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Troubleshooting Guide

TROUBLESHOOTING AND ELECTRICAL SYSTEM

TROUBLESHOOTING GUIDE

SYMPTOM

POSSIBLE CAUSES

CORRECTIVE ACTION

Inlet valve or seat is leaking, dirty, worn, or

damaged

Section 15 — S10 FE350 Fuel System

Section 16 — S27 FE 350 Fuel System

Float is damaged and filled with fuel

Section 15 — S10 FE350 Fuel System

Section 16 — S27 FE 350 Fuel System

Float needle valve not functioning properly

Section 15 — S10 FE350 Fuel System

Section 16 — S27 FE 350 Fuel System

Carburetor floods.

Carburetor vent is clogged

Section 15 — S10 FE350 Fuel System

Section 16 — S27 FE 350 Fuel System

Neutral lockout switch is in the MAINTENANCE

position

Place switch in OPERATE position or, if

servicing, place shifter in neutral. Test

Procedure 24 – Neutral Lockout Switch on

page 11-40

Fuse is blown

Test Procedure 2 –

Fuse

Battery is dead

Test Procedure 1 –

Battery

Starter control circuit is not operating

Section 11 — Troubleshooting and Electrical

System

Starter/generator failed

Test Procedure 8 –

Neutral Lockout Limit

Switch

Starter solenoid failed

Test Procedure 7 –

Solenoid

Accelerator pedal limit switch failed

Test Procedure 6 –

Accelerator Pedal Limit

Switch

Key switch failed

Test Procedure 4 –

Key Switch (Starter Circuit)

Neutral lockout limit switch failed

Test Procedure 8 –

Neutral Lockout Limit

Switch

Loose or broken wire in starter/generator

circuit

Starter/Generator on page 12-1

Cylinder and/or crankcase flooded with fuel

Section 15 — S10 FE350 Fuel System

Section 16 — S27 FE 350 Fuel System

Starter fails to operate.

Relay failure (key-start vehicle only)

Test Procedure 30 – Relay (Starter and Neutral

Lockout Circuits) on page 11-46

Loose or broken wire in the starter/ generator

circuit

Test Procedure 11 –

Starter/Generator

(Generator Function)

Generator field coil is shorted

Test Procedure 11 –

Starter/Generator

(Generator Function)

Brushes are worn or commutator is dirty

Starter/Generator on page 12-1

Starter/generator belt is loose or slipping

Belt Tension Adjustment on page 12-12

Voltage regulator failed

Test Procedure 12 –

Voltage Regulator

Starter/generator does not charge battery.

Battery failed

Test Procedure 1 –

Battery

TABLE CONTINUED ON NEXT PAGE

Page 11-4

2009 FE 350 Maintenance and Service Supplement

Summary of Contents for FE 350

Page 1: ...2009 FE 350 Maintenance and Service Supplement FE 350 Gasoline Vehicles Manual Number 103472709 Edition Code 0509A00000 ...

Page 2: ......

Page 3: ...for the trained technician who already possesses knowledge and skills in electrical and mechanical repair If the technician does not have such knowledge 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...

Page 4: ...se improvements may affect servicing procedures Any modification and or significant change in specifications or procedures 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 the obligation of making changes to...

Page 5: ...Performance Inspection 10 4 General Information 10 5 S10 and S27 Engine Differences 10 5 Neutral Lockout Maintenance Operate Switch 10 5 Periodic Service Schedules 10 6 Periodic Lubrication Schedules 10 8 Engine Oil 10 9 Engine Oil Level Check 10 9 Engine Oil And Filter Change 10 9 Fueling Instructions 10 12 Battery 10 13 SECTION 11 TROUBLESHOOTING AND ELECTRICAL SYSTEM 11 1 General Information 11...

Page 6: ... Limit Switch Removal 12 20 Neutral Lockout Limit Switch Installation 12 21 Reverse Warning Buzzer 12 21 Front Reverse Warning Buzzer Removal 12 21 Front Reverse Warning Buzzer Installation 12 22 Rear Reverse Warning Buzzer Removal 12 23 Rear Reverse Warning Buzzer Installation 12 23 Reverse Buzzer Limit Switch 12 24 Reverse Buzzer Limit Switch Removal 12 24 Reverse Buzzer Limit Switch Installatio...

Page 7: ...nformation 12 43 Testing the Battery 12 43 Preventive Maintenance 12 43 Self Discharge 12 44 Water Level 12 44 Vibration Damage 12 44 Mineral Content 12 45 Battery Removal 12 46 Charging the Battery 12 46 Battery Installation 12 46 Battery Storage 12 47 Charging a Dead Battery 12 47 Ground Cables 12 47 SECTION 13 S10 FE 350 ENGINE 13 1 General Information 13 1 Before Servicing 13 1 Engine Rotation...

Page 8: ...e Chart 15 3 Changing the Main Jet 15 3 Engine Control Linkage 15 6 General Information 15 6 Accelerator Rod 15 6 Governor Cable 15 8 Accelerator Cable 15 10 Closed Throttle or Idle Adjustment 15 10 Engine RPM Adjustment 15 11 Choke and Air Intake System 15 12 General Information 15 12 Choke Cable Removal 15 12 Choke Cable Installation 15 12 Air Box Removal 15 13 Air Box Installation 15 13 Intake ...

Page 9: ...ters 16 18 General Information 16 18 Fuel Filter Removal 16 18 Fuel Filter Installation 16 18 Fuel Pump 16 21 General Information 16 21 Fuel Pump Removal 16 21 Fuel Pump Disassembly 16 22 Fuel Pump Cleaning and Inspection 16 22 Fuel Pump Assembly 16 23 Fuel Pump Installation 16 23 Fuel Tank 16 25 General Information 16 25 Fuel Tank Removal 16 25 Fuel Tank Disposal 16 26 Fuel Tank Storage 16 26 Fue...

Page 10: ...1 Troubleshooting 19 1 Drive Belt 19 3 Drive Belt Removal 19 3 Drive Belt Installation 19 3 Drive Clutch 19 4 Drive Clutch Removal 19 4 Drive Clutch Cleaning and Inspection 19 5 Drive Clutch Disassembly 19 7 Inspection of Drive Clutch Parts 19 9 Drive Clutch Assembly 19 10 Drive Clutch Installation 19 11 Driven Clutch 19 12 Driven Clutch Removal 19 12 Driven Clutch Disassembly 19 12 Driven Clutch ...

Page 11: ...ON 1 SAFETY 1 For information regarding this particular section see the appropriate maintenance and service manual covering the vehicle being serviced 2009 FE 350 Maintenance and Service Supplement Page 1 1 ...

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Page 13: ...ICLE SPECIFICATIONS 2 For information regarding this particular section see the appropriate maintenance and service manual covering the vehicle being serviced 2009 FE 350 Maintenance and Service Supplement Page 2 1 ...

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Page 15: ...ENERAL INFORMATION 3 For information regarding this particular section see the appropriate maintenance and service manual covering the vehicle being serviced 2009 FE 350 Maintenance and Service Supplement Page 3 1 ...

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Page 17: ...4 BODY AND TRIM 4 For information regarding this particular section see the appropriate maintenance and service manual covering the vehicle being serviced 2009 FE 350 Maintenance and Service Supplement Page 4 1 ...

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Page 19: ...TOR AND BRAKE PEDAL GROUP 5 For information regarding this particular section see the appropriate maintenance and service manual covering the vehicle being serviced 2009 FE 350 Maintenance and Service Supplement Page 5 1 ...

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Page 21: ...EL BRAKE ASSEMBLIES 6 For information regarding this particular section see the appropriate maintenance and service manual covering the vehicle being serviced 2009 FE 350 Maintenance and Service Supplement Page 6 1 ...

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Page 23: ...NG AND FRONT SUSPENSION 7 For information regarding this particular section see the appropriate maintenance and service manual covering the vehicle being serviced 2009 FE 350 Maintenance and Service Supplement Page 7 1 ...

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Page 25: ...WHEELS AND TIRES 8 For information regarding this particular section see the appropriate maintenance and service manual covering the vehicle being serviced 2009 FE 350 Maintenance and Service Supplement Page 8 1 ...

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Page 27: ... REAR SUSPENSION 9 For information regarding this particular section see the appropriate maintenance and service manual covering the vehicle being serviced 2009 FE 350 Maintenance and Service Supplement Page 9 1 ...

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Page 29: ... 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 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 veh...

Page 30: ...eels 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 secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or death For vehicles with cargo beds remove all cargo bef...

Page 31: ...de 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 Performance Inspection on page 10 4 and the Periodic Service Schedules on page 10 6 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 a...

Page 32: ...r any circumstance Park brake When latched the park brake should lock the wheels and hold the vehicle stationary on an incline of 20 or less It should release when either the accelerator or brake pedal is pressed 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...

Page 33: ...s an oil reservoir crankcase similar to automobiles trucks aircraft heavy equipment machinery and other applications designed for reliable heavy duty service The engine has two major component assemblies the cylinder assembly and the crankcase assembly S10 AND S27 ENGINE DIFFERENCES The S10 and S27 engines are similar except the S27 has the following items Hemispherical design combustion chamber c...

Page 34: ...edal start vehicle Be sure to return the switch to the OPERATE position after servicing the vehicle or it will not run with the Forward Reverse handle in either the FORWARD or REVERSE position Key start vehicle The switch must be returned to the OPERATE position after servicing is complete or the engine will stop running when the accelerator pedal is pressed and the Forward Reverse handle is in th...

Page 35: ...ber Check and adjust if necessary See Steering and Front Suspension Section Electrical wiring and connections Check for tightness and damage Check brake shoes replace if necessary or adjust as required See Wheel Brake Assemblies Section Lubricate brake slides per Lubrication Schedule See Wheel Brake Assemblies Section Semiannual service by trained technician only or every 50 hours of operation whi...

Page 36: ...ever comes first Brake slides Dry Moly Lube CCI P N 1012151 Check fill unitized transaxle to plug level 27 oz 8 liters 80 90 WT API Class GL 3 or 80 90 WT AGMA Class EP Gear Lube Annually by trained technician only or every 100 hours of operation whichever comes first Inspect front wheel bearings Repack as necessary 7 Chassis Lube EP NLGI Grade 2 First change 100 hours additional change every 200 ...

Page 37: ...fe level 3 4 Insert the dipstick into the oil filler tube See following NOTE NOTE Properly recycle or dispose of used oil in accordance with local state and federal regulations 1 3 2 1 Full level 2 Safe level 3 Low level 23 Figure 10 4 Engine Oil Level Check ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 100 hours of operation After that they should be cha...

Page 38: ... clockwise and tighten to 18 ft lb 24 4 N m 8 Relocate the oil drain pan to a position under the engine oil filter Figure 10 5 9 Remove the engine oil filter 1 turning it counterclockwise allowing the residual oil in the filter port and filter to drain into the oil drain pan 2 Figure 10 6 See following NOTE NOTE An oil drip guard 3 can be used to prevent excess oil from dripping into the engine ba...

Page 39: ...engine oil into the dipstick port Use a funnel or pour spout to direct the oil into the dipstick port With filter change the engine requires 38 ounces 1 12 liters of oil per change Refer to oil viscosity guidelines for selection of oil grade Figure 10 8 Replace the dipstick SAE 5 W 30 SAE 10W 30 SAE 10W 40 SAE 30 SAE 40 27 Figure 10 7 Coat Oil Filter Rubber Seal 213 Figure 10 8 Oil Viscosity Chart...

