Club Car FE350 2005 Maintenance Service Supplement Download Page 3 | Manualshive

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Club Car FE350 2005 Maintenance Service Supplement Download Page 3

2005 FE350 Gasoline Vehicle Maintenance and Service Supplement

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FOREWORD

Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.

This supplement provides detailed information for the maintenance and repair of FE350 gasoline vehicles and
should be used in conjunction with the appropriate maintenance and service manual. This supplement also
provides detailed information for removing and replacing FE290 engines and transaxles, but does not contain
information for the disassembly, repair or rebuilding of FE290 engines or transaxles. For complete detailed
disassembly, repair or rebuild procedures, see the Engines and Drivetrain Components, Repair and Rebuild
Manual (CCI P/N 102396501).

If you do not have the appropriate maintenance and service manual, you may order one from your local Club
Car representative. Maintenance and service manuals available include the following:

This supplement and corresponding maintenance and service manual should be thoroughly reviewed prior to
servicing the vehicle. The procedures provided must be properly implemented, and the DANGER, WARNING,
and CAUTION statements must be heeded.

This manual was written for the trained technician who already has 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-trained tech-
nician.

It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.

This supplement, used in conjunction with the appropriate maintenance and service manual, covers all
aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle.
If it appears that a service question is not answered in this manual, you may write to us at: Club Car, Inc., P.O.
Box 204658, Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech-
nical Service Representative at (706) 863-3000, ext. 3580.

2005 Turf/Carryall Vehicle Maintenance and Service Manual

Publication Part No. 102680404

2005 Transportation Vehicle Maintenance and Service Manual

Publication Part No. 102680405

Engines and Drivetrain Components, Repair and Rebuild Manual

Publication Part No. 102396501

Copyright © 2005 Club Car, Inc.

Club Car, Carryall,

and

ArmorFlex

are registered trademarks of Club Car, Inc.
This manual effective July 28, 2004.

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Summary of Contents for FE350 2005

Page 1: ...Club Car MANUAL NUMBER 102680410 EDITION CODE 0405A00000 FE350 GASOLINE VEHICLES 2005 MAINTENANCE SERVICE SUPPLEMENT...

Page 2: ......

Page 3: ...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 pe...

Page 4: ...hicles and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or proce dures will be forwarded to all Club Car and Carryall...

Page 5: ...Information 11 1 Troubleshooting Guide 11 1 Wiring Diagrams 11 6 Electrical System 11 13 Test Procedures 11 13 Index of Test Procedures 11 13 SECTION 12 ELECTRICAL COMPONENTS Starter Generator 12 1 Vo...

Page 6: ...ore Servicing 13 1 Engine Rotation 13 1 Spark Plug 13 1 Cylinder Head 13 3 General Information 13 3 Breather Valve Reed Valve 13 3 Valve Clearance Check and Adjustment 13 3 Crankcase 13 4 Engine Remov...

Page 7: ...5 Intake Duct Installation 14 16 Intake Duct Repair 14 17 Air Filter 14 17 Fuel Filters 14 18 General Information 14 18 Fuel Filter Removal 14 18 Fuel Filter Installation 14 18 Fuel Pump 14 20 General...

Page 8: ...Shifter Cable Installation 16 21 Forward Reverse Shifter Cable Adjustment 16 23 SECTION 17 TORQUE CONVERTER General Information 17 1 Troubleshooting 17 1 Drive Belt 17 2 Drive Belt Removal 17 3 Drive...

Page 9: ...rea 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 CAU...

Page 10: ...um lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor...

Page 11: ...ontact your local authorized Club Car distributor dealer to perform all repairs and semiannual and annual periodic service PERIODIC SERVICE SCHEDULE See General Warning on page 10 1 WARNING Service re...

Page 12: ...n terminals and wash dirt from casing check electrolyte level See Battery Section 12 Page 12 37 Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspensi...

Page 13: ...ion 5 fittings Chassis Lube EP NLGI Grade 2 Brake slides Dry Moly Lube CCI P N 1012151 Annually by trained technician only every 100 hours of operation Check fill unitized transaxle to plug level 27 o...

Page 14: ...10 3 Page 10 6 See following CAUTION CAUTION Do not remove dipstick while engine is running 2 Check oil level by fully inserting the dipstick into the oil filler tube and immediately removing it again...

