Club Car FE290 Maintenance Service Supplement Download

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FE290 GASOLINE VEHICLES

MANUAL NUMBER 102067508

EDITION CODE 0500A00000

2000

MAINTENANCE

S E R V I C E

SUPPLEMENT

Summary of Contents for FE290

Page 1: ...FE290 GASOLINE VEHICLES MANUAL NUMBER 102067508 EDITION CODE 0500A00000 2000 MAINTENANCE S E RV I C E SUPPLEMENT...

Page 2: ......

Page 3: ...l repairs and or service be performed by an authorized Club Car distributor dealer representative or by a Club Car factory trained technician It is the policy of Club Car Inc to assist its distributor...

Page 4: ...DEALERS AND WILL WHEN APPLICABLE APPEAR IN FUTURE EDITIONS OF THIS SUPPLEMENT DAMAGE TO A VEHICLE OR COMPONENT THEREOF NOT RESULTING FROM A DEFECT OR WHICH OCCURS DUE TO UNREASONABLE OR UNINTENDED US...

Page 5: ...Electrical Circuits 11 7 Starter Circuit 11 7 Generator Circuit 11 8 Engine Ignition Circuit 11 8 Engine Kill Circuit 11 9 Reverse Buzzer Circuit 11 9 Low Oil Warning Circuit 11 10 Neutral Lockout Cir...

Page 6: ...vel Sending Unit 12 22 RPM Limiter 12 22 Ignition Coil 12 23 Oil Level Sensor 12 26 Battery 12 26 Ground Straps 12 31 SECTION 13 FE290 ENGINE General Information 13 1 Special Engine Service Tools Avai...

Page 7: ...Flywheel 13 30 Oil Pump 13 31 Oil Pressure Relief Valve 13 32 Crankshaft and Counterbalance 13 34 Counterbalance Weight 13 36 Oil Screen 13 39 Ball Bearing 13 39 Oil Seals 13 40 Piston and Connecting...

Page 8: ...n 14 15 Intake Duct Repair 14 16 Air Filter 14 16 Fuel Filters 14 18 General Information 14 18 Fuel Filter Removal 14 18 Fuel Filter Installation 14 18 Fuel Pump 14 20 General Information 14 20 Fuel P...

Page 9: ...nsaxle Component Inspection 16 22 Component Assembly 16 23 Idler Shaft Assembly 16 23 Intermediate Gear Assembly 16 23 Synchronizer Gear Assembly 16 23 Shifter Fork Assembly 16 25 Differential Gear Ca...

Page 10: ...d Service Supplement Drive Clutch Assembly 17 9 Drive Clutch Installation 17 11 Driven Clutch 17 13 Driven Clutch Removal 17 13 Driven Clutch Disassembly 17 13 Driven Clutch Inspection 17 14 Driven Cl...

Page 11: ...STATEMENTS LISTED IN THIS SUPPLEMENT AS WELL AS THOSE AFFIXED TO THE VEHICLE IMPROPER USE OF THE VEHICLE OR FAILURE TO PROPERLY MAINTAIN IT COULD RESULT IN DECREASED VEHICLE PERFORMANCE OR SEVERE PER...

Page 12: ...m TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT BATTERY CABLES NEGATIVE FIRST FIGURE 10 1 PAGE 10 2 DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG TURN FUEL SHUT OFF VALVE TO CLOSED OFF...

Page 13: ...D THE PERIODIC LUBRICATION SCHEDULE MUST BE FOLLOWED TO KEEP THE VEHICLE IN OPTIMUM OPERATING CONDITION PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Monthly Service by Owner or Trained Technicia...

Page 14: ...hours of operation or every 400 rounds for golf cars Fuel Filters Replace Dispose of used filters properly IF ANY PROBLEMS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE...

Page 15: ...32 F 0 C or SAE 5W20 below 32 F 0 C API Class SE SF or SG Oil or higher Figure 10 2 Lubrication Points LIQUID CAPACITIES GASOLINE VEHICLES Engine Crankcase without filter 32 oz 95 liters Engine Crankc...

Page 16: ...ature as shown Figure 10 5 Page 10 6 DO NOT REMOVE DIPSTICK WHILE ENGINE IS RUNNING Figure 10 3 Checking Engine Oil Figure 10 4 GasolineTank Figure 10 5 Oil Viscosity Chart USING MULTI GRADE OILS 5W 2...

Page 17: ...ENGINE IS HOT OR WHILE IT IS RUNNING TO AVOID ELECTRIC ARC CAUSED BY STATIC ELECTRICITY THE FUEL STORAGE PUMPING DEVICE MUST BE GROUNDED IF THE PUMP IS NOT GROUNDED THE VEHICLE MUST BE GROUNDED TO TH...

Page 18: ...10...

Page 19: ...ICAL AND MECHANICAL REPAIR FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL AND HEED ALL DANGER WARNING AND CAUTION STATEMENTS LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE WEAR...

Page 20: ...Y DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION USE APPROVED JACK STANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE SYMPTOM POSSIBLE CAUSES REFER TO Engine does not start easily 1...

Page 21: ...chamber Section 13 Engine 2 Spark plug heat range is incorrect for the engine Section 13 Engine 3 Unsuitable or contaminated fuel Section 14 Fuel System Loss of engine power 1 Exhaust valve is restri...

Page 22: ...Section 11 Troubleshooting Test Procedure 7 10 Loose or broken wire in starter generator circuit Section 12 Electrical Components Starter Generator page 12 2 11 Cylinder and or crankcase flooded with...

Page 23: ...4 14 Torque converter does not shift smoothly 1 Drive belt is worn cracked glazed or frayed Section 17 Torque Converter 2 Drive clutch malfunction Section 17 Torque Converter 3 Driven clutch malfuncti...

Page 24: ...F2 DF F1 A2 A1 1 2 1 3 4 BLACK YELLOW YELLOW RED YELLOW WHITE BLACK YELLOW WHITE WHITE WHITE BLACK YELLOW WHITE RED WHITE BLACK ORANGE GREEN WHITE BLACK BLUE BLUE ORANGE RED ORANGE YELLOW RED RED RED...

Page 25: ...o the solenoid completing the circuit between the positive post of the battery and the F2 post of the starter generator The starter generator then turns and cranks the engine through belt driven pulle...

Page 26: ...arging current to the battery To prevent battery overcharging the voltage regulator senses battery voltage and by opening and closing an electronic switch controls the amount of charge going to the ba...