Page 40: ...k Avoid spilling fuel NOTE Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Vehicles to be stored for extended periods should be prepared for storage as instructed See Preparing the Vehicle for Extended Storage in Section 3 of the appropriate maintenance and service manual For Villager 6 and 8 vehicles 1 Lift and remove the second forward facing seat 2 The fue...

Page 41: ... 4 1 3 1 Vent 2 Fuel Shut off Valve 3 Fuel Vent Line 4 Fuel Tank 24 Figure 10 9 Fuel Tank Villager 6 and 8 89A Figure 10 10 Fuel Tank Turf and Carryall BATTERY For periodic battery maintenance see Battery on page 12 42 2009 FE 350 Maintenance and Service Supplement Page 10 13 ...

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Page 43: ...MPTOM POSSIBLE CAUSES CORRECTIVE ACTION Spark plug is partially fouled or in poor condition Section 13 S10 FE 350 Engine Section 14 S27 FE 350 Engine Spark plug wire is damaged or loose Section 13 S10 FE 350 Engine Section 14 S27 FE 350 Engine Loose wire connection at ignition coil or RPM limiter Test Procedures 14 Ignition Spark 15 RPM Limiter and 16 Ignition Coil Intermittent ignition coil failu...

Page 44: ...park plug wire damaged or loose Section 13 S10 FE 350 Engine Section 14 S27 FE 350 Engine Loose wire connection at ignition coil or RPM limiter Test Procedures 14 Ignition Spark 15 RPM Limiter and 16 Ignition Coil Ignition coil or RPM limiter failed Test Procedures 14 Ignition Spark 15 RPM Limiter and 16 Ignition Coil Engine flooded with fuel as result of excess choking See Owner s Manual Controls...

Page 45: ...rottle linkage out of adjustment Section 15 S10 FE350 Fuel System Section 16 S27 FE 350 Fuel System Low cylinder compression Section 13 S10 FE 350 Engine Section 14 S27 FE 350 Engine Spark plug failed Section 13 S10 FE 350 Engine Section 14 S27 FE 350 Engine Restricted fuel flow Section 15 S10 FE350 Fuel System Section 16 S27 FE 350 Fuel System Loss of engine power Torque converter is not backshif...

Page 46: ...witch Starter solenoid failed Test Procedure 7 Solenoid Accelerator pedal limit switch failed Test Procedure 6 Accelerator Pedal Limit Switch Key switch failed Test Procedure 4 Key Switch Starter Circuit Neutral lockout limit switch failed Test Procedure 8 Neutral Lockout Limit Switch Loose or broken wire in starter generator circuit Starter Generator on page 12 1 Cylinder and or crankcase flooded...

Page 47: ...ged starter generator pulley Starter Generator on page 12 1 Excessive vehicle vibration RPM setting is incorrect Section 15 S10 FE350 Fuel System Section 16 S27 FE 350 Fuel System Engine RPM Adjustment on page 15 11 Drive belt is worn cracked glazed or frayed Section 19 Torque Converter Drive clutch malfunction Section 19 Torque Converter Driven clutch malfunction Section 19 Torque Converter Torqu...

Page 48: ...RAMS 18_BLK W16 18_ORG W23 18_WHT W40 18_BLU W41 1 2 3 4 5 6 FUEL GAUGE HOUR METER Through mid 2007 DETAIL 6 7 1 4 2 FUEL HOUR METER GAUGE WD103197101B5 L Figure 11 1 Wiring Diagram for Turf 2 and Carryall 2 Front Page 11 6 2009 FE 350 Maintenance and Service Supplement ...

Page 49: ...TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams 11 WD103197101B5 R Figure 11 2 Wiring Diagram for Turf 2 and Carryall 2 Rear 2009 FE 350 Maintenance and Service Supplement Page 11 7 ...

Page 50: ...OUBLESHOOTING AND ELECTRICAL SYSTEM WD1032208C7 L FUEL HOUR METER GUAGE 6 7 1 4 2 Figure 11 3 Wiring Diagram for Carryall 6 Villager 6 and TransPorter Vehicles Front Page 11 8 2009 FE 350 Maintenance and Service Supplement ...

Page 51: ...BLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams 11 WD1032208C7 R Figure 11 4 Wiring Diagram for Carryall 6 Villager 6 and TransPorter Vehicles Rear 2009 FE 350 Maintenance and Service Supplement Page 11 9 ...

Page 52: ...11 Wiring Diagrams TROUBLESHOOTING AND ELECTRICAL SYSTEM WD1032639C7 L Figure 11 5 Wiring Diagram for Turf 6 Front Page 11 10 2009 FE 350 Maintenance and Service Supplement ...

Page 53: ...TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams 11 6 7 1 4 2 WD1032639C7 R Figure 11 6 Wiring Diagram for Turf 6 Rear 2009 FE 350 Maintenance and Service Supplement Page 11 11 ...

Page 54: ...11 Wiring Diagrams TROUBLESHOOTING AND ELECTRICAL SYSTEM 6 7 1 4 2 WD1032209D7 L Figure 11 7 Wiring Diagram for Villager 8 Front Page 11 12 2009 FE 350 Maintenance and Service Supplement ...

Page 55: ...TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams 11 WD1032209D7 R Figure 11 8 Wiring Diagram for Villager 8 Rear 2009 FE 350 Maintenance and Service Supplement Page 11 13 ...

Page 56: ...11 Wiring Diagrams TROUBLESHOOTING AND ELECTRICAL SYSTEM WD1031980B5 L 6 7 1 4 2 Figure 11 9 Wiring Diagram for Carryall 2 Plus Front Page 11 14 2009 FE 350 Maintenance and Service Supplement ...

Page 57: ...TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams 11 WD1031980B5 R Figure 11 10 Wiring Diagram for Carryall 2 Plus Rear 2009 FE 350 Maintenance and Service Supplement Page 11 15 ...

Page 58: ...ce of an electrical problem Use the appropriate test procedure to correct the electrical problem See Test Procedures on page 11 16 For a complete wiring diagram see page 11 6 TEST PROCEDURES Index of Test Procedures 1 Battery 2 Fuse 3 Ground Cables 4 Key Switch Starter Circuit 5 Key Switch For Key Start Vehicles Only Accessory Terminal 6 Accelerator Pedal Limit Switch 7 Solenoid 8 Neutral Lockout ...

Page 59: ...ating 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 ...

Page 60: ...awing electrolyte up into the glass tube of the hydrometer 5 When the float rises off the bottom adjust the electrolyte level 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 Hol...

Page 61: ...roblem 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 than 50 points Open ...

Page 62: ...cles Section 10 Page 10 2 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 and place the black probe on the vehicle frame Figure 11 13 Page 11 20 The reading should be continuity If the reading is incorrect clean and tighten cable connections If the connections are good and the reading is incorrect repair ...

Page 63: ...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 6 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 3 1 1 ...

Page 64: ...nd hold the key in the START position The reading should be continuity If the reading is incorrect replace the key switch Figure 11 17 Page 11 22 With the red probe of the multimeter on the B terminal and the black probe on the A terminal of the key switch the reading should be continuity If either reading is incorrect replace the key switch See Key Switch Removal Section 12 Page 12 14 6 Connect b...

Page 65: ...the red probe on the common COM terminal green wire of the limit switch and place the black probe on the normally closed NC terminal orange wire of the limit switch 4 Make sure the battery is disconnected With the key switch in the OFF 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 t...

Page 66: ...ndle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position Turn the key switch to the ON position With the accelerator in the UP position the reading on the multimeter should be no continuity Press the accelerator pedal and listen for the solenoid click There should be continuity If either reading is incorrect replace the solenoid 9 With the Forward Reverse handle stil...

Page 67: ...either reading is incorrect replace the limit switch Figure 11 22 Page 11 25 4 Check to be sure the lobe on the cam is pressing the neutral lockout limit switch as the Forward Reverse shifter 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 lobe and replace cam if necessary 5 Connect battery and spark plug wire s See Connectin...

Page 68: ...nd 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 on page 12 1 6 With the wires still disconnected using a multimete...

Page 69: ...n the meter If the voltage rises above 15 3 volts DC test the voltage regulator See Voltage Regulator on page 11 27 If the voltage does not rise a tear down inspection of the starter generator will be necessary See Starter Generator Removal on page 12 1 5 Connect the yellow wire to the DF terminal on the starter generator TEST PROCEDURE 12 Voltage Regulator See General Warning on page 10 1 NOTE Ke...

Page 70: ... white black wire at the bullet connector located next to the RPM limiter Figure 11 27 Page 11 29 3 Start the engine in a well ventilated area Turn the key switch to the ON position Press the accelerator pedal 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 Key Switch Engine Kill Circuit on ...

Page 71: ...ure 11 26 Page 11 29 2 1 Adjust the tester probes to approximately 18 000 volts 18 Kv setting SE Small Engine Setting on the Thexton 404 tool Connect the tester to the spark plug wire and connect the alligator clip to a solid engine ground 2 2 Start the engine 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 re...

Page 72: ...uld be no continuity If the reading is not correct replace the RPM Limiter 4 This test will find most bad RPM Limiters Some of them may bench test okay but fail under a load due to heat while operating Another method of testing is to replace the RPM Limiter and then run the engine If the engine runs properly keep the new RPM Limiter in the circuit 5 Connect battery and spark plug wire s See Connec...

Page 73: ...hicle Test 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 2 Using a multimeter set to 200 ohms measure the primary coil resistance 2 1 Disconnect both of the bullet terminals at the RPM limiter Figure 11 28 Page 11 30 Place the red probe of the meter on the male bullet terminal of the wire connecting to the ignition coil under the fa...

Page 74: ... of the engine or frame Figure 11 30 Page 11 32 3 2 If the resistance is between 12 0k 14 0k ohms the secondary coil and spark plug cap are within acceptable limits proceed to step 6 on page 12 25 If the resistance is not between 12 0k 14 0k ohms the spark plug cap and secondary coil must be tested independently from each other 4 Test the spark plug cap separately from the secondary coil 4 1 Remov...

Page 75: ... and place the black probe into the end of the cap with the internal screw Figure 11 33 Page 11 33 If the resistance is not between 4 5k 6 0k ohms the cap has failed and must be replaced Proceed to the next step with the spark plug cap still removed 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 1 1 20k Ohm Setting 2 Spa...

Page 76: ...e resistance is between 6 0k 11 0k ohms the secondary coil is within acceptable limits If the resistance is not between 6 0k 11 0k ohms bench test the ignition coil 6 If the preceding tests indicate that the ignition coil resistance readings are within acceptable ranges but the coil fails to function properly proceed to the following bench test procedures Ignition Coil Bench Test 1 Remove the coil...

Page 77: ...Ohm Setting 2 Core 3 Spark Plug Cap 473 Figure 11 35 Primary Coil Resistance Bench Test 474 Figure 11 36 Secondary Coil and Cap Resistance Bench Test 2 2 If the resistance is not between 0 6 1 7 ohms replace the ignition coil 3 Using a multimeter set to 20k ohms measure the resistance of the secondary coil and spark plug cap together 3 1 Place the red probe of the meter into the end of the spark p...

Page 78: ...eter set to 20k 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 33 Page 11 33 If the resistance is not between 4 5k 6 0k ohms the cap has failed and must be replaced Proceed to the next step with the spark plug cap still removed 5 Test the secon...

Page 79: ...eplace the limit switch Figure 11 38 Page 11 37 For key start vehicles Place the red probe of the multimeter on the common COM terminal orange wire of the limit switch Place the black probe on the normally open NO terminal brown wire of the limit switch Without the lever pressed the reading should be no continuity Press the lever and the reading should be continuity If either reading is incorrect ...