Page 15: ...grounded If the pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation If the vehicle has an all weather enclosure installed the fuel tank must be prope...

Page 16: ...hicle and open completely before refueling 2 The fuel tank is located on the passenger side of the vehicle Figure 10 4 Page 10 6 Remove fuel cap and fill the fuel tank with fresh unleaded fuel only Se...

Page 17: ...used in making these checks can be found in the referenced sections in this supplement or the appropriate maintenance and ser vice manual TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTI...

Page 18: ...flooded with fuel as result of excess choking Vehicle Owner s Manual Controls and Indicators See Choke Kill circuit grounded Section 11 Troubleshooting and Electrical System Test Procedures 14 15 and...

Page 19: ...ystem Float needle valve not functioning properly Section 14 Fuel System Carburetor vent is clogged Section 14 Fuel System Starter fails to operate Neutral lockout cam is in the wrong position Test Pr...

Page 20: ...el of lubricant or wrong type of lubricant in transmission Section 16 Unitized Transaxle Internal gears are damaged or worn Section 16 Unitized Transaxle Synchronizer rings are worn damaged or jammed...

Page 21: ...vehicle only Section 11 Troubleshooting and Electrical System Test Procedures 4 and 18 Accelerator pedal linkage out of adjustment causing engine kill limit switch not to activate Section 14 Fuel Syst...

Page 22: ...CK LEFT HEADLIGHT BLUE BLUE BLACK FRAME GROUND BLACK KEY SWITCH RED WHITE WHITE BLACK RED WHITE BLACK BLUE YELLOW YELLOW BLACK BLUE WHITE B L U E RE D WHI T E BLACK WHITE WHITE BLACK WHITE BLACK BLACK...

Page 23: ...OUND BLACK KEY SWITCH RED WHITE WHITE BLACK RED WHITE BLACK BLUE YELLOW YELLOW WHITE B L U E RE D WHI T E BLACK WHITE WHITE BLACK WHITE BLACK BLACK BLUE RED RED R E D FUSE BLOCK ORANGE Y E LLO W RPM L...

Page 24: ...TER OIL LIGHT FRONT REVERSE BUZZER KEY SWITCH LIGHT SWITCH PARK LIMIT SWITCH HORN BUTTON TWO PIN CONNECTOR B R O W N ORANGE WHITE RED WHITE ORANGE YELLOW GREEN WHITE BLACK RED WHITE YELLOW BLACK BROWN...

Page 25: ...LAC WHITE BLACK WHITE BLACK BRAIDED GROUND WIRE SOLENOID WHIT RED BLUE BLACK ORANGE RED WHITE BROWN BROWN BLACK SONIC WELD ORANGE RED WHITE RED WHITE YELLOW WHITE BLACK RED WHITE RED WHITE YELLOW YELL...

Page 26: ...RONT REVERSE BUZZER KEY SWITCH LIGHT SWITCH PARK LIMIT SWITCH HORN BUTTON TWO PIN CONNECTOR B R O W N ORANGE WHITE RED WHITE ORANGE YELLOW WHITE BLACK RED WHITE YELLOW BLACK BROWN BLUE RED WHITE YELLO...

Page 27: ...LACK BRAIDED GROUND WIRE SOLENOID WHIT RED BLUE ORANGE GREEN BLACK SONIC WELD ORANGE RED WHITE RED WHITE ORANGE YELLOW YELLOW WHITE WHITE BLACK RED WHITE RED WHITE YELLOW BLACK BROWN BROWN BLUE BLUE R...

Page 28: ...SE BUZZER LIMIT SWITCH RELAY FUSE BLOCK KILL LIMIT SWITCH VOLTAGE REGULATOR ORANGE WHITE BROWN RED RED WHITE YELLOW R E D WHI T E O R A NGE WHIT E W H IT E B LA C K WHI TE B LAC K YELLOW R E D ORANGE...

Page 29: ...ager vehicles Horn Circuit Turf 6 Carryall 6 TransPorter and Villager vehicles Recognizing and understanding the function of each of these circuits will help to quickly isolate the source of an electr...

