 in lb 3 8 N m Figure 17 9 Page 17 8 16 Install the thrust washer 11 onto the moveable face assembly Figure 17 ...

Page 156: ...erminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 6 Connect the spark plug wire to the plug 7 Drive the vehicle and check for proper operation DRIVEN CLUTCH See General Warning Section 10 Page 10 1 DRIVEN CLUTCH REMOVAL 1 Remove the drive belt as instructed See Drive Belt Removal on page 17 3 2 Remove the bolt 11 and mounting washer 12 from the clutch shaft Figur...

Page 157: ... bearing bore diameter is more than 1 384 inch 35 15 mm the entire moveable face assembly must be replaced 5 Inspect the shaft of the fixed face assembly There should be no noticeable wear Replace the shaft if it is worn scratched or damaged DRIVEN CLUTCH ASSEMBLY 1 Place the three drive buttons 6 in position Apply one drop of Loctite 222 to each of the socket head cap screws and then install and ...

Page 158: ...TORQUE CONVERTER Driven Clutch Page 17 14 2005 FE 290 Gasoline Vehicle Maintenance and Service Supplement 17 A Figure 17 18 Driven Clutch Assembly 2 3 4 5 6 7 8 11 12 1 10 9 TYPICAL 3 PLACES ...

Page 159: ...ining ring can be reused if the O D does not exceed 1 607 inches 40 82 mm otherwise it must be replaced with a new ring CCI P N 1014080 5 1 4 While holding onto the cam tap the end of the fixed face shaft lightly with a plastic mallet until the cam seats against the retaining ring See following CAUTION ý CAUTION Do not use a metal hammer to tap the fixed face hub A metal hammer will damage the sha...

Page 160: ...am onto the keyed shaft Advance the press hub until it is firm against the shaft end 5 2 8 Remove the cam press hub 6 and installation tool and install the retaining ring NOTE The retaining ring can be reused if the O D does not exceed 1 607 inches 40 82 mm otherwise it must be replaced with a new ring CCI P N 1014080 DRIVEN CLUTCH INSTALLATION 1 To install the driven clutch reverse the removal pr...

Page 161: ... main 14 2 elevation size chart 14 2 choke choke and air intake system 14 1 14 12 choke button installation 14 12 removal 14 12 clutch torque converter troubleshooting 17 1 clutch drive see drive clutch clutch driven see driven clutch crankcase cover installation 13 6 removal 13 4 cylinder head 13 3 D diagram schematic 11 6 differential see unitized transaxle drive belt inspection 17 2 installatio...

Page 162: ...4 22 storage 14 23 fuel hour gauge installation 12 22 removal 12 22 fueling instructions 10 7 fuse installation 12 15 removal 12 15 testing 11 11 G governor governor system 16 2 governor cable installation and adjustment 14 9 removal 14 8 ground straps 12 32 testing 11 11 H hour meter circuit 11 7 I ignition testing 11 20 ignition coil installation 12 26 13 8 removal 12 24 13 7 testing 11 21 inspe...

Page 163: ...testing 11 28 RPM adjustment 14 11 RPM limiter installation 12 23 removal 12 23 testing 11 20 S schematic diagram 11 6 service schedule see periodic service schedule see also periodic lubrication schedule service tools torque converter kit 17 1 unitized transaxle 16 2 solenoid installation 12 14 removal 12 14 testing 11 13 spark plug 13 1 14 1 cleaning inspection and repair 13 2 gap adjustment 13 ...

Page 164: ...ensor 11 29 reverse buzzer 11 28 reverse buzzer limit switch 11 28 RPM limiter 11 20 solenoid 11 13 starter generator 11 15 11 17 voltage regulator 11 18 wire continuity 11 17 test procedures index of 11 7 testing spark plug 13 2 starter generator ground test 12 8 tools see service tools torque converter troubleshooting 17 1 troubleshooting torque converter 17 1 vehicle troubleshooting guide 11 1 ...

Page 165: ...Clarity of Illustrations 4 Index Usability 5 Troubleshooting Chart Usability Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in the following catgories Your Comments Are Appreciated Please select y our ca tegory Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other __...

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Page 168: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808 ...

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