Page 27: ...ave the vehicle in reverse and to warn anyone in the area that the vehicle is in reverse The reverse buzzer circuit consists of a reverse buzzer reverse buzzer limit switch fuse fuse block and connect...

Page 28: ...ned technician there is a neutral lockout cam yellow knob located on the back of the Forward Reverse shifter inside the engine compartment If the neutral lockout cam is pulled out approximately 3 8 in...

Page 29: ...uel is in the tank Figure 11 12 Page 11 11 HOUR GAUGE CIRCUIT The hour gauge circuit consists of the fuel hour gauge key switch solenoid and connecting wires Figure 11 13 Page 11 11 BE SURE TO RETURN...

Page 30: ...GINE IGNITION CIRCUIT Read DANGER and WARNING on page 11 1 Use the following chart Figure 11 15 Page 11 13 to begin troubleshooting problems with the engine ignition circuit Figure 11 14 Testing the S...

Page 31: ...INDER HEAD IN SECTION 13 IGNITION GAP TEST NOT GOOD DISCONNECT ENGINE KILL WIRE GOOD SPARK NO SPARK CHECK RPM LIMITER TEST PROCEDURE 14 CHECK KEY SWITCH TEST PROCEDURE 17 CHECK PLUG GAP SEE SETTING TH...

Page 32: ...LY CONNECTED REPLACE KEY SWITCH CONNECT WIRES CORRECTLY REPLACE WIRE CHECK CONTINUITY OF CIRCUIT WIRES TEST PROCEDURE 9 NO CONTINUITY ENGINE WILL NOT STOP RUNNING WHEN KEY SWITCH IS IN OFF POSITION CH...

Page 33: ...SWITCH REVERSE BUZZER WILL NOT FUNCTION AND ENGINE WILL NOT CRANK CHECK BATTERY TEST PROCEDURE 2 CHECK FUSE TEST PROCEDURE 1 DETERMINE CAUSE OF THE BLOWN FUSE REPLACE FUSE CHECK GROUND STRAPS TEST PRO...

Page 34: ...OIL WARNING LIGHT TEST PROCEDURE 22 REPLACE OIL LEVEL SENSOR REPLACE OIL LEVEL SENSOR REPLACE LOW OIL WARNING LIGHT REPLACE YELLOW WIRE WIRES INCORRECTLY CONNECTED WIRES CORRECTLY CONNECTED LOW OIL WA...

Page 35: ...PROCEDURE 7 CHECK CONNECTION OF BLACK WIRE INCORRECT CONTINUITY READING CORRECT CONTINUITY READING WIRE INCORRECTLY CONNECTED WIRE CORRECTLY CONNECTED REPLACE LIMIT SWITCH RECONNECT WIRE REPLACE WIRE...

Page 36: ...Level Sending Unit 26 Fuel Gauge 27 Hour Meter TEST PROCEDURE 1 FUSE Read DANGER and WARNING on page 11 1 The fuse red 10 amp is located in the electrical component box 1 Place the neutral lockout ca...

Page 37: ...lease the bulb drawing 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 s...

Page 38: ...from the reading Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table If the difference between the cells is 0 020 or more the lo...

Page 39: ...correct ambient temperature 4 If the battery is found to be good or if the electrical problem continues after the battery has been replaced with a good one test the electrical circuits TEST PROCEDURE...

Page 40: ...frame connection and clean the bolt ring terminal and nut Reinstall the frame connection 4 2 Set the multimeter to 200 ohms Place the red probe on the unconnected end of the 6 gauge black wire and pl...

Page 41: ...cted to this limit switch 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse shifter handle in the NEUTRAL position chock the wheels and disconnect battery negative cable...

Page 42: ...should be NO continuity Depress 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...

Page 43: ...in the SERVICE position put the Forward Reverse shifter handle in the NEUTRAL position chock the wheels and disconnect battery negative cable first 2 Check that wires are connected correctly and are...

Page 44: ...nts Page 12 2 6 With the wires still disconnected using a multimeter set on 200 ohms place the red probe on the F1 terminal and the black probe on the F2 terminal The reading should be between approxi...

Page 45: ...ound Then using a jumper wire ground the DF terminal to the A2 terminal Figure 11 34 Page 11 26 4 Using a multimeter set to volts DC 20v range place the red probe on the positive post of the battery a...

Page 46: ...ER and WARNING on page 11 1 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse handle in the NEUTRAL position chock the wheels and turn the key switch OFF 2 Disconnect the...

Page 47: ...re is no spark or if the spark is a faint yellow or red color test components of the ignition circuit 3 If the spark gap tester tool indicates a strong blue spark it is possible the spark plug has fai...

Page 48: ...under the fan housing and place the red probe on a clean unpainted surface of the engine or frame Figure 11 38 Page 11 30 2 2 If the resistance is not between 0 6 1 7 ohms remove the coil from the eng...

Page 49: ...and black wire connected to it 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse shifter handle in the NEUTRAL position chock the wheels and disconnect battery negative...

Page 50: ...inals 4 Place the red probe of the multimeter on the M terminal of the key switch and the black probe on the M terminal With the key switch turned OFF the reading should be continuity With the key swi...

Page 51: ...reading is incorrect replace the limit switch See Reverse Buzzer Limit Switch Removal Section 12 Electrical Components Page 12 19 TEST PROCEDURE 20 REVERSE BUZZER Read DANGER and WARNING on page 11 1...

Page 52: ...switch to the oil light If there is NO continuity in the wire replace the wire then test the key switch See Test Procedure 4 Key Switch Starter Circuit Page 11 23 If the yellow wire and the key switch...

Page 53: ...ending unit is operating correctly Make sure the float is at the surface of the fuel in the tank 5 If the readings are within the specifications listed above the fuel level sending unit is working pro...

Page 54: ...ative post of the battery Record the voltage reading 6 Set a multimeter to 20 volts DC and place the red probe of the multimeter on the 2 terminal of the fuel gauge with the blue wire Place the black...

Page 55: ...e fuel gauge Figure 11 45 Page 11 36 TEST PROCEDURE 27 HOUR GAUGE Read DANGER and WARNING on page 11 1 1 Place the Forward Reverse handle in the NEUTRAL position place the neutral lockout cam in the S...

Page 56: ...11...

Page 57: ...EXPERIENCE IN ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE TURN KEY...