Page 30: ...ill Wire 20 Reverse Buzzer Limit Switch 21 Reverse Buzzer 22 Low Oil Warning Light 23 Oil Level Sensor 24 Neutral Lockout Cam 25 Battery Test Under Load 26 Fuel Level Sending Unit 27 Fuel Gauge 28 Hou...

Page 31: ...verse han dle in the NEUTRAL position and chock the wheels 2 Check for loose or corroded battery terminal connections Remove the negative cable first and clean tighten and replace connections as neces...

Page 32: ...ed for temperature For each 10 F 5 6 C above 80 F 27 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 27 C subtract 0 004 from the reading Interpreting the Results of the Hydrometer Test The...

Page 33: ...to the ON position 3 Read the battery voltage after the load tester has been turned ON for 15 seconds Compare the battery s voltage reading with the following table Make sure you have the correct ambi...

Page 34: ...e 11 11 Page 11 18 Place the black probe on the vehicle frame The reading should be continuity If the reading is incorrect clean and tighten cable connections If the connections are good and the readi...

Page 35: ...the key switch The reading should be continuity If the reading is incorrect replace the key switch See Key Switch Removal Section 12 Page 12 13 5 2 With the key still in the ON position place the red...

Page 36: ...limit switch present on pedal start vehicles only is the top switch located in the elec trical component box There is an 18 gauge green wire and an 18 gauge orange wire connected to this limit switch...

Page 37: ...gauge white wire the 16 gauge red wire and 16 gauge white wire from the large post of the solenoid Do not allow the wires to touch the frame or other components of the vehicle Figure 11 16 Page 11 21...

Page 38: ...cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Check for proper wiring and tight connections 3 Set the multimeter to 200 ohms Place the r...

Page 39: ...removed from the vehicle and disassembled by a qualified technician See Starter Generator Removal Section 12 Page 12 1 An incorrect reading from the A1 or A2 terminal indicates three possible problem...

Page 40: ...disconnected using a multimeter set to 200 ohms place the red probe on the DF terminal and the black probe on the F1 terminal The reading should be between 4 5 and 5 5 ohms If the reading is incorrec...

Page 41: ...t the yellow wire to the DF terminal on the starter generator TEST PROCEDURE 12 VOLTAGE REGULATOR See General Warning Section 10 Page 10 1 NOTE Keep the battery connected while performing this test pr...

Page 42: ...key all the way to the START position and release after the engine is started The engine will idle 4 If the engine begins to run test the engine kill circuit for a shorted wire or other failed compone...

Page 43: ...ng 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...

Page 44: ...ocedures will properly detect a coil that has failed in most cases however in rare cases some ignition coils can fail to operate at normal warmer operating temperatures If the ignition coil has tested...

Page 45: ...l Resistance In Vehicle Test Figure 11 27 Secondary Coil Test In Vehicle Test 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...

Page 46: ...tep 6 on page 11 32 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 s...

Page 47: ...Spark Plug Cap Test Figure 11 31 Secondary Coil Test Without Cap 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 20k OHM SE...

Page 48: ...e 16B Ignition Coil Bench Test 1 Remove the coil from the engine See Ignition Coil Removal Section 12 Page 12 25 2 Using a multimeter set to 200 ohms measure the primary coil resistance 2 1 Place the...

Page 49: ...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 30 Page 11 31 If the resistance is not between 4 5k 6 0k ohms the cap...

Page 50: ...e reading should be continuity If either reading is incorrect replace the limit switch Figure 11 35 Page 11 34 For key start vehicles Place the red probe of the multimeter on the common COM terminal o...

Page 51: ...et connector located at the engine RPM limiter Figure 11 24 Page 11 27 3 Connect red probe of multimeter to the male bullet terminal on the white black wire and connect the black probe to the vehicle...

Page 52: ...ket at the left rear of the vehicle 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 To test the front reverse buzz...

Page 53: ...ld make an audible click as it is pressed If it does not check for wear on the cam lobes Be sure the cam has snapped fully back into place If the cam lobes still do not activate the limit switch repla...

Page 54: ...Page 10 1 2 Disconnect the orange wire from the center post of the fuel level sending unit 3 With a multimeter set to 2 k ohms place the red probe of the multimeter on the center post of the sending...

Page 55: ...our meter 4 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 r...