Page 80: ...y Gasoline Vehicles Section 10 Page 10 3 1 M 2 M 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 A 1 200 Ohm Setting A Key Switch OFF 1407 Figure 11 40 Key Switch Test Engine Kill Circuit TEST PROCEDURE 19 Engine Kill Wire See General Warning on page 10 1 1 Disconnect battery and spark plug wire s See Disconnecting the Ba...

Page 81: ...emoval Section 12 Page 12 14 3 Check for proper wiring and tight connections Using a multimeter individually check for continuity through each wire that connects to the reverse buzzer See Wiring Diagrams on page 11 6 If the buzzer will not function when properly wired replace the buzzer 4 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 TEST P...

Page 82: ...o be replaced See Oil Level Sensor Removal Section 14 Page 14 6 5 Install a new oil filter and fill the engine with new oil before returning the vehicle to service See Engine Oil Section 10 Page 10 9 TEST PROCEDURE 24 Neutral Lockout Switch See General Warning on page 10 1 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 2 Remove the w...

Page 83: ...ve the Forward Reverse shifter in the NEUTRAL position and press the accelerator pedal with the accelerator pedal pressed the battery is under load 3 2 Key start vehicles Turn the key switch to the ON position and hold it in the START position while noting the voltage reading on the multimeter with the key in the START position the battery is under load 4 If the voltage reading is over 9 6 volts w...

Page 84: ...nk empty 240 20 ohms Empty Center position tank half full 120 20 ohms Half full Upper position tank full 60 20 ohms Full 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 3 2 1 2k Ohm Setting 2 Black Wire 3 Ground 479 Figure 11 42 Fuel Level Sending Unit Test 5 If the readings are within the specifications listed above the ...

Page 85: ...m the fuel gauge hour meter 5 Set a multimeter to 20 volts DC and place the red probe of the multimeter on the positive post of the battery Place the black probe on the negative post of the battery Record the voltage reading 6 Set a multimeter to 20 volts DC and place the red probe on the 2 terminal of the fuel gauge hour meter with the blue wire is connected Place the black probe on the 1 termina...

Page 86: ...lay It is powered by an internal battery and should always be on even with the engine off and the key removed Figure 11 43 Page 11 43 3 Start the engine and let it idle See following DANGER DANGER Do not operate vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 4 With engine idling the hour glass icon should flash If not c...

Page 87: ...0 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 2 5 4 6 3 1 200 Ohm Setting 2 White Black 3 Brown 4 Orange 5 Green 6 Black 1408 Figure 11 46 Engine Kill Circuit Relay Test 5 Connect battery See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 6 Using a multimeter set to 200 ohms place the two probes onto the two normally closed NC terminals on the relay ...

Page 88: ...lay With the key switch to the OFF position the reading should show no continuity Turn the key switch to the START position The reading should be continuity If either reading is incorrect replace the relay 7 Disconnect battery See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 8 Connect the wires to the relay Install the electrical component box cover 9 Connect the 6 gauge white ...

Page 89: ... terminal block located on the frame under the front body Figure 11 48 Page 11 46 5 Remove the fuse located at the yellow wire position in the fuse block 6 Place the red probe of the multimeter on the terminal connector inside the fuse block across from the yellow wire connector NOTE Make sure the red probe is placed on the same side hot side as the 10 gauge red wire 7 Set the multimeter to 20 vol...

Page 90: ...rim or other parts of the vehicle frame Place a dry towel between the body trim and the center dash to prevent an electrical short 5 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 6 With the light switch in the OFF position the reading should be zero volts With the light in the ON position the reading should be between 11 and 12 5 volts If t...

Page 91: ...Battery Gasoline Vehicles Section 10 Page 10 3 6 Pull the light switch to the ON position The reading should be 11 12 volts If the there is no voltage reading check continuity of the 16 gauge black wire from the headlight to the voltage limiter Check continuity of the 16 gauge black wire from voltage limiter to the ground terminal block If the wires show continuity and the readings are still incor...

Page 92: ...age reading at the wire harness check continuity of the 16 gauge blue wire from the headlight to the light switch Using a multimeter set to 20 volts DC attach using an alligator clip the black probe of multimeter onto the negative battery terminal and place the red probe into the blue wire terminal of the wire harness If multimeter reading is approximately 12 volts the blue wire has continuity 7 C...

Page 93: ...is pressed proceed to step 7 4 If the brake lights illuminate when the brake pedal is pressed and the key switch is in the OFF position the brake light relay has failed closed 5 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 6 Remove the center dash assembly See Key Switch Removal Section 12 Page 12 14 7 Test the relay for the failed c...

Page 94: ...elay bypassed inspect the brake lights for proper operation See following NOTE NOTE The aid of an assistant will be required to inspect the brake light relay for proper operation 10 1 With the key switch in the OFF position and the key removed press the brake pedal while an assistant observes the brake lights The brake lights should illuminate regardless of the key switch position ON or OFF 18 15 ...

Page 95: ...th no tone emitted 12 3 Reverse the multimeter probes and observe the multimeter The multimeter should continue to indicate an overlimit with no tone emitted 12 4 If a tone is emitted indicating a closed circuit then the voltage suppressor has failed closed and should be replaced 13 Test the brake light relay coil 13 1 Remove the voltage suppressor wire assembly 17 from the relay 10 coil terminals...

Page 96: ...light Bulb Socket on page 11 56 Check taillight bulbs for continuity Brake pedal limit switch See Test Procedure 39 Brake Pedal Limit Switch on page 11 56 Park brake pedal limit switch See Test Procedure 38 Park Brake Limit Switch on page 11 56 For Turf 2 vehicle Check the continuity of the yellow wire from the inline fuse holder to the light switch Check the continuity of the fuse in the inline f...

Page 97: ...d occur which could blow the fuse or cause wire damage 4 To test brake light circuit place the red probe on wire contact connected to the 18 gauge red wire 5 To test taillight circuit place the red probe on wire contact connected to the 18 gauge brown wire 6 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 7 To test taillights place light swit...

Page 98: ...ould indicate no continuity 5 If the readings are incorrect replace the limit switch 6 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 TEST PROCEDURE 39 Brake Pedal Limit Switch See General Warning on page 10 1 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 2 Using a multimeter ...

Page 99: ...uge orange wire from the horn terminal and remove the 18 gauge black wire from the horn mounting stud 5 Using a multimeter set on 20 volts DC place an alligator clip on the black probe Connect the black probe to the 18 gauge black wire ring terminal Place the red probe into the spade terminal on the orange wire Figure 11 59 Page 11 58 See following CAUTION CAUTION Before connecting battery cables ...

Page 100: ...ch See General Warning on page 10 1 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 2 Disconnect the orange and red white wires at the horn button from the wire harness 3 Using a multimeter set to 200 ohms place the probes into the two terminal plug holes on the horn harness Figure 11 60 Page 11 58 4 The reading should show no continu...

Page 101: ...age 10 2 2 Place the neutral lockout switch in the MAINTENANCE position Access the engine compartment by removing the seat 3 Disconnect the wires from the starter generator 1 Mark wires before disconnecting Loosen the pivot nuts 7 and bolts 5 Figure 12 1 Page 12 2 4 Remove the mounting adjustment nut 12 washer 9 and bolt 11 Lower the starter generator and remove the belt 4 from the pulley 10 5 Sup...

Page 102: ...ushes 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 Figure 12 3 Page 12 2 See following NOTE NOTE To clean and inspect the armature commutator and the bearings see ...

Page 103: ...sh 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 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 point will damage springs 0 5 1...

Page 104: ...emaining three brush covers 29 in the openings in the commutator end cover 23 Figure 12 3 Page 12 2 1 491 Figure 12 6 Pull Brushes Away From Center of the Commutator End Cover DISASSEMBLY OF THE STARTER GENERATOR TO SERVICE THE ARMATURE COMMUTATOR 1 If the brushes are not removed contact between the brushes and commutator as the commutator end cover is being removed or installed could damage the b...

Page 105: ... metal of the bearing Bearings 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 A B 493 Figure 12 8 Bearing Play Inspection BEARING REMOVAL 1 Place the wedge attachment tool CCI P N 1012812 between the bearing and the armature Make sure the wedge attachment tool is supporting the inner race of...

Page 106: ...n electrical test indicates that it is necessary Figure 12 10 Page 12 7 See Starter Generator Starter Function on page 11 26 VISUAL INSPECTION OF ARMATURE Obvious defects can be seen by examining the armature If an armature has frayed or charred insulation broken wires or thrown solder it is obvious without testing that it should be replaced Faults seen during the visual inspection can aid in diag...

Page 107: ...tor can be polished away with 400 grit or finer sandpaper See following CAUTION 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 along the commutator If the commutator outside diameter is less than 1 53...

Page 108: ...tor bars Using a multimeter set on 200 ohms place the positive probe on the commutator bars and the negative 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 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 3 2 497 Fi...

Page 109: ...ok alike fit into the slots next to the F1 and F2 markings on the outside of the housing The insulator that looks different slides into the slot next to the DF marking 2 After the insulators are seated in the slots install the threaded terminals through the wire connectors and then through the insulators Install a flat washer lock washer and nut onto each threaded terminal on the outside of the ho...

Page 110: ...d 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 2 Install a flat washer lock washer and nut onto each terminal and tighten to 48 in lb 5 4 N m 2 Install two 3 8 inch hex head pivot bolts 5 into the mounting bracket with the heads of th...

Page 111: ... Starter Generator 12 13 7 5 2 3 10 4 11 1 9 12 498 Figure 12 13 Starter Generator Installation 1 2 Belt Tension Gauge 2 End View 499 Figure 12 14 Belt Tension Gauge 2009 FE 350 Maintenance and Service Supplement Page 12 11 ...

Page 112: ...ator belt 3 around 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 start...

Page 113: ...two black wires 5 and 6 at the NC and COIL terminals respectively on the relay and the black wire 7 at the battery frame ground Figure 12 16 Page 12 13 4 Remove the voltage regulator mounting screw 8 and remove the voltage regulator 9 7 8 4 1 2 3 9 1 Red wire to solenoid 2 To kill limit switch 3 To frame ground 4 To bullet connector 8 5 6 9 1 2 4 3 7 1 Red wire to solenoid 2 To small post of solen...

Page 114: ...ning on page 10 1 TESTING THE KEY SWITCH See Test Procedure 4 Key Switch Starter Circuit on page 11 22 See Test Procedure 18 Key Switch Engine Kill Circuit on page 11 38 KEY SWITCH REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 2 Remove the center dash panel 2 1 If equipped remove the shifter knob from shifter handle 2 2 Remo...

Page 115: ...the keyed washer with key switch 1 2 502 Figure 12 18 Key Switch Removal KEY SWITCH INSTALLATION 1 Reverse removal procedures to install key switch in the dash Connect wires to key switch See Wiring Diagrams on page 11 6 Coat the connectors with Battery Terminal Protector Spray CCI P N 1014305 to prevent corrosion Be sure that key switch terminals cannot touch the frame and that panel is properly ...

Page 116: ... and the 10 gauge red wire from the fuse block to the other large post on the solenoid Connect the 18 gauge blue wire from the key switch to the small post on the solenoid Connect the 18 gauge orange wire from the accelerator pedal limit switch to the other small post on the solenoid Carryall 2 Plus vehicles Connect the 6 gauge white wire from the starter generator the 18 gauge white wire from the...