Page 58: ...t fall to the ground Remove the pivot nuts 7 and bolts 5 from the mounting bracket 6 Remove the starter generator from the vehicle FOR VEHICLES WITH CARGO BEDS REMOVE ALL CARGO BEFORE RAISING THE BED...

Page 59: ...THE BRUSHES ARE NOT REMOVED CONTACT BETWEEN THE BRUSHES AND COMMUTATOR AS THE COMMUTATOR END COVER IS BEING REMOVED OR INSTALLED COULD DAMAGE THE BRUSHES LIFT THE BRUSH SPRINGS OUT OF THE NOTCHES IN T...

Page 60: ...Install the four brushes 27 into their holders and insert the four brush springs 28 Figure 12 4 Page 12 4 Using a spring scale test brush spring tension If any spring has a tension less than 24 ounces...

Page 61: ...s 20 and tighten to 100 in lb 11 3 N m Figure 12 3 Page 12 4 4 Push the brushes down into the holders Position springs into the notches in the brushes Install the brush cover 30 that has the drain hol...

Page 62: ...1 Using a clean cloth wipe the carbon dust from the two bearings Inspect bearings by spinning them by hand and checking for both axial A and radial B play Figure 12 9 Page 12 6 2 Replace the bearing i...

Page 63: ...field coils from the inside of the housing Figure 12 11 Page 12 8 See following NOTE Visual Inspection of Armature Obvious defects can be seen by examining the armature If an armature has frayed or ch...

Page 64: ...owing CAUTION 2 Using a micrometer measure the outside diameter at two points along the commutator If the commutator outside diameter is less than 1 535 inches 39 mm replace the armature and bearings...

Page 65: ...ils is questionable Burned or scorched coil insulation indicates the starter generator has overheated due to overloads or grounded or shorted coil windings Be sure the insulators are tight in the hous...

Page 66: ...ing retainer 32 to the cover using three M5 x 8 x 18mm screws 43 and tighten to 39 in lb 4 4 N m Figure 12 8 Page 12 6 7 Slide the housing with field coils over the armature Use the locating pin to al...

Page 67: ...er side of the vehicle Position the starter generator in the mounting bracket so that the screws will go through the starter generator before going through the bracket Install a locknut 7 onto each sc...

Page 68: ...nsion for a new starter generator belt should be 75 ft lb 101 7 N m or for an existing belt 45 ft lb 61 N m Figure 12 15 Page 12 11 7 While maintaining the tension tighten the adjustment nut 12 to 12...

Page 69: ...See Test Procedure 11 Section 11 Page 11 27 KEY SWITCH Read DANGER and WARNING on page 12 1 Testing the Key Switch See Test Procedure 17 Section 11 Page 11 32 and Test Procedure 4 page 11 23 Key Switc...

Page 70: ...witch in the dash Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place 2 Connect battery cables positive cable first and tighten terminals to...

Page 71: ...sts to 22 in lb 2 5 N m 8 Install the snap on electrical box cover by firmly pressing down on all corners and install the screw tightening to 18 in lb 2 0 N m 9 Connect battery cables positive cable f...

Page 72: ...ke sure that the switch is being actuated when the pedal is released 4 Connect battery cables positive cable first and tighten terminals to 20 ft lb 27 1 N m Figure 12 1 Page 12 2 Coat terminals with...

Page 73: ...ral lockout limit switch 5 located on the back of the Forward Reverse shifter assembly Figure 12 19 Page 12 18 3 Remove the nuts 2 and washers 6 from the neutral lockout limit switch 5 and slide the n...

Page 74: ...er operation NEUTRAL LOCKOUT CAM If the cam lobes have worn to the point where they will no longer actuate the neutral lockout limit switch the cam must be replaced Testing the Neutral Lockout Cam See...

Page 75: ...r bracket tabs and tighten to 4 in lb 0 45 N m 2 Connect black wire 4 from key switch to the negative terminal on the buzzer Figure 12 21 Page 12 19 3 Connect the red white wire 1 from the wire harnes...

Page 76: ...EVERSE and make sure that both switches actuate 4 Connect the orange wire to the common COM terminal and the red white wire to the normally open NO terminal of the reverse buzzer limit switch 4 Figure...

Page 77: ...he key switch in the OFF position the fuel hour gauge fields are black When the key switch is turned to ON both fields activate The fuel gauge initially registers full for a brief moment before indica...

Page 78: ...EL LEVEL SENDING UNIT Read DANGER and WARNING on page 12 1 Testing the Fuel Level Sending Unit See Section 11 Test Procedure 25 Page 11 35 The fuel level sending unit is an integral part of the fuel t...

Page 79: ...n page 12 1 Testing Ignition Coil See Section 11 Test Procedure 13 Page 11 29 Test Procedure 14 Page 11 29 and Test Procedure 15 Page 11 30 Ignition Coil Removal 1 Disconnect the battery cables negati...

Page 80: ...ire grommet 5 from the housing and Figure 12 28 Page 12 24 9 Disconnect the 18 gauge black wire 8 from the spade terminal on ignition coil 6 and remove coil by removing two bolts 7 Figure 12 28 Page 1...

Page 81: ...se three or four revolutions while applying light pressure on the cap Figure 12 28 Page 12 24 8 Install the gasket 2 on the cap 1 9 Position the ignition coil onto the cast mounting bosses on the engi...

Page 82: ...tiffener 17 Install the fan shroud with four pan head bolts Tighten to 50 in lb 5 7 N m Figure 12 27 Page 12 24 18 Install the muffler See Section 15 Exhaust System 19 Place the governor guard 1 onto...

Page 83: ...s with Battery Protector Spray Club Car Part No 1014305 to prevent future corrosion 2 The battery should be kept clean and dry to prevent self discharge Any dirt grime or acid spillage should be remov...

Page 84: ...rt of the plate to become permanently inactive Check the water level more frequently in hot weather or when the battery becomes old Vibration Damage The battery clamp should always be tight enough to...

Page 85: ...ttery 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 reac...

Page 86: ...charge periodically A battery that is discharged and left in a cold environment can freeze and crack If the specific gravity drops below 1 220 the battery should be recharged 6 The frequency of recha...

Page 87: ...cle is equipped with a starter generator The generator is not designed to charge a dead battery If the vehicle battery has become discharged it must be charged using a properly rated automotive type c...

Page 88: ...12...

Page 89: ...SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE...

Page 90: ...ay be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for the removal of screws particularly those held by a locking agent in...

Page 91: ...al Grease Seal During assembly use new oil or grease seals to replace any that were removed as removal generally dam ages seals To avoid damaging the seal lips a seal guide is required for installatio...