Page 56: ...LAY ENGINE KILL CIRCUIT See General Warning Section 10 Page 10 1 The relay present on key start vehicles only is located in the electrical component box See Relay Removal Section 12 Page 12 28 1 Disco...

Page 57: ...on 12 Page 12 28 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Disconnect the 6 gauge white wire from the F2 pos...

Page 58: ...ter 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...

Page 59: ...connecting battery cables make sure none of the electrical components touch the front body trim or other parts of the vehicle frame Place a dry towel between the body trim and the center dash to preve...

Page 60: ...should not illuminate with the park brake engaged 2 If the brake lights operate exactly as described in step 1 the brake light relay is operating correctly 3 If the brake lights do not illuminate when...

Page 61: ...ng Section 10 Page 10 1 7 1 3 Remove the center dash assembly See step 2 of Key Switch Removal Section 12 Page 12 13 7 2 Locate the red jumper wire 12 in the area behind the center dash panel Figure 1...

Page 62: ...with no tone emitted 11 3 Reverse the multimeter probes and observe the multimeter The multimeter should continue to indi cate an overlimit with no tone emitted 11 4 If a tone is emitted indicating a...

Page 63: ...51 Park brake pedal limit switch See Test Procedure 38 Park Brake Limit Switch on page 11 51 For Turf 2 vehicle Check the continuity of the yellow wire from the inline fuse holder to the light switch...

Page 64: ...d the center dash to prevent an electrical short circuit 5 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 N m 6 Pull the light switch to the ON position The reading sh...

Page 65: ...d probe on wire contact connected to the 18 gauge brown wire 6 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 N m 7 To test taillights place light switch in the ON pos...

Page 66: ...12 volts replace the head light bulb 6 If there is no voltage reading at the wiring harness check continuity of the 16 gauge blue wire from the headlight to the light switch Using a multimeter set to...

Page 67: ...200 ohms and with alligator clips on the multimeter probes place the probes onto the two terminal screws securing the green white and red white wires to the limit switch located under the floorboard...

Page 68: ...n the orange wire Figure 11 56 Page 11 52 See following CAUTION CAUTION Before connecting battery cables make sure no terminal ends or probes touch each other the front body trim or other parts of the...

Page 69: ...ING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Disconnect the orange and red white wires at the horn button from the wire harness 3 Using a multimeter set to 200 ohms...

Page 70: ...11...

Page 71: ...enerator Function on page 11 25 Starter Generator Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Place th...

Page 72: ...g removed or installed could damage the brushes Lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on...

Page 73: ...Using a spring scale test brush spring tension If any spring has a tension less than 24 ounces 6 67 N replace all four springs Figure 12 5 Page 12 3 See following CAUTION CAUTION When checking brush s...

Page 74: ...wn into the holders Position springs into the notches in the brushes Install the brush cover 30 that has the drain hole in it next to the A2 terminal Install the remaining three brush cov ers 29 in th...

Page 75: ...age 12 5 2 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearings and replace if rusted worn cracked or if there is an abnormal color change in the metal of...

Page 76: ...e housing Remove the four pole pieces from inside the housing Remove the field coils from the inside of the housing Figure 12 10 Page 12 7 See following NOTE NOTE Do not remove the insulators or the f...

Page 77: ...oil from the commutator Visually inspect the commutator for worn burned or glazed areas Check for loose or raised commutator bars Slight roughness of the commutator can be polished away with 400 grit...

Page 78: ...a clean cloth and remove carbon dust and metal particles from between commutator bars 1 Using a multimeter set on 200 ohms place the positive probe on the commutator bars and the neg ative probe on t...

Page 79: ...washer lock washer and nut onto each threaded terminal on the outside of the housing Tighten nuts to 47 5 in lb 5 4 N m Figure 12 10 Page 12 7 CAUTION Route the field terminal wires so that they will...

Page 80: ...e shaft Insert the shaft key 34 into the shaft Install the belt pulley 39 onto the shaft and install the lock washer 40 and M14 nut 41 Tighten the nut to 28 ft lb 38 0 N m Figure 12 7 Page 12 5 Starte...

Page 81: ...all the starter generator 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 s...

Page 82: ...ire 4 at the bullet con nector the 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 12 4 Remove the...

Page 83: ...nect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove the center dash panel 2 1 Remove the plastic cap 1 covering the mou...