Page 117: ...Figure 11 3 Figure 11 4 Figure 11 7 and Figure 11 8 Page 11 13 Connect the 6 gauge red wire from the battery terminal and the 10 gauge red wire from the fuse block to the other large post on the solenoid Connect the 18 gauge white wire from the voltage regulator and the diode opposite directional line to the small post on the solenoid Connect the 18 gauge orange wire from the accelerator pedal lim...

Page 118: ...e See following WARNING WARNING If a fuse is blown determine 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 tightening to 18 in lb 2 N m...

Page 119: ...nd the black wire from the kill limit switch 12 5 Remove the kill limit switch 12 15 9 10 12 13 8 1 A 20 16 21 11 A To Voltage Regulator 517 Figure 12 19 Accelerator Starter and Kill Limit Switches KILL LIMIT SWITCH INSTALLATION 1 Install the kill limit switch 12 onto the two screws 16 Figure 12 19 Page 12 19 2 Connect the two white black wires to the common COM terminal and the black wire to the ...

Page 120: ... 10 1 TESTING THE NEUTRAL LOCKOUT LIMIT SWITCH See Test Procedure 8 Neutral Lockout Limit Switch on page 11 25 NEUTRAL LOCKOUT LIMIT SWITCH REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 2 Remove the center dash panel See Key Switch Removal Section 12 Page 12 14 3 Disconnect the wires from the neutral lockout limit switch loc...

Page 121: ...y switch to the ON position The engine should not crank when pressing the accelerator If the engine does crank turn the key switch OFF and readjust the shift linkage Key Start vehicles Place the Forward Reverse handle in the NEUTRAL position The neutral lockout switch should be in the OPERATE position Make sure everyone is clear of the vehicle Turn the key switch to the START position and hold unt...

Page 122: ...minal on the buzzer 4 Reverse removal procedures to install the center dash in the vehicle Be sure that the key switch terminals cannot touch the frame and that the panel is properly seated and snapped in place 5 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 1 M 2 M 3 2 As seen from front driver side of vehicle with body removed 9 12 13 14 ...

Page 123: ...he left rear fender REAR REVERSE WARNING BUZZER INSTALLATION For Turf 6 Carryall 6 Villager and TransPorter vehicles 1 Install the screws 10 through the buzzer bracket tabs and tighten to a torque of 3 5 in lb 0 40 N m Figure 12 23 Page 12 22 2 Connect black wire 11 from frame ground to the negative terminal on the buzzer 3 Connect the red white wire from the wire harness to the positive terminal ...

Page 124: ...WITCH INSTALLATION 1 Place the reverse buzzer limit switch onto the two screws followed by the neutral lockout limit switch and secure with the two washers and two nuts Figure 12 21 Page 12 20 Tighten to 5 in lb 0 6 N m Place the Forward Reverse control in REVERSE to make sure that both switches actuate See following CAUTION CAUTION Do not overtighten the retaining nuts If the nuts are overtighten...

Page 125: ...ing 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 24 Page 12 25 2 Connect yellow wire from the key switch and yellow wire from the oil level sensor to the low oil warning light 3 Install the center dash in reverse order of removal Be sure that key switch terminals cannot...

Page 126: ...Key Switch Removal on page 12 14 3 Disconnect the wires from the fuel gauge hour meter 1 Do not allow wires to touch 4 Remove the mounting clip 2 that secures the gauge meter Figure 12 25 Page 12 25 Alternate pulling the lower and upper tabs away from the gauge housing to remove clip Pull gauge meter from the instrument panel FUEL GAUGE HOUR METER INSTALLATION 1 Install a new fuel gauge hour meter...

Page 127: ...ove the key Place the Forward Reverse handle in the NEUTRAL position Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 3 Disconnect the white black wire 1 from the black wire 2 at the bullet connector 3 located near the RPM limiter 4 Figure 12 26 Page 12 27 4 Disconnect the black wire 5 at the other bullet connector 6 n...

Page 128: ...1 TESTING THE IGNITION COIL See Test Procedure 14 Ignition Spark on page 11 29 and Test Procedure 16 Ignition Coil on page 11 31 IGNITION COIL REMOVAL 1 Remove the starter generator See Starter Generator Removal on page 12 1 See following NOTE NOTE The crankshaft has left hand threads at the clutch mounting hole 2 Remove the muffler See Muffler Removal on page 17 1 3 Cut the wire tie holding the w...

Page 129: ...st be removed from the old coil and installed on the new coil See steps 1 through 8 for procedures to remove and install these existing parts If the existing ignition coil will be remounted proceed to step 9 1 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the spark plug wire Figure 12 30 Page 12 30 2 Remove the cap 2 from the wire by turning the cap counterclockwise ...

Page 130: ...ze feeler gauge to set the air gap between the ignition coil and the flywheel magnet Tighten the two mounting bolts 6 to 30 in lb 3 4 N m Figure 12 31 Page 12 30 11 Connect the 18 gauge black wire to the spade terminal on the coil 12 Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch on the housing 13 When installing fan housing make sure the top ...

Page 131: ...OIL LEVEL SENSOR INSTALLATION See Oil Level Sensor Installation Section 14 Page 14 6 RELAY See General Warning on page 10 1 TESTING THE RELAY See Test Procedure 29 Relay Engine Kill Circuit on page 11 45 See Test Procedure 30 Relay Starter and Neutral Lockout Circuits on page 11 46 RELAY REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 P...

Page 132: ...in place 2 Connect the wires to the terminals on the relay See Wiring Diagrams Section 11 Page 11 6 3 Secure the relay and mounting bracket to the electrical component box Tighten hardware to 22 in lb 2 5 N m Figure 12 32 Page 12 32 4 Install snap on electrical component box cover Firmly press down all corners before installing screw to 18 in lb 2 N m 5 Connect battery and spark plug wire s See Co...

Page 133: ...s on the connector 4 and remove halogen bulb assembly 6 7 6 4 513 Figure 12 33 Headlight Assembly HEADLIGHT BULB INSTALLATION NOTE When handling halogen bulbs do not touch glass portion of bulb Oil from finger tips can cause premature failure of bulb 1 Connect wire harness 4 to the halogen bulb assembly 6 The retaining tab should lock onto the halogen bulb assembly Figure 12 33 Page 12 33 2 From t...

Page 134: ...inal for solid black wire and terminal for black white wire 5 Remove the mounting hardware 2 from the voltage limiter and remove it from the vehicle VOLTAGE LIMITER INSTALLATION 1 Mount the voltage limiter to the frame using the mounting hardware and tighten to 25 in lb 2 8 N m Figure 12 34 Page 12 34 2 Connect the black white wire from harness to the negative terminal on the voltage limiter 3 Con...

Page 135: ...sides Insert the switch through the center dash and install the nut on the outside of the dash Tighten the nut to 14 in lb 1 6 N m Figure 12 35 Page 12 34 3 Push the light switch shaft in Screw the knob onto the end of the shaft until the knob touches the outer nut Then turn the knob in the opposite direction until the headlight beams on the knob are horizontal to the ground Tighten the set screw ...

Page 136: ...ll the screws 3 Connect battery See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 2 3 1 5 6 4 7 8 1 1425 Figure 12 36 Taillight Assembly 1426 Figure 12 37 Mount Taillight To Rear Fender TAILLIGHT REMOVAL 1 Disconnect battery See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 2 Remove the screws 1 securing the taillight 7 to the rear fender 8 Figure 12 37 Page 12 3...

Page 137: ...vice manual 4 Remove the two voltage suppressor wires 11 from the coil terminals of the brake light relay 12 Figure 12 38 Page 12 37 Figure 12 39 Page 12 37 Figure 12 40 Page 12 38 and Figure 12 40 Page 12 38 5 Remove the two wires from the contact terminals of the brake light relay 6 Remove the two nuts 15 two screws 13 and two washers 14 from the brake light relay 12 7 Remove the brake light rel...

Page 138: ...ts to 30 in lb 3 4 N m 2 Connect the two wires from the voltage suppressor 11 to the coil terminals on the brake light relay 12 as shown 3 Connect the two brake light wires to the COM common and NO normally open terminals of the brake light relay 4 Install the front body See Front Body Installation in Section 4 of the appropriate maintenance and service manual 5 Install the center dash panel in th...

Page 139: ...3 1 5 4 2 1431 Figure 12 42 Park Brake Limit Switch 1433 Figure 12 43 Mount Brake Pedal Limit Switch to Brake Pedal Mounting Bracket PARK BRAKE LIMIT SWITCH INSTALLATION 1 Secure the switch to the brake pedal with lock nuts 5 and hex head machine screws 4 Figure 12 42 Page 12 39 Set the gap between the switch and the top of the park brake rod to no more than 0 030 of an inch 0 762 mm Figure 12 43 ...

Page 140: ... Disconnect the wires from the switch and remove the switch 1433 Figure 12 44 Mount Brake Pedal Limit Switch to Brake Pedal Mounting Bracket BRAKE PEDAL LIMIT SWITCH INSTALLATION 1 Connect the 6 gauge orange white wire to the NC terminal and the 16 gauge green white wire to the COM terminal Tighten the screws 1 to 10 in lb 1 1 N m 2 Secure the switch to the bracket with lock nuts 4 and hex head ma...

Page 141: ...black wire 5 from the mounting stud on the front of the horn 5 Remove the horn from the vehicle HORN INSTALLATION 1 Install the orange wire onto the horn Slip the black wire ring terminal onto the mounting stud 2 Install the horn stud through the mounting bracket 6 Install the lock washer and nut onto the mounting stud to tighten the horn to 8 ft lb 10 8 N m Figure 12 45 Page 12 41 NOTE Shoulder o...

Page 142: ...le in the rubber cap Tighten the jam nut to 22 in lb 2 5 N m Figure 12 46 Page 12 41 3 Connect wire harness at the connector on the horn switch 4 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 BATTERY See General Warning on page 10 1 DANGER Due to the danger of an exploding battery wear a full face shield and rubber gloves when working on or...

Page 143: ...hes H 21 0 cm W x 16 5 cm 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 Battery on page 11 17 See Test Procedure 25 Battery Test Under Load on page 11 41 PREVENTIVE MAINTENANCE 1 To keep the battery in good operating condition remove any corrosion immediately Post connections should be clean and tig...

Page 144: ...nually to be sure water is at its proper level Figure 12 47 Page 12 44 Never allow the water level to fall below the tops of the plates because this will cause the exposed part of the plate to become permanently inactive Check the water level more frequently in hot weather or when the battery becomes old 1 3 2 1 Level Indicator 2 Cap 3 Plates Electrolyte level at least 1 2 inch 13 MM above plates ...

Page 145: ...ates lower on charge voltage Ammonia 8 0 Slight self discharge of both plates Organic matter 50 0 Corrosion of positive plate Nitrates 10 0 Increased sulfation at negative Nitrites 5 0 Corrosion at both plates loss of capacity reduced life Chloride 5 0 Loss of capacity in both plates greater loss in positive Color Clear and White Antimony 5 0 Self discharge by local action reduces life lower on ch...

Page 146: ...e to the positive battery post 3 Attach the negative charger cable to the negative battery post 4 The battery may be charged with a slow charge 3 10 amps or a fast charge 20 30 amps Charge until the specific gravity reaches 1 250 See following WARNING WARNING If the battery case feels hot approximately 125 F 52 C or more emits gases or fluid boils from vents stop charging immediately Failure to st...

Page 147: ...ific gravity drops below 1 220 the battery should be recharged See following WARNING WARNING If the battery is frozen or the container is bulged discard battery A frozen battery can explode 6 The frequency of recharging required depends on the temperature of the storage area but it is recommended that the battery be monitored for state of charge every month Also if the storage area is unheated in ...