Page 92: ...al part 3 Never replace a defective electrical component without first determining what caused the failure If the failure was brought on by some other item or items they too must be repaired or replac...

Page 93: ...essure of the spring the ball is forced off its seat against the spring pressure and excess oil is routed back into the sump crankcase thus relieving the pressure When the pressure drops below the pre...

Page 94: ...the engine fuel and air mixture and ignition system If all of the above conditions are proper the spark plug should be a light brown color There should be no bridging between the electrode and base T...

Page 95: ...tighten the spark plug to 20 ft lb 27 N m ENGINE MOUNTING PLATE See Engine Removal Page 13 23 CYLINDER HEAD Read DANGER and WARNING on page 13 1 GENERAL INFORMATION Prior to attempting time consuming...

Page 96: ...g with throttle spring 8 and throttle spring bracket 23 Figure 13 6 Page 13 9 9 Remove muffler See Section 15 Exhaust System 10 If the engine is to be totally disassembled drain oil and remove the oil...

Page 97: ...13 7 and 13 8 Page 13 10 ROCKER ARM AND PUSH ROD REMOVAL 1 Remove the two bolts 1 and remove the rocker cover 2 along with breather tube 3 Figure 13 9 Page 13 10 See following NOTE MAKE SURE VEHICLE I...

Page 98: ...12 Page 13 11 VALVE REMOVAL 1 Compress the valve spring with the valve spring compressor 5 Club Car Part No 101641101 and remove the collet halves 6 Figure 13 13 Page 13 12 2 Remove spring compressor...

Page 99: ...ase but the one way reed valve blocks return flow It thus maintains a vacuum in the crankcase Oil laden air in the crankcase passes through the reed valve and expands into the rocker chamber In the ro...

Page 100: ...Guide Inspection 1 Measure the inside diameter of each guide with a telescoping gauge Figure 13 18 Page 13 13 2 If the inside diameter exceeds 0 2781 inch 7 065 mm replace the guide Valve Guide Repla...

Page 101: ...mm Figure 13 21 Page 13 14 VALVE SEATS Read DANGER and WARNING on page 13 1 Valve Seat Inspection 1 Inspect the valve seats for damage If the seats are warped or distorted beyond reconditioning replac...

Page 102: ...the way around See Valve Seat Inspection Page 13 14 2 2 Measure the seat width of the 45 angle portion of the seat at several places around the seat Figure 13 25 Page 13 16 2 3 If the seat width is m...

Page 103: ...in the seat is evident after lapping the valve 4 If the seat does not make proper contact lap the valve into the seat with a vacuum cup tool 4 1 Coat the surface of the valve sparingly with a fine la...

Page 104: ...Page 13 17 4 Inspect the stem for obvious wear discoloration and stem end damage 5 If the stem is obviously worn or discolored replace the valve Valve Head Thickness 1 Measure the thickness of the va...

Page 105: ...stallation is the reverse of removal See Page 13 11 and following NOTE Figure 13 29 Measure Valve Stem Bend Figure 13 30 Measure Valve Stem Diameter Figure 13 31 Measure Free Length of Spring Figure 1...

Page 106: ...Figure 13 33 Page 13 19 If the outside diameter is less than the service limit of 0 4704 inch 11 949 mm replace the shaft PUSH ROD INSPECTION 1 Support the rod in V blocks at each end of rod Position...

Page 107: ...nst the exhaust rocker and fit the E ring 1 into the groove in the rocker shaft 2 Figure 13 36 Page 13 19 4 Install cylinder head assembly to engine 5 Tighten the bolts down evenly by hand 6 Using a t...

Page 108: ...m Figure 13 39 Page 13 21 6 Recheck the clearance on both valves BREATHER VALVE REED VALVE General Information The function of the breather valve is to create a vacuum in the crankcase which prevents...

Page 109: ...ll carburetor 11 throttle spring 12 and throttle spring bracket 13 Tighten to 50 in lb 5 6 N m Figure 13 43 Page 13 23 6 Connect fuel lines See Section 14 Fuel System Tighten fuel line hose clamp at t...

Page 110: ...Maintenance 11 Run the engine for three minutes to check for leaking oil CRANKCASE Read DANGER and WARNING on page 13 1 ENGINE REMOVAL To perform repairs on crankcase components the engine must be rem...

Page 111: ...12 Figure 13 46 Page 13 24 2 Remove nuts and clamps at two ended bolts 1 and 2 Figure 13 44 Page 13 24 3 Remove eight bolts 3 and remove the crankcase cover 4 Figure 13 44 Page 13 24 See following NOT...

Page 112: ...case 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 remove...

Page 113: ...he shaft replace camshaft 5 If the lobe height is less than 1 287 inches 32 690 mm for either lobe replace the camshaft Camshaft Installation See Page 13 46 PISTON AND CONNECTING ROD Read DANGER and W...

Page 114: ...s Figure 13 52 Page 13 27 6 If the top groove has a clearance greater than 0 0063 inch 0 16 mm replace the piston 7 If the second groove has a clearance greater than 0 0055 inch 0 14 mm replace the pi...

Page 115: ...55 Page 13 28 2 If the pin diameter is smaller than 0 747 inch 18 974 mm replace the piston pin 3 Using an inside micrometer or telescoping gauge measure the inside diameter of the piston pin hole in...

Page 116: ...g Rod Installation See Page 13 43 CYLINDER BLOCK Read DANGER and WARNING on page 13 1 While the engine is disassembled inspect the cylinder block for cracks stripped bolt holes broken fins or cylinder...

Page 117: ...hes 78 460 78 480 mm See Specifications for Resizing Cylinder Bore Table Page 13 50 2 Hone the cylinder that is to be 0 010 inch over standard size so that the final bore size diameter is 3 0799 3 080...

Page 118: ...5 and using a 22 mm socket remove the flywheel nut and flat washer by turning it counterclockwise Figure 13 63 Page 13 32 4 Remove the flywheel with a puller Club Car Part No 1016627 5 Remove the flyw...

Page 119: ...Tighten the two ignition coil bolts to 30 in lb 3 4 N m OIL PUMP Read DANGER and WARNING on page 13 1 Oil Pump Cover Removal 1 Remove the six screws 1 and take off the oil pump cover 2 Figure 13 65 P...