Page 84: ...napped in place 2 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 N m See Figure 10 1 Section 10 Page 10 3 Coat terminals with Battery Terminal Protector Spray CCI P N...

Page 85: ...l line to the small post on the solenoid Connect the 18 gauge orange wire from the accelerator pedal limit switch the 18 gauge orange white wire from the key switch the 18 gauge blue wire from the vol...

Page 86: ...bles as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove electrical component box cover 3 Remove the fuse from the fuse block Fuse Installation...

Page 87: ...o the common COM terminal and the black wire to the normally open NO terminal of the kill limit switch 12 and place the switch on the mounting screws located in the electrical component box Place the...

Page 88: ...UTION CAUTION Do not overtighten the retaining nuts If the nuts are overtightened limit switches could be damaged 2 Connect wires to Neutral Lockout Limit Switch Pedal Start vehicles Connect the black...

Page 89: ...t the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove the external snap ring 14 Figure 12 20 Page 12 19 3 Remove the plastic...

Page 90: ...perly seated and snapped in place 5 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 N m See Figure 10 1 Section 10 Page 10 3 Coat terminals with Battery Terminal Protec...

Page 91: ...12 19 Page 12 19 3 Remove the nuts 2 and washers 6 from the neutral lockout limit switch 5 and slide the neutral lockout limit switch off of the screws Do not disconnect the wires 4 Remove the spacer...

Page 92: ...0 1 2 Remove the center dash panel See Key Switch Removal on page 12 13 3 Disconnect the wires from the low oil warning light 11 Figure 12 23 Page 12 23 Do not allow wires to touch 4 Press the retaini...

Page 93: ...re 12 24 Page 12 23 2 Slide the mounting bracket onto the two threaded studs on the fuel gauge hour meter and secure with two lock washers and two hex nuts Tighten to 2 5 in lb 0 28 N m Place one drop...

Page 94: ...miter See Test Procedure 15 Section 11 Page 11 28 RPM Limiter Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10...

Page 95: ...10 1 Testing the Ignition Coil See Section 11 Test Procedure 14 Page 11 27 and Test Procedure 16 Page 11 28 Ignition Coil Removal 1 Disconnect the battery cables as instructed See WARNING To avoid uni...

Page 96: ...steps 1 through 8 for pro cedures 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...

Page 97: ...Rotate the flywheel 8 until the magnet is positioned directly under the ignition coil Use a 0 012 inch 0 304 mm bronze feeler gauge to set the air gap between the ignition coil and the flywheel magne...

Page 98: ...10 1 Section 10 Page 10 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion OIL LEVEL SENSOR See General Warning Section 10 Page 10 1 Testing the Oil Level Se...

Page 99: ...tion 10 Page 10 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion HEADLIGHTS See General Warning Section 10 Page 10 1 Testing the Headlight Socket See Test P...

Page 100: ...ery cables positive cable first and tighten hardware to 12 ft lb 16 N m See Figure 10 1 Section 10 Page 10 3 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion...

Page 101: ...the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove the screws 1 securing the taillight 7 to the rear fender 8 Figure 12 34...

Page 102: ...nimize corrosion HEADLIGHT SWITCH See General Warning Section 10 Page 10 1 Testing the Light Switch See Test Procedure 32 Section 11 Page 11 43 Headlight Switch Removal 1 Disconnect the battery cables...

Page 103: ...n 4 of the appropriate maintenance and service manual 4 Remove the two voltage suppressor wires 11 from the coil terminals of the brake light relay 12 Figure 12 37 Page 12 33 or Figure 12 38 Page 12 3...

Page 104: ...RK BRAKE LIMIT SWITCH See General Warning Section 10 Page 10 1 Testing the Park Brake Limit Switch See Test Procedure 38 Section 11 Page 11 51 Park Brake Limit Switch Removal 1 Disconnect the battery...

Page 105: ...s instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove the hardware 4 and 5 securing the brake switch 2 to the bracket 3 Figure 12 41 Page 12 35 3...

Page 106: ...e 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 f...

Page 107: ...CCI P N 1014305 to minimize corrosion BATTERY See General Warning Section 10 Page 10 1 DANGER Due to the danger of an exploding battery wear a full face shield and rubber gloves when working around a...