Page 148: ......

Page 149: ... complete instruction on engine disassembly repair rebuilding and reassembly see your authorized dealer BEFORE SERVICING Carefully read the applicable information and instructions before beginning engine service Diagrams DANGER WARNING CAUTION and NOTE statements and detailed descriptions have been included wherever necessary Anyone attempting engine service should have knowledge and experience in...

Page 150: ...e are an indication of worn rings valve guides cylinder wall etc Also examine the spark plug wire Remove rubber boot and inspect internal spring for damage Inspect spark plug wire for damage and be sure spring coil is securely attached to spark plug See following WARNING WARNING Remove spark plug wire to avoid accidental start up of the engine when servicing vehicle To avoid ignition of fuel and s...

Page 151: ...ld vary slightly depending on wear of components affecting compression Pedal Start engines Pedal start engines are not equipped with an automatic compression release valve ACR At a normal cranking speed of 550 600 RPM the compression should typically be 156 psi This value could vary slightly depending on wear of components affecting compression See the Engines and Drivetrain Components Repair and ...

Page 152: ...age 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 13 4 3 Remove eight bolts 3...

Page 153: ...ire 2 from the cord connection 1 Figure 13 2 Page 13 4 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 Oil Level Sensor Installation 1 If the oil level sensor was removed from the bracket install sensor 6 into ...

Page 154: ...come 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 3 Install and finger tighten evenly the eight cover mounting bolts Figure 13 6 Page 13 7 4 Tighten...

Page 155: ... housing Figure 13 7 Page 13 7 2 Disconnect the ignition coil 11 from its primary lead wire at the connector 12 Remove the two bolts 10 and take out the ignition coil Figure 13 8 Page 13 7 2 1 1 12 11 13 10 531 Figure 13 7 Flywheel Housing 510 Figure 13 8 Ignition Coil 3 Hold the flywheel 4 not the fan 7 with a strap wrench 5 and using a 25 mm socket remove the flywheel nut and flat washer by turn...

Page 156: ...keyway in the crankshaft Then align the keyway in the flywheel to the key and push the flywheel and fan assembly onto the crankshaft until it seats Install flat washer and nut finger tight 2 Use a strap wrench 3 to keep the flywheel and fan assembly 1 from turning while tightening the flywheel nut to 63 ft lb 85 4 N m Figure 13 11 Page 13 9 See following CAUTION CAUTION The flywheel nut has right ...

Page 157: ...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 Install drive clutch See Drive Clutch Installation on page 19 11 3 Install drive belt See Drive Belt Installation on page 19 3 4 Install muffler See Muffler Installation on page 17 1 5 Install starter generator and belt See Starter Generator...

Page 158: ...aned spark plug gapped to 0 027 0 031 inch 0 69 0 79 mm 11 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 12 Adjust the engine RPM setting See Engine RPM Adjustment on page 15 11 13 Test drive vehicle to ensure all systems are functional and correctly adjusted TORQUE SPECIFICATIONS ITEM SIZE LIMITS Flywheel retaining nut M16 63 ft lb 86 N m ...

Page 159: ... 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 156 psi 1076 kPa Engine RPM 3050 30 RPM for Key Start Vehicles 2900 30 RPM for Pedal Start Vehicles 2009 FE 350 Maintenance and Service Supplement Page 13 11 ...

Page 160: ......

Page 161: ...emoving and replacing the engine For complete instruction on engine disassembly repair rebuilding and reassembly see your authorized dealer BEFORE SERVICING Carefully read the applicable information and instructions before beginning engine service Diagrams DANGER WARNING CAUTION and NOTE statements and detailed descriptions have been included wherever necessary Anyone attempting engine service sho...

Page 162: ...move spark plug wire to avoid accidental start up of the engine when servicing vehicle To avoid ignition of fuel and serious personal injury or death never try to start the engine with plug removed from engine A 524 Figure 14 1 Spark Plug Testing the Spark Plug Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible Spark should be blue and strong and ...

Page 163: ...vents oil from being forced out of the engine through the piston rings oil seals or gaskets The breather has a reed valve which limits the direction of air flow caused by the piston moving up and down Air can flow out of the crankcase but the one way reed valve blocks return flow and therefore maintains a vacuum in the crankcase Oil laden air in the crankcase passes through the reed valve and expa...

Page 164: ...ve the powertrain See Unitized Transaxle Removal on page 18 8 See following NOTE NOTE The crankshaft has left hand threads at the clutch mounting hole 2 Remove starter generator See Starter Generator Removal Section 12 Page 12 1 3 Remove drive clutch See Drive Clutch Removal on page 19 4 and preceding NOTE 4 Remove muffler See Muffler Removal on page 17 1 5 Remove engine mounting hardware items 1 ...

Page 165: ...clamps at two ended bolts 1 and 2 Figure 14 5 Page 14 5 3 Remove eight bolts 3 and remove the crankcase cover 4 See following NOTE NOTE If the crankcase cover sticks tap lightly with a plastic mallet on alternate sides near the dowel pins 5 Figure 14 5 Page 14 5 4 Remove the crankcase cover gasket completely It may stick to the flanged surface of the crankcase 11 12 3 4 1 2 5 5 526 Figure 14 4 Oil...

Page 166: ...ire 2 from the cord connection 1 Figure 14 7 Page 14 7 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 Oil Level Sensor Installation 1 If the oil level sensor was removed from the bracket install sensor 6 into ...

Page 167: ...come 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 3 Install and finger tighten evenly the eight cover mounting bolts 4 Tighten the cover mounting bo...

Page 168: ...ousing Figure 14 9 Page 14 8 2 Disconnect the ignition coil 11 from its primary lead wire at the connector 12 Remove the two bolts 10 and take out the ignition coil Figure 14 10 Page 14 8 2 1 1 12 11 13 10 531 Figure 14 9 Flywheel Housing 510 Figure 14 10 Ignition Coil 3 Hold the flywheel 4 not the fan 7 with a strap wrench 5 and using a 25 mm socket remove the flywheel nut and flat washer by turn...

Page 169: ...keyway in the crankshaft Then align the keyway in the flywheel to the key and push the flywheel and fan assembly onto the crankshaft until it seats Install flat washer and nut finger tight 2 Use a strap wrench 3 to keep the flywheel and fan assembly 1 from turning while tightening the flywheel nut to 63 ft lb 85 4 N m Figure 14 13 Page 14 10 See following CAUTION CAUTION The flywheel nut has right...

Page 170: ...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 14 6 Page 14 6 2 Install drive clutch See Drive Clutch Installation on page 19 11 3 Install drive belt See Drive Belt Installation on page 19 3 4 Install muffler See Muffler Installation on page 17 1 5 Install starter generator and belt See Starter Generator...

Page 171: ...lug gapped to 0 027 0 031 inch 0 69 0 79 mm 11 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 12 Adjust the engine RPM setting See Engine RPM Adjustment on page 16 11 13 Test drive vehicle to ensure all systems are functional and correctly adjusted TORQUE SPECIFICATIONS ITEM SIZE LIMITS Flywheel retaining nut M16 63 ft lb 86 N m Crankcase co...

Page 172: ...k 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 128 psi 883 kPa Engine RPM 3050 30 RPM for Key Start Vehicles 2900 30 RPM for Pedal Start Vehicles Page 14 12 2009 FE 350 Maintenance and Service Supplement ...

Page 173: ...s See Fuel Filters on page 15 19 Choke and air intake system for restriction of air flow See Choke and Air Intake System on page 15 12 Fuel pump See Fuel Pump on page 15 22 Fuel lines from fuel tank to filter to pump to carburetor See Fuel Lines on page 15 28 Exhaust system for restrictions See Exhaust System on page 17 1 If the carburetor floods or leaks fuel at the float bowl gasket or carbureto...

Page 174: ...uretor S10 FE350 FUEL SYSTEM 000 000 000 000 000 000 000 000 1 2 3 4 13 15 12 30 21 26 10 21 11 19 18 22 23 14 16 17 534 Figure 15 1 Carburetor Mounting Page 15 2 2009 FE 350 Maintenance and Service Supplement ...

Page 175: ...arily plug the end of the fuel line to prevent fuel leakage 2 7 Remove the carburetor retaining nuts 19 intake pipe 17 and carburetor 12 See following NOTE NOTE Note the orientation of the gasket 16 between the carburetor intake pipe 17 and the carburetor body 12 so that it can be replaced in the same orientation Figure 15 1 Page 15 2 When removing the carburetor body the throttle return spring 11...

Page 176: ... 15 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 7 Remove the main jet 8 from the carburetor body and discard it Figure 15 4 Page 15 4 See following NOTE NOTE Make sure the fuel nozzle 7 does not fall out of the carburetor body after removal of the main jet This is be...

Page 177: ...pinched 1 4 5 1 3 2 1 If spring looks like this 2 then adjust spring to look like this by 3 holding float firmly and rotating valve counterclockwise to seat spring in seat of float bowl 4 Check for coil located in groove above both ears 5 Check for spring seated in recess of float 538 Figure 15 5 Inspect Float Valve Spring Assembly Adjust If Required 11 Install the fuel bowl retaining screw and ti...

Page 178: ...vicing the vehicle Disconnect battery cables negative cable first Disconnect the spark plug wire from the spark plug See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 GENERAL INFORMATION For proper vehicle operation it is important the accelerator pedal governor linkage and throttle adjustments are done correctly and in the proper sequence See following CAUTION CAUTION Improper ...

Page 179: ...rical box screw and cover Figure 15 7 Page 15 8 5 Adjust length of accelerator rod With the ball joint jam nuts 3 loose Figure 15 6 Page 15 7 adjust the length of the accelerator rod so the indicated cam edge is parallel with the electrical component box as shown Figure 15 7 Page 15 8 See following CAUTION CAUTION Be sure that approximately an equal number of threads are exposed at each end of the...

Page 180: ...or rod are properly adjusted adjust the engine RPM setting See Engine RPM Adjustment on page 15 11 12 Install the electrical box cover and tighten retaining screw to 18 in lb 2 0 N m 13 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 GOVERNOR CABLE Governor Cable Removal 1 Turn the key switch to the OFF position and remove the key place the F...

Page 181: ...15 9 5 With the governor lever arm loose on the governor shaft use a 1 8 inch punch or scratch awl to turn the governor arm shaft counterclockwise until it stops Then pull the governor lever arm rearward until the carburetor throttle is in the wide open throttle WOT position 6 While holding the arm and shaft in the fully counterclockwise position tighten the governor arm lever nut to 36 in lb 4 0 ...

Page 182: ...ing 16 to the engine governor arm Figure 15 9 Page 15 9 4 Install cable in accelerator cable bracket 5 Figure 15 9 Page 15 9 5 Push the cable dust shield onto the spring end of the cable conduit 6 Before tightening the cable housing retaining nuts make sure the engine RPM adjustment is correct See Engine RPM Adjustment on page 15 11 7 Install the electrical box cover and tighten the retaining scre...

Page 183: ...t Vehicles Place the Forward Reverse handle in the NEUTRAL position chock the wheels and the neutral lockout switch in the MAINTENANCE position 5 Connect a tachometer CCI P N 1016112 to the spark plug lead 6 With the tachometer connected and the engine at normal operating temperature check high speed RPM With the accelerator pedal pressed to the floor the tachometer should read Turf 2 with two whe...

Page 184: ...creases engine horsepower and extends air filter life The choke system aids in starting the engine in cold weather When starting a cold engine the choke cable handle is pulled This restricts the air flow creating a fuel rich mixture in the carburetor The choke cable handle is pulled until the engine starts and then is released The air flow to the engine is no longer restricted and the engine opera...