Page 120: ...627 mm Figure 13 67 Page 13 33 4 2 Using a micrometer measure the diameter of the outer rotor at several points Figure 13 68 Page 13 33 4 3 If the rotor diameter is less than 1 5931 inches 40 467 mm...

Page 121: ...reverse of removal If necessary put the ball in position and lightly tap the ball with a plastic hammer to form a perfect seat Oil Pump Installation 1 Installation is the reverse of removal 2 Install...

Page 122: ...3 36 2 If the link rods need replacing place the gear yoke Club Car Part No 1016418 under the spur gear with the small end of the connecting rod located opposite the crankpin Figure 13 74 Page 13 35 3...

Page 123: ...k rod Figure 13 78 Page 13 37 1 3 If the inside diameter of the large end is greater than 1 8554 inches 47 127 mm replace the bearing Figure 13 79 Page 13 37 See following note ALWAYS USE A PRESS WHEN...

Page 124: ...ter to a depth of 0 039 inch 0 991 mm from the surface Figure 13 81 Page 13 37 COUNTERBALANCE WEIGHT Counterbalance Weight Inspection 1 Clean the inside of the bore surface and inspect it for wear or...

Page 125: ...ary 2 Using a micrometer measure both main journals PTO side and flywheel side at several points along their lengths Figure 13 84 Page 13 38 2 1 If either journal diameter is less than 1 1783 inches 2...

Page 126: ...ccept an undersized connecting rod with a 1 3779 inches 35 0 mm inside diameter Grinding the crankshaft is required before using the undersized connecting rod 1 Have a reliable repair shop grind the c...

Page 127: ...ce the crankcase cover 1 on a bench with its outside up gasket surface against bench Figure 13 90 Page 13 40 3 Using a bearing driver 2 Part of Club Car Bearing Driver Kit Part No 1016416 drive out th...

Page 128: ...outside edge and the inner lip of the oil seal to assist instal lation 2 Install all oil seals with their lips facing the center of the engine 3 Using the 1 37 inch 35 mm seal driver press the oil se...

Page 129: ...he inside diameter is greater than 1 1841 inches 30 075 mm replace the crankcase Figure 13 92 Page 13 41 Crankshaft Installation Read DANGER and WARNING on page 13 1 1 Installation is the reverse of r...

Page 130: ...e retaining rings should be facing towards the crankshaft Make sure the retaining rings are seated in their grooves Make sure the connecting rod moves freely Figure 13 97 Page 13 44 ALWAYS USE A PRESS...

Page 131: ...lb 23 N m CRANKSHAFT AXIAL PLAY ADJUSTMENT See DANGER and WARNING on page 13 1 1 With the gasket installed on the crankcase measure from the gasket surface 1 to the helical gear sur face 2 Record mea...

Page 132: ...FOR FE290 ENGINES RANGE FROM 1 13 TO 1 53MM Figure 13 99 Determine Crankshaft Shim Size Figure 13 100 Install Shim on Crankshaft Figure 13 101 Crankshaft Shim Table NOTE A B 1 3 2 4 5 6 1 5 3 1 4 8 1...

Page 133: ...E 13 103 PAGE 13 46 IF THE OIL PUMP TANG IS NOT SEATED IN THE SLOT IN THE CAMSHAFT SERIOUS ENGINE DAMAGE WILL RESULT Figure 13 102 Align Timing Marks between Camshaft and Crankshaft Figure 13 103 Prop...

Page 134: ...4 Page 13 47 ENGINE ASSEMBLY Read DANGER and WARNING on page 13 1 1 Install cylinder head See Cylinder Head Installation Page 13 20 2 Insert the flywheel key into the keyway in the crankshaft Then ali...

Page 135: ...lm of oil on the seal of a new oil filter and install the filter on the crankcase Fill the crankcase to the proper level with the correct type of oil This engine should be regarded as a new engine for...

Page 136: ...aring I D MAX 0 4750 inch 12 064 mm Piston Top Ring Groove Clearance with NEW ring MAX 0 0063 inch 0 16 mm Piston Second Ring Groove Clearance with NEW ring MAX 0 0055 inch 0 14 mm Piston Oil Ring Gro...

Page 137: ...D MAX 1 0283 inches 26 118 mm Support Shaft O D MIN 1 0199 inches 25 907 mm Breather Reed Valve Valve Tip Air Gap MAX 0 008 inch 0 2 mm Valve Stem IN and EX Stem Bend MAX 0 0012 inch 0 03 mm Push Rod...

Page 138: ...m 30 in lb 3 4 N m ITEM LIMITS Spark Plug Gap Standard 0 027 to 031 inch 0 69 to 0 79 mm Ignition Coil Air Gap Standard 0 012 inch 0 304 mm Oil Pressure MIN at fast idle speed 45 5 psi 314 kPa Oil Fil...

Page 139: ...E THE VEHICLE WHILE IT IS RUNNING USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS USE EXTREME CAUTION TO AVOID SHORTING OF COMPONENTS OR WIRING FRAME GROUND DO NOT ALLOW TOOL...

Page 140: ...se the mixture to become too lean An overly rich mixture could be caused by a clogged air passage clogged air holes in the main nozzle a loose main jet or by a loose main nozzle If the engine exhibits...

Page 141: ...14 3 Page 14 3 The air fuel mixture is adjusted by the pilot screw needle valve Figure 14 3 Page 14 3 Figure 14 3 Carburetor AIR FUEL AIR FUEL MIXTURE BYPASS HOLES PILOT AIR JET MAIN AIR PASSAGE MAIN...

Page 142: ...r float chamber by an external impulse pump that draws fuel from the fuel tank and through the fuel filters The fuel then passes through the inlet valve 5 Figure 14 4 Page 14 4 and into the float bowl...

Page 143: ...retor end only Temporarily plug the end of the fuel line to prevent fuel leakage 1 8 Remove the carburetor retaining nuts 19 intake pipe 17 and carburetor 12 See following NOTE 2 Position the carburet...

Page 144: ...SEATED IN THE CARBURETOR BODY WHEN THE FUEL BOWL IS REMOVED FIGURE 14 7 PAGE 14 7 DURING NORMAL OPERATION THE FUEL BOWL RETAINS THE FLOAT PIVOT PIN 6 MAKE SURE THAT THE FLOAT PIVOT PIN DOES NOT FALL...

Page 145: ...BURETOR UPSIDE DOWN DURING MAIN JET REMOVAL FIGURE 14 7 PAGE 14 7 DO NOT REMOVE THE VALVE SPRING ASSEMBLY FROM THE FLOAT ASSEMBLY DOING SO WILL DAMAGE THE SPRING Figure 14 7 Changing the Main Jet NOTE...