Page 185: ...ntake duct must be in place before the air box can be installed 1 Check to be sure the intake seal 14 is seated correctly Figure 15 12 Page 15 16 or Figure 15 13 Page 15 17 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 undersid...

Page 186: ...Be careful that the intake seal on the bottom of the air box assembly is not dislodged in the process 3 Drill out the two pop rivets 25 in the retaining bracket 27 Figure 15 13 Page 15 17 4 Pull the air duct forward through the hole in the floorboard and up and out of the vehicle The Villager has no floorboard under the front seat INTAKE DUCT INSTALLATION Turf 2 Carryall 2 and Carryall 2 Plus The ...

Page 187: ...steering joint 5 1 Position steering joint assembly 1 on vehicle as shown Install three lock washers and three bolts and tighten to 15 ft lb 20 3 N m Figure 15 11 Page 15 14 5 2 Align the flat portion of the steering shaft spline with the bolt hole in the universal joint and then slide the shaft into the upper universal joint Install the bolt and lock washer on the upper universal joint and tighte...

Page 188: ...FUEL SYSTEM 25 31 26 30 25 26 26 24 16 15 15 13 12 18 4 17 5 6 11 10 9 8 3 2 1 7 22 23 14 21 20 19 833 Figure 15 12 Air Intake and Choke Assemblies Turf 2 Carryall 2 and Carryall 2 Plus Page 15 16 2009 FE 350 Maintenance and Service Supplement ...

Page 189: ...6 11 10 9 8 13 12 17 7 26 1394 Figure 15 13 Air Intake and Choke Assemblies Turf 6 Carryall 6 TransPorter and Villager Turf 6 Carryall 6 TransPorter and Villager 1 Remove front seat and insert air duct through the hole in the floorboard under the seat 2009 FE 350 Maintenance and Service Supplement Page 15 17 ...

Page 190: ... box fully Remove filter element 12 4 Using a clean cloth wipe away any dust or dirt from inside the air box Remove all dirt build up around the inside lip of the box or the box will not seal properly 5 Install new air filter by inserting back edge first and pushing down using the palm of your hand to seat filter evenly onto inside lip of air box Ensure filter fits correctly and that the wire latc...

Page 191: ...4 Remove the fuel filter 17 Figure 15 14 Page 15 20 or Figure 15 15 Page 15 21 4 1 Remove the clamps 16 and fuel lines 1 and 2 from the filter and plug the fuel lines FUEL FILTER INSTALLATION 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 fuel filter 17 in the f...

Page 192: ...UEL LINE NO ROUTING SOLID COLOR CLEAR 1 Fuel tank to primary fuel filter 6 0 in 15 2 cm 2 Primary fuel filter to fuel pump 6 0 in 15 2 cm 3 Fuel pump to carburetor 17 0 in 43 2 cm 4 Vent tube Carburetor 22 0 in 55 9 cm 5 Vent tube Fuel Tank 17 0 in 43 2 cm 6 Impulse line 17 0 in 43 2 cm Total 46 0 in 116 8 cm 39 0 in 99 1 cm Page 15 20 2009 FE 350 Maintenance and Service Supplement ...

Page 193: ...to primary fuel filter 14 0 in 35 6 cm 11 5 in 29 2 cm 2 Primary fuel filter to fuel pump 6 0 in 15 0 cm 2 5 in 6 4 cm 3 Fuel pump to carburetor 17 0 in 43 2 cm 17 0 in 43 2 cm 4 Vent tube Carburetor 22 0 in 55 9 cm 22 0 in 55 9 cm 5 Vent tube Fuel Tank 17 0 in 43 2 cm 17 0 in 43 2 cm 6 Impulse line 14 0 in 35 6 cm 17 0 in 43 2 cm Total 51 0 in 129 4 cm 39 0 in 99 1 cm 48 0 in 122 cm 39 0 in 99 1 ...

Page 194: ...ion Figure 15 21 Page 15 29 or Figure 15 22 Page 15 29 4 Remove hardware attaching the fuel pump 24 and lift the fuel pump out of the engine compartment Figure 15 14 Page 15 20 or Figure 15 15 Page 15 21 5 Remove the clamp 20 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 WARNING Carefully drain any fu...

Page 195: ...nonflammable solvent clean the front cover pumping chamber and back cover Be sure the vent 40 on the front cover is clean both inside and out 2 Inspect the valve assemblies 31 32 and 33 and all gaskets and diaphragms for damage Figure 15 16 Page 15 23 3 If a valve assembly is damaged the rubber retaining plug 33 and valve assembly must be replaced 24 32 31 30 35 38 34 36 33 39 40 25 37 27 28 29 1 ...

Page 196: ... Figure 15 17 Page 15 23 2 Connect to the output side of the fuel pump the fuel line 3 that goes to the carburetor Figure 15 14 Page 15 20 or Figure 15 15 Page 15 21 3 Connect the impulse line 7 to the bottom nipple on the fuel pump Use a new clamp 20 4 Install the fuel pump For Villager 6 and 8 vehicles install the fuel pump on the frame and tighten the mounting bolts and lock nuts to 60 in lb 6 ...

Page 197: ...closed OFF position and run the engine until fuel remaining in the carburetor fuel pump and fuel lines is used up and the engine stalls Figure 15 21 Page 15 29 or Figure 15 22 Page 15 29 5 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 6 Disconnect battery See Disconnecting the Battery Gasoline Vehicles Secti...

Page 198: ...the speed nut Figure 15 15 Page 15 21 12 For Turf Carryall and TransPorter remove the filler neck from the polyurethane filler bezel 13 Lift the fuel tank out of the vehicle 549 Figure 15 18 Fuel Level Sending Unit FUEL TANK DISPOSAL 1 Remove the cap from the tank and thoroughly rinse it with water The cap may be discarded or kept as a spare 2 In a well ventilated area flush the fuel tank with wat...

Page 199: ...o the center stud and install the flat washer lock washer and nut Tighten to 18 in lb 2 0 N m 7 Slide the rubber boot over the stud Figure 15 18 Page 15 26 8 Add fuel to the tank 9 Connect battery See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 10 Check to be sure the fuel shut off valve on top of the fuel tank is in the open ON position Figure 15 21 Page 15 29 or Figure 15 22 Pa...

Page 200: ...nd are properly routed Failure to heed this warning could result in damage to fuel lines and fire Fuel line no 1 runs directly from the fuel tank to the fuel filter 17 The fuel filter 17 has an arrow indicating fuel flow direction Figure 15 14 Page 15 20 or Figure 15 15 Page 15 21 Fuel line no 2 runs directly from the fuel filter to the fuel inlet of the fuel pump Fuel line no 3 runs directly from...

Page 201: ... part of a procedure the fuel shut off valve should also be closed OFF before performing maintenance or service procedures 1 2 3 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully opened or fully closed 2 1 3 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully opened or fully closed 449 Figure ...

Page 202: ......

Page 203: ...e Fuel Filters on page 16 18 Choke and air intake system for restriction of air flow See Choke and Air Intake System on page 16 12 Fuel pump See Fuel Pump on page 16 21 Fuel lines from fuel tank to filter to pump to carburetor See Fuel Lines on page 16 28 Exhaust system for restrictions See Exhaust System on page 17 1 If the carburetor floods or leaks fuel at the float bowl gasket or carburetor ve...

Page 204: ...21 11 19 18 22 23 14 16 17 534 Figure 16 1 Carburetor Mounting MAIN JET ELEVATION SIZE CHART ALTITUDE FE350 ENGINE MAIN JET SIZE 0 3200 ft 0 975 m 82 3200 6500 ft 975 1981 m 80 6500 9800 ft 1981 2987 m 78 9800 ft and above 2987 m and above 76 Page 16 2 2009 FE 350 Maintenance and Service Supplement ...

Page 205: ...rientation Figure 16 1 Page 16 2 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 3 Position the carburetor with the drain screw 11 over a catch basin Figure 16 2 Page 16 3 4 Turn the carburetor bowl drain screw counterclockwise two o...

Page 206: ...n Size Chart on page 16 2 Check the size designation on the jet to make sure it is the correct part 9 Install the new main jet and tighten it to 12 in lb 1 4 N m See following CAUTION and NOTE CAUTION Do not remove the valve spring assembly from the float assembly Doing so will damage the spring NOTE Inspect the main jet nozzle 7 and pilot jet 4 to ensure they are free from contamination Figure 16...

Page 207: ...uretor on the engine Figure 16 1 Page 16 2 13 1 Attach the throttle return spring 11 to the carburetor and then to the throttle bracket 4 just before positioning the carburetor and securing it to the engine 13 2 Install the intake pipe gasket 16 check for proper orientation and intake pipe 17 13 3 Install the carburetor retaining nuts 19 and tighten them to 50 in lb 5 7 N m 14 Connect fuel supply ...

Page 208: ...rectly and in the proper sequence See following CAUTION CAUTION Improper adjustment can result in poor vehicle performance and or damage to the engine components ACCELERATOR ROD Accelerator Rod Removal 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 2 Raise the front of the vehicle Place chocks at the rear wheels and lift the front of...

Page 209: ...l joint jam nuts 3 loose Figure 16 6 Page 16 7 adjust the length of the accelerator rod so the indicated cam edge is parallel with the electrical component box as shown Figure 16 7 Page 16 8 See following CAUTION 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 c...

Page 210: ...roperly adjusted adjust the engine RPM setting See Engine RPM Adjustment on page 16 11 12 Install the electrical box cover and tighten retaining screw to 18 in lb 2 0 N m 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 Access the engine compartment 3 Disconnect battery...

Page 211: ...aft counterclockwise until it stops Then pull the governor lever arm rearward until the carburetor throttle is in the wide open throttle WOT position 6 While holding the arm and shaft in the fully counterclockwise position tighten the governor arm lever nut to 36 in lb 4 0 N m 7 Check engine RPM adjustment See Engine RPM Adjustment on page 16 11 6 14 12 10 15 17 13 11 1 2 2 6 16 5 3 4 542 Figure 1...

Page 212: ...16 9 Page 16 9 4 Install cable in accelerator cable bracket 5 5 Push the cable dust shield onto the spring end of the cable conduit 6 Before tightening the cable housing retaining nuts make sure the engine RPM adjustment is correct See Engine RPM Adjustment on page 16 11 7 Install the electrical box cover and tighten the retaining screw to 18 in lb 2 0 N m CLOSED THROTTLE OR IDLE ADJUSTMENT Pedal ...

Page 213: ...170 30 RPM Turf 2 with four wheel brakes 3170 30 RPM Turf 2 with four wheel brakes and portable refreshment center 3050 30 RPM Turf 6 3050 30 RPM Carryall 2 3170 30 RPM Carryall 2 Plus 3650 30 RPM Carryall 2 Plus with portable refreshment center 3050 30 RPM Carryall 6 3050 30 RPM Villager 6 and 8 3050 30 RPM TransPorter vehicles 3050 30 RPM 7 To reduce RPM loosen the accelerator cable retaining nu...

Page 214: ...LE 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 battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 10 Page 10 2 3 Remove the screw 17 securing cable to air box and detach cable end from choke lever 6 Figure 16 11 Page 16 13 and Figure 16 12 Page 16 1...

Page 215: ...e System 16 25 31 26 30 25 26 26 24 16 15 15 13 12 18 4 17 5 6 11 10 9 8 3 2 1 7 22 23 14 21 20 19 833 Figure 16 11 Air Intake and Choke Assemblies Turf 2 Carryall 2 and Carryall 2 Plus 2009 FE 350 Maintenance and Service Supplement Page 16 13 ...

Page 216: ...FUEL SYSTEM 27 26 25 24 21 20 19 28 22 23 14 16 15 15 3 2 1 18 4 5 6 11 10 9 8 13 12 17 7 26 1394 Figure 16 12 Air Intake and Choke Assemblies Turf 6 Carryall 6 TransPorter and Villager Page 16 14 2009 FE 350 Maintenance and Service Supplement ...

Page 217: ... 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 16 11 Page 16 13 and Figure 16 12 Page 16 14 Tighten to 33 in lb 3 7 N m 3 Place hose onto air box and secure with wire clamp 4 Attach the choke cable to the air box top See Choke Cable Installation o...

Page 218: ...t the end of the intake duct through the slot in the front of the air box mounting plate 2 Secure the front of the duct to the underside of the floorboard with two pop rivets 25 and flat washers 26 Figure 16 11 Page 16 13 3 Install the air duct shield 30 3 1 Remove any old double sided tape that may still be adhered to the air duct shield or frame 3 2 Place a new strip of double sided tape on the ...

Page 219: ... box fully Remove filter element 12 4 Using a clean cloth wipe away any dust or dirt from inside the air box Remove all dirt build up around the inside lip of the box or the box will not seal properly 5 Install new air filter by inserting back edge first and pushing down using the palm of your hand to seat filter evenly onto inside lip of air box Ensure filter fits correctly and that the wire latc...

Page 220: ...Page 16 29 4 Remove the fuel filter 17 Figure 16 14 Page 16 19 and Figure 16 15 Page 16 20 4 1 Remove the clamps 16 and fuel lines 1 and 2 from the filter and plug the fuel lines FUEL FILTER INSTALLATION 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 fuel filter...

Page 221: ...UEL LINE NO ROUTING SOLID COLOR CLEAR 1 Fuel tank to primary fuel filter 6 0 in 15 2 cm 2 Primary fuel filter to fuel pump 6 0 in 15 2 cm 3 Fuel pump to carburetor 17 0 in 43 2 cm 4 Vent tube Carburetor 22 0 in 55 9 cm 5 Vent tube Fuel Tank 17 0 in 43 2 cm 6 Impulse line 17 0 in 43 2 cm Total 46 0 in 116 8 cm 39 0 in 99 1 cm 2009 FE 350 Maintenance and Service Supplement Page 16 19 ...

Page 222: ... 350 FUEL SYSTEM 16 20 5 20 17 23 14 6 23 1 16 16 2 21 7 14 13 19 9 28 4 10 27 15 26 8 16 25 24 22 18 29 3 12 11 1310 Figure 16 15 Fuel and Vent Lines Side Fill Tank Page 16 20 2009 FE 350 Maintenance and Service Supplement ...

Page 223: ... operating properly perform the following tests Make sure all hose clamps are tight Inspect the impulse line and fuel lines for damage or clogging Make sure the air vent on the fuel pump is not clogged with dirt Make sure the fuel filters are not clogged To clean the air vent the fuel pump must be disassembled FUEL PUMP REMOVAL 1 Turn the key switch to the OFF position and remove the key place the...

Page 224: ...24 and lock washers 25 from front of the fuel pump Figure 16 16 Page 16 23 3 Remove the front cover 37 of the fuel pump while holding the rest of the pump intact 4 Note the orientations of the impulse gasket 27 the diaphragm 28 and the gasket 29 then remove them from the pump 5 If the impulse gasket 27 and the diaphragm 28 come off with the front cover note their orientations and remove them 6 Rem...

Page 225: ...he front of the front cover 4 Install the gasket 29 clear impulse diaphragm 28 and the paper impulse gasket 27 to the pumping chamber 30 5 Install the front cover 37 and then the lock washers 25 and four screws 24 on the assembly Be sure the arrows on the front cover point from the fuel inlet to the fuel outlet Figure 16 17 Page 16 23 Tighten the screws to 26 in lb 3 0 N m FUEL PUMP INSTALLATION 1...

Page 226: ... the Battery Gasoline Vehicles Section 10 Page 10 3 6 Turn the fuel shut off valve on top of the fuel tank to the open position Figure 16 21 Page 16 29 or Figure 16 22 Page 16 29 7 Key Start Vehicles Place the Forward Reverse handle in the NEUTRAL position and chock the wheels See following DANGER 8 Pedal Start Vehicles Place the Forward Reverse handle in the NEUTRAL position chock the wheels and ...

Page 227: ...closed OFF position and run the engine until fuel remaining in the carburetor fuel pump and fuel lines is used up and the engine stalls Figure 16 21 Page 16 29 or Figure 16 22 Page 16 29 5 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 6 Disconnect battery See Disconnecting the Battery Gasoline Vehicles Secti...

Page 228: ...13 Lift the fuel tank out of the vehicle 1309 Figure 16 18 Fuel Level Sending Unit FUEL TANK DISPOSAL 1 Remove the cap from the tank and thoroughly rinse it with water The cap may be discarded 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 s...

Page 229: ...tud Figure 16 18 Page 16 26 8 Add fuel to the tank 9 Connect battery See Connecting the Battery Gasoline Vehicles Section 10 Page 10 3 10 Check to be sure the fuel shut off valve on top of the fuel tank is in the open ON position Figure 16 21 Page 16 29 or Figure 16 22 Page 16 29 11 Key Start Vehicles Place the Forward Reverse handle in the NEUTRAL position and chock the wheels See following DANGE...

Page 230: ...nd are properly routed Failure to heed this warning could result in damage to fuel lines and fire Fuel line no 1 runs directly from the fuel tank to the fuel filter 17 The fuel filter 17 has an arrow indicating fuel flow direction Figure 16 14 Page 16 19 and Figure 16 15 Page 16 20 Fuel line no 2 runs directly from the fuel filter to the fuel inlet of the fuel pump Fuel line no 3 runs directly fro...

Page 231: ...s part of a procedure the fuel shut off valve should also be closed OFF before performing maintenance or service procedures 1 2 3 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully opened or fully closed 2 1 3 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully opened or fully closed 449 Figure...

Page 232: ......

Page 233: ...cket 2 with clamp 6 2 Place a new gasket 12 on the cylinder block exhaust stud bolts 3 Attach muffler manifold with lock washers 11 and hex nuts 10 and finger tighten 4 Loosely secure muffler 1 mounting bracket and governor cable bracket 13 using hex head cap screw 7 lock washer 8 and flat washer 9 5 Tighten manifold hex nuts 10 to 11 ft lb 14 9 N m 6 Tighten the hex cap screw 7 to 14 ft lb 18 9 N...

Page 234: ...See following DANGER DANGER Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 1 2 3 4 5 7 11 8 12 000 000 6 10 9 13 835 Figure 17 1 Exhaust System Page 17 2 2009 FE 350 Maintenance and Service Supplement ...

Page 235: ...river from starting the vehicle in NEUTRAL If the vehicle is started in FORWARD or REVERSE and then shifted to NEUTRAL the engine will stop running The key start FE350 vehicle will start in NEUTRAL however if the accelerator pedal is pressed while the Forward Reverse handle is in the NEUTRAL position the engine will stop running For the convenience of the trained technician there is a neutral lock...

Page 236: ...FORWARD or REVERSE position 81 Figure 18 1 Neutral Lockout Switch GOVERNOR SYSTEM The governor system regulates vehicle ground speed It is mounted inside the unitized transaxle and is driven by transaxle gears If any of the governor linkages are removed in order to service other components readjustment of the governor linkage is required See Governor Cable Installation and Adjustment on page 15 9 ...

Page 237: ...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 indicator hole Tighten the plug to 20 ft lb 27 1 N m AXLE SHAFT See General Warning on page 10 1 Removal of the unitized transaxle is not required for servicing or replacing axle shafts axle bearings or axle shaft oil seals ...

Page 238: ...6 Seal Lip 9 Inspect the axle shaft assembly to be sure the bearing 71 and collar 73 have not slipped and are still seated against the shoulder on the axle shaft Figure 18 7 Page 18 5 10 Inspect the bearing If the bearing is damaged or worn replace it AXLE BEARING Axle Bearing Removal 1 Use external retaining ring pliers 0 047 inch tip to remove the retaining ring 74 Place a bearing puller wedge a...

Page 239: ...emove it Do not remove the large axle retaining ring 70 from the axle Figure 18 7 Page 18 5 Since the inner diameter of the retaining ring 70 is smaller than the outer diameter of the bearing 71 the ring must be in place on the axle before a new bearing and collar are pressed on 74 73 70 71 74 73 70 68 76 75 67 70 71 73 74 72 71 72 557 Figure 18 7 Differential Gear Case and Axle Tubes Axle Bearing...

Page 240: ...n 7 Use external snap ring pliers 0 047 in tip to install collar retaining ring 74 Figure 18 7 Page 18 5 AXLE SHAFT INSTALLATION 1 Clean bearing and seal seats in axle tube 75 or 76 Figure 18 7 Page 18 5 2 Place a new oil seal 72 in axle tube with seal lip facing inside of the axle tube Figure 18 7 Page 18 5 Use an axle seal tool CCI P N 1012811 to press it in until it seats firmly in position Fig...

Page 241: ...assembly will separate from the transaxle and damage the axle assembly and other components Loss of vehicle control could result in severe personal injury or death 558 Figure 18 8 Press Bearing and Collar From Shaft Using Bearing Puller Wedge Attachment 559 Figure 18 9 Axle Seal and Seal Tool 2009 FE 350 Maintenance and Service Supplement Page 18 7 ...

Page 242: ...hoses etc connecting the powertrain to the vehicle 4 1 Disconnect the carburetor vent tube from the carburetor Figure 18 10 Page 18 8 4 2 Disconnect the air intake hose from the carburetor Figure 18 11 Page 18 8 847 Figure 18 10 Carburetor Vent Tube 561 Figure 18 11 Air Intake Hose 4 3 Disconnect impulse line from fuel pump Figure 18 12 Page 18 8 4 4 Loosen the hose clamp and then disconnect the f...

Page 243: ...ion 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 18 17 Page 18 9 1 2 1 Loosen nuts 2 Pull spring release back to remove shifter cable from lever DF F2 1 2 3 1 Yellow Wire 2 White Wire 3 Ground Wire at A2 Terminal 566 Figure 18 16 Shifter Cable Top View 836 Figure 18 17 Generator Wires 4 9 Disconn...

Page 244: ...ble support bracket Figure 18 20 Page 18 10 1 4 3 2 570 Figure 18 20 Brake Cable Rear View 6 Remove the lower shock mounting hardware from both rear shocks Figure 18 21 Page 18 11 7 If equipped with a stabilizer bar remove the two bolts securing the stabilizer bar to the stabilizer bar links See Rear Suspension Section 8 Position a floor jack under the vehicle frame crossmember or trailer hitch mo...

Page 245: ... 6 And Carryall 6 837 Figure 18 21 Shock Absorbers 1500 18500 10248 Figure 18 22 Floor Jack Positioned Under Hitch Bracket 9 Raise vehicle just enough to relieve tension from leaf springs then remove the bolts securing the leaf springs to the shackles Figure 18 23 Page 18 11 10 Remove the bolts securing the leaf springs to their front mounts Figure 18 24 Page 18 11 838 Figure 18 23 Rear Shackles 8...

Page 246: ... 13 Pull the floor jack from beneath the vehicle and move it away 14 Carefully lift the snubber out of the snubber bracket in the vehicle frame and lower it to the floor Figure 18 27 Page 18 12 The powertrain should be completely disconnected from the vehicle and resting on the floor 15 Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle...