Page 146: ...14 Install carburetor vent line 14 and clamp 13 15 Install the governor cable clevis pin 24 and cotter pin 25 16 Install the governor guard 5 flat washer and nylon locknut Tighten to 30 in lb 3 4 N m...

Page 147: ...1 Before installing the accelerator rod adjust accelerator pedal position See Section 5 Accelerator and Brake Pedal Group in the appropriate maintenance and service manual 2 Install the ball joint on...

Page 148: ...ical box Figure 14 11 Page 14 11 7 Before tightening the jam nuts set the park brake to the first latch and pawl position and check for proper activation of switches 8 While pressing the accelerator p...

Page 149: ...Figure 14 12 Page 14 12 Governor Cable Installation and Adjustment 1 Install the cable onto the governor cable support bracket 10 and the engine bracket 11 and attach an E ring 7 at each end Figure 14...

Page 150: ...Linkage Page 14 12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 14 Figure 14 12 Governor and Accelerator Cables REFERENCE EXHAUST SECTION TYPICAL 2 PLACES 7 1 8 7 11 9 6 10 9 7 12 1...

Page 151: ...ame number of threads visible between the jam nuts as are visible from the nut inside the box to the end of the cable housing Figure 14 9 or Figure 14 10 Page 14 10 Tighten the nuts finger tight 3 Con...

Page 152: ...f the accelerator cable is properly positioned Excessive belt and torque converter wear can also pre vent proper rpm adjustment Check them for excessive wear See Section 17 Torque Converter CHOKE AND...

Page 153: ...o 33 in lb 3 7 N m 3 Place hose onto air box and secure with wire clamp If equipped with screw clamp tighten to 17 in lb 1 9 N m 4 Test choke for proper operation INTAKE DUCT REMOVAL To remove the int...

Page 154: ...be checked every year or 100 hours More frequent service may be required in extremely dirty operating environments Need for immediate servicing will be indicated by a loss of power sluggish accelerati...

Page 155: ...hicle Maintenance and Service Supplement Page 14 17 14 Figure 14 15 Air Intake and Choke Assemblies REFERENCE CARBURETOR TYPICAL 2 PLACES 1 2 3 TYPICAL 3 PLACES 17 20 21 19 22 15 15 16 5 17 18 6 11 4...

Page 156: ...exceed two years or 200 hours FUEL FILTER REMOVAL 1 Remove seat or lift bed to access engine compartment 2 To prevent gasoline drainage turn the fuel shut off valve 15 on the gas tank 19 Figure 14 16...

Page 157: ...2 11 NO 7 IMPULSE LINE NO 1 FUEL LINE NO 5 CARBURETOR AIR VENT TUBE NO 2 FUEL LINE 3 7 16 16 23 14 16 16 17 16 16 4 22 1 25 26 2 NO 6 FUEL TANK VENT TUBE NO 4 FUEL LINE NO 3 FUEL LINE FUEL LINE No ROU...

Page 158: ...n the fuel shut off valve on top of the gas tank to the closed OFF position Figure 14 21 Page 14 26 2 Remove hardware attaching the fuel pump 24 and lift the fuel pump out of the engine compartment Fi...

Page 159: ...BLY 1 Install the fuel gasket 35 and diaphragm 34 on the back cover 36 Figure 14 17 Page 14 21 2 Install the valve assembly in the pumping chamber 30 Figure 14 17 Page 14 21 3 Install the pumping cham...

Page 160: ...g screws and tighten to 40 in lb 4 5 N m 5 Turn the fuel shut off valve on top of the gas tank to the open ON position Figure 14 22 Page 14 26 6 Place the Forward Reverse handle in the NEUTRAL positio...

Page 161: ...used up and the engine stalls Figure 14 21 Page 14 26 5 Return the neutral lockout cam to the OPERATE position 6 Disconnect the battery negative cable first 7 Loosen do not remove the carburetor drai...

Page 162: ...2 In a well ventilated area flush the fuel tank with water to remove any remaining gasoline 3 In a well ventilated area set the tank upside down so that the water can drain out of it To make sure that...

Page 163: ...d the Forward Reverse handle is in the NEUTRAL position and that the neutral lockout cam is in the SERVICE position 11 Check to be sure the fuel shut off valve on top of the gas tank is in the open ON...

Page 164: ...14 19 FUEL SHUT OFF VALVE Read DANGER and WARNING on page 14 1 The fuel shut off valve is located on top of the fuel tank Figure 14 20 Page 14 25 The fuel shut off valve should always be turned to the...

Page 165: ...YSTEM Fuel Shut Off Valve 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14 27 14 Figure 14 23 Incorrect Fuel Shut off Valve VIEWED FROM SELECTOR SIDE OF VALVE PARTIALLY CLOSED PO...

Page 166: ...14...

Page 167: ...HANDLE IN THE NEUTRAL POSITION AND REMOVE KEY PRIOR TO SERVICING MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES...

Page 168: ...p and bracket 2 Place a new gasket 12 on the exhaust manifold mounting flange as shown 3 Position the muffler and bracket assembly and the governor cable bracket 13 and install the bolts 5 lock washer...

Page 169: ...AL position and the neutral lockout cam in the SER VICE position Start the engine and check for exhaust leaks and proper engine operation See follow ing DANGER 13 After checking the exhaust and engine...

Page 170: ...15...

Page 171: ...N ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHI...

Page 172: ...sition the vehicle will not operate if the Forward Reverse handle is placed in either the FORWARD or REVERSE position To put the cam back into the OPERATE position pull the cam out approximately 3 8 i...

Page 173: ...hen do not remove the wheels axle shafts or axle tubes first Instructions for removing the unitized transaxle from the vehicle begin on page 16 7 Hydraulic floor jack or Chain Hoist 12 to 18 inch Stra...

Page 174: ...enance and Service Supplement 16 Axle Shaft Continued Figure 16 5 Differential Gear Case Axle Tubes ClubCar REFERENCE PASSENGER SIDE CASE 74 73 70 68 69 78 77 76 79 87 86 90 89 85 91 84 82 89 85 88 81...

Page 175: ...not slipped and are still seated against the shoulder on the axle shaft Figure 16 5 Page 16 4 8 Inspect the bearing If the bearing is damaged or worn replace it AXLE BEARING Axle Bearing Removal 1 Use...