Page 247: ... 18 Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle Figure 18 31 Page 18 13 19 Loosen but do not remove the governor arm retaining bolt 1 Figure 18 32 Page 18 13 Remove the governor arm from the shaft Do not disconnect cables 1 581 Figure 18 31 Driven Clutch 582 Figure 18 32 Governor Arm 20 Remove screws 1 securing the governor cable bracket to tran...

Page 248: ...axle to the engine 22 1 Remove four transaxle mounting bolts one at each corner of the transaxle mounting plate Figure 18 35 Page 18 14 22 2 Remove two middle transaxle mounting nuts from the engine block studs 23 Remove leaf springs stabilizer bar wheels and brake assemblies from the transaxle 585 Figure 18 35 Transaxle Mounting Page 18 14 2009 FE 350 Maintenance and Service Supplement ...

Page 249: ...Transaxle Mounting 586 Figure 18 37 Governor Arm 8 Install the governor cable bracket on transaxle case Tighten the mounting screws to 134 in lb 15 1 N m Figure 18 33 Page 18 14 9 Install governor lever arm on governor shaft Figure 18 37 Page 18 15 9 1 With the governor lever arm loose on the governor shaft turn the governor arm shaft counterclockwise until it stops Then pull the governor lever ar...

Page 250: ...st the vehicle height with the floor jack to position the leaf springs for mounting in the shackles Install the mounting bolts and lock nuts Figure 18 41 Page 18 16 Clu bCar Clu bCar Clu bCar Club Car 844 Figure 18 40 Leaf Springs 845 Figure 18 41 Leaf Springs and Shackles 17 Position shocks in the shock mounts and install cushions mounting washers and nuts Figure 18 42 Page 18 17 Tighten nuts unt...

Page 251: ...lb 5 4 N m Connect the 16 gauge yellow wire to the DF post on the starter generator and tighten to 30 in lb 3 4 N m Figure 18 45 Page 18 17 DF F2 1 2 3 1 Yellow Wire 2 White Wire 3 Ground Wire at A2 Terminal 568 Figure 18 44 Oil Level Sensor Jumper wire 836 Figure 18 45 Starter Generator 23 Position the shifter cable in the shifter cable mounting bracket on the engine and tighten the mounting nuts...

Page 252: ...to 18 in lb 2 0 N m Figure 18 48 Page 18 18 Install electrical box cover and tighten mounting screw 26 Remove the 1 4 inch bolt from the fuel line and connect the fuel line to the carburetor and secure with a hose clamp Figure 18 49 Page 18 18 564 Figure 18 48 Connect Cable to Cam and Secure with Retaining Nuts 846 Figure 18 49 Connect Fuel Line 27 Connect the impulse line to the fuel pump and sec...

Page 253: ...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 See following WARNING WARNING If wires are removed or replaced make sure wiring and wiring harness is properly routed and secured to vehicle frame Failure to properly route and secure wiring could result in vehicle malfunction pr...

Page 254: ...rm ball stud 5 on the transaxle 6 Loosen the retaining nuts 6 anchoring rear of cable jacket to bracket 7 at starter generator 7 If equipped remove wire tie s securing cable jacket to frame rail 8 Remove cable 8 from the vehicle FORWARD REVERSE SHIFTER CABLE INSTALLATION 1 Begin at the Forward Reverse shifter and route the cable 8 exactly as it was originally to the transaxle shifter lever 2 Secur...

Page 255: ...UNITIZED TRANSAXLE Forward Reverse Shifter Cable 18 8 2 3 9 1 6 4 7 5 10 591 Figure 18 53 Forward Reverse Shifter Cable 2009 FE 350 Maintenance and Service Supplement Page 18 21 ...

Page 256: ...ION Be sure threads of cable are engaged in ball joint socket at least 1 4 inch 6 35 mm If ball joint socket comes loose from the cable the Forward Reverse shifter will not operate properly F N R 592 Figure 18 54 Forward Reverse Shifter Positions For major adjustments the cable jacket retaining nuts 6 must be loosened and adjusted When the cable is properly adjusted with the Forward Reverse handle...

Page 257: ...ch 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 engine RPM The engine and torque converter rotat...

Page 258: ...oblem disassemble and thoroughly clean all parts of the drive clutch Be sure to clean the plastic drive buttons 10 Figure 19 5 Page 19 6 CCI P N 1014496 CCI P N 1014507 CCI P N 101809101 CCI P N 1014497 CCI P N 1015524 CCI P N 101808401 CCI P N 1014508 WARNING 1 2 3 7 5 4 6 1 Drive Clutch Hub Puller 2 Driven Clutch Cam Puller 3 Driven Clutch Cam Press Tool 4 Drive Clutch Holder Tool 5 Driven Clutc...

Page 259: ...d driven 1 clutches Lift upward on the belt to force the sheaves of the DRIVEN clutch apart then roll the belt off the DRIVEN clutch by rotating the clutch counterclockwise Figure 19 2 Page 19 3 See following CAUTION CAUTION Make sure fingers are not underneath the belt when rolling the belt off the driven clutch 3 Remove the belt from the drive clutch 1 2 594 Figure 19 2 Drive Belt Removal DRIVE ...

Page 260: ...ing hardware and then remove the starter belt See WARNING Moving parts Do not in General Warning on page 10 1 WAR NING 1 2 3 CCI P N 1014496 2 1 595 Figure 19 3 Loosen Retaining Bolt 596 Figure 19 4 Drive Clutch Removal 3 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle This will allow t...

Page 261: ... the threaded portion of the clutch puller tool 1 with a light oil and thread the clutch puller tool into the clutch retaining bolt hole Figure 19 4 Page 19 4 6 Use a 1 2 inch drive air wrench to tighten the clutch puller tool The drive clutch 2 will pull free of the crankshaft 7 Support the drive clutch assembly in your hand and back the clutch puller tool out of the crankshaft CAUTION Do not hit...

Page 262: ...19 Drive Clutch TORQUE CONVERTER 2 1 3 13 4 5 6 7 11 12 12 16 15 14 22 20 21 17 19 10 597 Figure 19 5 Drive Clutch Assembly Page 19 6 2009 FE 350 Maintenance and Service Supplement ...

Page 263: ...CI P N 1014497 into clutch until the stop nut touches the clutch then back the bolt out one half turn Figure 19 7 Page 19 7 2 3 Thread the three small bolts of the puller 1 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 19 7 Page 19 7 2 4 Unscrew the puller center bolt out of the clutch to pull drive...

Page 264: ...2 Pull the weight assemblies 3 with pins from slots 4 in the clutch See following NOTE NOTE Before removing note the orientation of the wave washer 1 and secondary weight 2 on the primary weight 3 Figure 19 10 Page 19 8 5 3 Remove the plastic washers weights 2 and 3 and wave washer 1 from the pin 4 Retain all parts 2 3 4 1 602 Figure 19 10 Primary and Secondary Weights Wave Washer and Pin Page 19 ...

Page 265: ...N OF DRIVE CLUTCH PARTS 1 Inspect the idler bearing 6 for smooth rotation or seal damage Figure 19 5 Page 19 6 See following 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 replaced if the bore is worn to a diameter of 0 883 inch 22 4 mm or larger Figure...

Page 266: ...pin protruding from it Figure 19 10 Page 19 8 9 Install the secondary weights 2 onto the mounting pins 4 with the weight pins on the secondary weights pointing away from the primary weights 3 The wave washers should be between the primary and secondary weights Figure 19 10 Page 19 8 10 Install white plastic flat washers on each end of the mounting pin and push them against the outside surfaces of ...

Page 267: ...rankshaft taper Position the mounting washer 19 on the bolt 17 and start the bolt into the crankshaft Figure 19 5 Page 19 6 See following NOTE NOTE The drive clutch retaining bolt has left hand threads The manufacturer recommends replacing the drive clutch retaining bolt CCI PN 103345701 when installing the drive clutch If a new bolt is not available clean the threads of the original bolt and appl...

Page 268: ... the retaining ring 4 Figure 19 15 Page 19 13 See following WARNING WARNING Do not place fingers under the cam when removing the cam The moveable face may spin when the cam buttons release from the cam ramps resulting in severe personal injury 2 Insert a puller plug 2 CCI P N 1014507 Figure 19 16 Page 19 13 into the shaft bore and use a driven clutch cam puller 1 CCI P N 1014508 to remove the cam ...

Page 269: ...bearing in the moveable face If the 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 he...

Page 270: ...ly on the shaft install the other end of the spring 5 into the center spring hole of the cam Rotate the cam until the keyway is aligned with the key 3 on the fixed face assembly and then start the cam onto the shaft approximately 1 4 to 3 8 inch 6 3 to 9 5 mm 5 1 Press Assembly Process Page 19 14 2009 FE 350 Maintenance and Service Supplement ...

Page 271: ...re 19 19 Cam Installation Tool 5 2 Field Assembly Process NOTE This process is for field assembly requirements where hydraulic and pneumatic press equipment is not available Use the cam installation tool CCI P N 101808401 for this process 5 2 1 With the clutch loosely assembled set the edge of the clutch body 5 on a clean flat surface Figure 19 19 Page 19 15 5 2 2 Assemble the threaded bolt 1 thro...

Page 272: ... 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 procedure Make sure that the washer 12 is mounted with the flat portion of the washer against the driven clutch Figure 19 17 Page 19 14 Secure with a new bolt 11 See following NOTE NOTE The bolt 11 must be replaced with a new bolt CCI P N 102242101 c...

Page 273: ...ake system 15 12 16 12 choke button installation 15 12 16 12 removal 15 12 16 12 clutch torque converter troubleshoot ing 19 1 clutch drive see drive clutch 19 4 clutch driven see driven clutch 19 12 commutator see starter generator 12 1 crankcase cover installation 13 6 14 7 removal 13 4 14 5 cylinder head 13 3 14 3 D diagram wiring pedal start gasoline vehicle 11 6 differential see unitized tran...

Page 274: ... 15 9 16 8 removal 15 8 16 8 ground cable testing 11 20 H headlight bulb installation 12 33 removal 12 33 headlight switch installation 12 35 removal 12 35 headlights see also lighting circuit 11 50 testing 11 50 horn testing 11 57 horn switch testing 11 58 hydrometer test 11 18 I ignition testing spark 11 29 ignition coil installation 12 29 13 9 14 10 removal 12 28 13 7 14 8 testing 11 31 inspect...

Page 275: ...nd repair 13 2 14 2 gap adjustment 13 2 14 2 installation 13 3 14 2 removal 13 2 14 1 testing 13 2 14 2 specifications torque 13 10 14 11 starter generator armature ground test 12 8 inspection 12 6 servicing 12 4 assembly 12 3 12 9 bearing cleaning 12 5 inspection 12 5 removal 12 5 belt tension adjustment 12 12 brush spring inspection 12 3 replacement 12 3 brushes 12 2 inspection 12 2 replacement ...

Page 276: ...imit switch 11 37 light switch 11 48 low oil warning light 11 39 neutral lockout limit switch 11 25 neutral lockout switch 11 40 oil level sensor 11 40 park brake limit switch 11 56 reverse buzzer 11 39 reverse buzzer limit switch 11 39 RPM limiter 11 30 solenoid 11 24 starter generator 11 26 11 27 taillight bulb socket 11 56 taillight socket voltage at 11 55 voltage limiter 11 49 voltage regulato...

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Page 278: ...or 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 Pleaseselectyour category Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other _____________________ 2009 FE 350 Maintenance and Service Supplement ...

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