Page 176: ...puller wedge attachment against collar and press both bearing and collar onto shaft Install the retaining ring 74 Figure 16 5 Page 16 4 See following CAUTION APPLY LOCTITE 271 TO THE INSIDE OF THE CO...

Page 177: ...re 16 3 Page 16 3 5 Place a 1 4 to 3 8 inch 6 10 mm diameter rod against the retaining ring and tap lightly at four to five locations to ensure it is properly seated See following WARNING UNITIZED TRA...

Page 178: ...racket Then disconnect the shifter cable rod end from the shifter arm on the unitized transaxle and remove the cable from the cable mounting bracket Figure 16 15 Page 16 9 3 8 Mark for proper reconnec...

Page 179: ...ng the leaf springs to the shackles Figure 16 22 Page 16 11 8 Remove the bolts securing the leaf springs to their front mounts Figure 16 23 Page 16 11 9 Continue raising vehicle until frame or trailer...

Page 180: ...pan so they will completely support the engine and keep it level to the floor Figure 16 24 Page 16 11 See following NOTE 15 Remove the drive belt 15 1 Grasp belt midway between drive and driven clutch...

Page 181: ...elerator cable bracket to transaxle Figure 16 33 Page 16 13 20 Remove screws 2 securing the transmission shift cable bracket 1 to transaxle Figure 16 35 Page 16 14 See following NOTE THE GOVERNOR CABL...

Page 182: ...age 16 13 22 Remove the leaf springs wheels and brake assemblies from the transaxle Figure 16 26 Raise Vehicle Figure 16 27 Position Jack Stands Figure 16 28 Snubber Figure 16 29 Remove Powertrain Clu...

Page 183: ...34 Transaxle Mounting Remove bolt and mounting washer from driven clutch Leave cable connected Loosen nut Then with governor and accelerator cables still attached remove the governor arm from the shaf...

Page 184: ...1 Figure 16 35 Transaxle Gear Casing and Brackets THE FOLLOWING INFORMATION PROVIDES INSTRUCTIONS FOR DISASSEMBLING THE UNITIZED TRANSAXLE HOWEVER THE TRANSAXLE CASE CAN BE SEPARATED AND GEARS ACCESS...

Page 185: ...gear assemblies inside the transaxle stay together in one either side of the case See following CAUTION 7 Turn the case section containing the gearing on edge as shown Figure 16 36 Page 16 15 While h...

Page 186: ...Figure 16 35 Page 16 14 13 4 Remove flat washer 12 from the shifter shaft on the outside of the case as shown then remove the shifter shaft by pushing it through the case toward the interior of transa...

Page 187: ...be necessary to tap the ring gear off with a plastic or rubber mallet Figure 16 45 Page 16 19 See following NOTE 2 Pull the cover 87 and thrust plate 86 from the differential gear carrier case Figure...

Page 188: ...and Service Supplement 16 Differential Gear Case Disassembly Continued Figure 16 42 Unitized Transaxle ClubCar REFERENCE DRIVER SIDE CASE 37 38 39 40 41 42 44 45 41 46 33 34 35 36 47 48 46 50 51 45 4...

Page 189: ...een the bearing and gear case 84 Figure 16 5 Page 16 4 and press the bearing off as shown Figure 16 47 Page 16 21 Repeat the process for the bearing on the carrier cover 87 Figure 16 5 Page 16 4 See f...

Page 190: ...ngs 43 thrust plate 41 and synchronizer ring 45 from the input shaft Figure 16 42 Page 16 18 5 Use a small flat blade screwdriver to remove two synchronizer springs snap rings 46 and then slide the sy...

Page 191: ...1 Page 16 22 See following CAUTION 2 Place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing and the larger gear on the idler shaft 65 Figure 16 42 Page 16 18 then press t...

Page 192: ...d be inspected for tooth surface damage or fractures 4 Synchronizer ring teeth should be inspected for severe wear fractures or other damage 5 Using a feeler gauge measure the distance X at several po...

Page 193: ...Page 16 18 SYNCHRONIZER GEAR ASSEMBLY 1 Press the synchronizer sleeve 47 onto the splines of the input shaft 51 Figure 16 42 Page 16 18 No particular orientation of the sleeve is necessary but toward...

Page 194: ...rd the end of the shaft Figure 16 42 Page 16 18 9 Press new bearing 54 Figure 16 42 Page 16 18 onto the shaft until it seats Make sure the input gear turns freely See following CAUTION 10 On the other...

Page 195: ...l and spring while inserting shift rod 33 into the shifter fork 34 Remove screwdriver when the shift rod is inserted far enough for it to depress the ball and spring then continue to insert rod until...

Page 196: ...st plate 86 and differential gear 90 into the carrier case cover 87 Figure 16 5 Page 16 4 as shown Figure 16 64 Page 16 27 Then while holding the thrust plate and differential gear in place position t...

Page 197: ...and thrust plate until pin is flush with outside of housing Position differential gear and thrust plate in carrier case cover then while holding gear and thrust plate in position rotate cover and pos...

Page 198: ...sh them onto the shaft until the gear snaps into the groove on the shaft 5 Position the interior washer on the pivot arm then install the pivot arm and washer into the left driver side case as shown F...

Page 199: ...aring should be flush Figure 16 79 Page 16 33 See following CAUTION 8 Make sure the mating surfaces of the left and right sides of the case are clean and free of oil grease or residue of any kind and...

Page 200: ...ase or residue of any kind USE ONLY THREE BOND NO 1215 SEALANT TO SEAL CASE DO NOT USE A SUBSTITUTE IF THE TWO SIDES OF THE CASE CANNOT BE EASILY CLOSED OR DO NOT MAKE COMPLETE CONTACT DO NOT FORCE TH...

Page 201: ...e 16 75 Oil Guide Figure 16 76 Synchronizer Ring Gear Install differential gear assembly into bore in the left side case Insert the idler gear assembly into casing bore gears do not mesh Mate tabs on...

Page 202: ...passenger side axle shaft 68 in the right axle tube 76 Figure 16 5 Page 16 4 Using 90 angle 90 tip snap ring pliers install the retaining ring as shown Figure 16 84 Page 16 34 See following WARNING BE...

Page 203: ...of the idler intermediate and differential bearings are on the same plane The synchronizer bearing protrudes slightly The edges of the input drive gear and large intermediate gear should be flush EDG...

Page 204: ...N m Figure 16 86 Page 16 35 7 Install the governor cable bracket on transaxle case Tighten the mounting screws to 134 in lb 15 1 N m Figure 16 87 Page 16 35 8 Install governor lever arm on governor s...

Page 205: ...age 16 36 16 Using the floor jack adjust vehicle height to position the leaf springs for mounting in the shackles Install the mounting bolts and locknuts Figure 16 92 Page 16 36 17 Position shocks in...

Page 206: ...6 gauge yellow wire to the DF post on the starter generator and tighten to 30 in lb 3 4 N m Figure 16 96 Page 16 37 Figure 16 89 Driven Clutch Figure 16 90 Snubber Figure 16 91 Leaf Springs Figure 16...

Page 207: ...mpulse line fitting of the fuel pump connect it to the carburetor and secure with a hose clamp Figure 16 100 Page 16 38 26 Connect the impulse line to the fuel pump and secure it with the hose clamp F...

Page 208: ...e 14 14 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 MALFUNC...

Page 209: ...e 16 41 2 Remove the ball joint socket 10 from the shifter arm ball stud 11 on the transaxle Figure 16 106 Page 16 41 Figure 16 101 Impulse Line Figure 16 102 Air Intake Hose Figure 16 103 Carburetor...

Page 210: ...e Figure 16 106 Page 16 41 Tighten nuts to 22 ft lb 29 8 N m 3 Secure the cable with a retaining nut 5 on each side of the shifter cable support bracket at the F R assembly Figure 16 106 Page 16 41 Ti...

Page 211: ...or major adjustments the cable retaining nuts 5 must be loosened and adjusted When the cable is properly adjusted with the Forward Reverse handle 9 Figure 16 106 Page 16 41 in the NEUTRAL position the...

Page 212: ...16...

Page 213: ...EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERY TURN KEY SWITCH OFF PLACE FORWARD REVERSE HANDLE IN THE NEUTRAL POSITION AND REMOVE KEY PRIOR TO SERVICING DO N...

Page 214: ...n 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 a...

Page 215: ...6 DRIVE BELT Read DANGER and WARNING on page 17 1 The drive belt should be inspected semiannually for wear and or glazing If it is excessively worn frayed or glazed replace the belt As the drive belt...

Page 216: ...Bolt Figure 17 4 Drive Clutch Removal BE VERY CAREFUL WHEN HANDLING THE CLUTCHES A CLUTCH THAT HAS BEEN DROPPED WILL NOT BE PROPERLY BALANCED IF EITHER CLUTCH IS DROPPED ASSUME THAT IT IS DAMAGED AND...

Page 217: ...ure 17 4 Page 17 4 7 Support the drive clutch assembly in your hand and back the clutch puller tool out of the crankshaft DRIVE CLUTCH CLEANING AND INSPECTION 1 Use a dry lint free cloth to clean clut...

Page 218: ...nd Inspection Continued 2 Inspect the belt contact surfaces of the clutch sheaves for wear If any area of a sheave contact surface has wear of 0 060 inch 1 52 mm or more the clutch should be replaced...

Page 219: ...d drive buttons as shown Figure 17 8 Page 17 8 5 Remove the clutch weights Figure 17 9 Page 17 8 5 1 Remove the screws and flat washers attaching the weights as shown Figure 17 9 Page 17 8 5 2 Pull th...

Page 220: ...ach end of the bore in the fixed face assembly Figure 17 5 Page 17 6 See Figure 17 11 Page 17 9 Discard the rings INSPECTION OF DRIVE CLUTCH PARTS 1 Inspect the idler bearing 6 for smooth rotation or...

Page 221: ...7 5 Page 17 6 7 Inspect the drive belt pulley sheaves for excessive wear or damage If the sheaves are excessively worn or damaged replace the entire fixed face drive assembly DRIVE CLUTCH ASSEMBLY 1 P...

Page 222: ...re 17 13 Page 17 10 10 Install white plastic flat washers on each end of the mounting pin and push them against the outside sur faces of the weights Center the weights and washers on the mounting pin...

Page 223: ...17 8 17 Install the thrust washer 11 onto the moveable face assembly Figure 17 5 Page 17 6 18 Install the hub assembly 1 on the moveable face assembly and align the match marks made before disassembl...

Page 224: ...cal System Tighten the starter generator mounting hardware to 23 ft lb 31 2 N m and the adjusting hardware to 13 ft lb 17 6 N m 4 Install the drive belt as instructed on page 17 4 5 Connect the batter...

Page 225: ...4 Figure 17 17 Page 17 13 See follow ing WARNING 2 Insert a puller plug Club Car Part No 1014507 Figure 17 18 Page 17 13 into the shaft bore and use a driven clutch cam puller Club Car Part No 101450...

Page 226: ...maged DRIVEN CLUTCH ASSEMBLY 1 Place the three drive buttons 6 in position Apply one drop of Loctite 222 to each of the socket head cap screws and then install and tighten them to 8 in lb 0 9 N m Figu...

Page 227: ...o install the driven clutch reverse the removal procedure Before tightening the center bolt 11 to 14 ft lb 19 0 N m make sure the mounting washer 12 is installed between the center bolt and the clutch...

Page 228: ...17...

Page 229: ...al 13 25 carburetor 14 4 choke and fresh air system 14 4 closed throttle or idle adjustment 14 13 float system 14 4 jet main 14 5 elevation size chart 14 5 main system 14 2 slow speed system 14 2 chok...

Page 230: ...tion 13 4 RPM adjustment 14 14 service specifications 13 48 engine mounting plate see engine removal engine oil 10 6 exhaust system 14 4 15 1 see also muffler F flywheel removal 13 30 forward reverse...

Page 231: ...bly 16 20 K key switch engine kill circuit testing 11 32 installation 12 14 removal 12 13 starter circuit 11 5 11 7 starter circuit testing 11 12 kill circuit engine 11 9 testing 11 28 11 31 11 32 kil...

Page 232: ...4 4 cleaning inspection and repair 13 6 gap adjustment 13 7 14 4 installation 13 7 removal 13 6 testing 13 7 specifications engine service 13 48 liquid capacities 10 5 torque 13 49 starter generator a...

Page 233: ...re 10 5 tools see service tools torque converter troubleshooting 17 3 transaxle see unitized transaxle troubleshooting torque converter 17 3 vehicle troubleshooting guide 11 2 U unitized transaxle ass...

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Page 236: ...Golf Cars and Utility Vehicles Club Car Inc P O Box 204658 Augusta GA 30917 4658...

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