Page 108: ...al Protector Spray CCI P N 1014305 to prevent future corrosion 2 The battery should be kept clean and dry to minimize self discharge Any dirt grime or acid spillage should be removed Wash the battery...

Page 109: ...attery and cannot be replaced Mineral Content For the longest battery life distilled water should be used in the battery however if tap water is going to be used contact your local water department to...

Page 110: ...attery 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 feel...

Page 111: ...0 the battery should be recharged See follow ing 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...

Page 112: ...12...

Page 113: ...information for removing and replacing the FE290 engine For complete instruction on engine disassembly repair rebuilding and reassembly see the Engines and Drivetrain Components Repair and Rebuild Man...

Page 114: ...bridging between the electrode and base The electrode should not be eroded Black color excessive carbon and or a wet plug indicate a too rich condition White burned or melted electrodes indicate a to...

Page 115: ...anking RPM resulting in lower compres sion At a normal cranking speed of 550 600 RPM the compression should typically be 71 psi This value could vary slightly depending on wear of components affecting...

Page 116: ...n 17 Page 17 4 See also following NOTE 5 Remove muffler See Muffler Removal Section 15 Page 15 1 6 Remove engine mounting hardware items 1 2 5 and 6 Figure 13 2 Page 13 5 7 Lift engine from the mounti...

Page 117: ...cle Maintenance and Service Supplement Page 13 5 13 Figure 13 2 Engine Mounting Plate Figure 13 3 Oil Level Sensor Wire Figure 13 4 Crankcase Cover TYPICAL 2 PLACES TYPICAL 4 PLACES 3 1 4 5 2 TYPICAL...

Page 118: ...ensor was removed from the bracket install sensor 6 into bracket 5 and secure with three screws 7 Figure 13 5 Page 13 6 Tighten to 17 in lb 1 9 N m 2 Position the sensor and bracket on inside of crank...

Page 119: ...m Then repeating the sequence tighten them to 250 in lb 28 2 N m 5 Connect the yellow jumper wire 11 to the cord connector 12 Figure 13 3 Page 13 5 IGNITION COIL AND FLYWHEEL See General Warning Sect...

Page 120: ...e screwdriver or pry bar in the fan blades 4 Remove the flywheel with a puller CCI P N 1016627 5 Remove the flywheel key from its groove Flywheel Installation See Flywheel Installation on page 13 9 Ig...

Page 121: ...ot to damage the fan blades Use a strap wrench to hold flywheel Do not place screwdriver or pry bar between fan blades 3 Install the fan housing and tighten the screws to 90 in lbs 10 N m ENGINE INSTA...

Page 122: ...d clean with cloth Figure 13 13 Page 13 10 9 2 Reinsert dip stick until fully seated 9 3 Oil must be in the SAFE LEVEL range CAUTION Do not overfill with oil 10 Install a new or cleaned spark plug gap...

Page 123: ...shroud screws M6 25 in lb 2 8 N m Bolts marked with 4 when used with nuts M8 M6 M5 130 in lb 15 N m 50 in lb 5 9 N m 30 in lb 3 4 N m ITEM LIMITS Spark plug gap standard 0 027 to 0 031 in 0 69 to 0 79...

Page 124: ...13...

Page 125: ...1 Air filter element See Air Filter on page 14 17 Fuel filters See Fuel Filters on page 14 18 Choke and air intake system for restriction of air flow See Choke and Air Intake System on page 14 12 Fue...

Page 126: ...re 14 1 Page 14 3 When removing the carburetor body the throttle return spring 11 must be disconnected Note its proper orientation so that it can be replaced in the same orientation The carburetor mus...

Page 127: ...in the carburetor body when the fuel bowl is removed Figure 14 2 Page 14 4 During normal operation the fuel bowl retains the float pivot pin 6 Make sure that the float pivot pin does not fall out of...

Page 128: ...part 8 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 spri...

Page 129: ...he throttle bracket 4 just before positioning the carburetor and securing it to the engine Figure 14 1 Page 14 3 12 2 Install the intake pipe gasket 16 check for proper orientation and intake pipe 17...

Page 130: ...ING Lift only one end of the vehicle in General Warning Section 10 Page 10 2 2 Remove the accelerator rod by disconnecting the ball joint 1 from the ball stud 2 on the accelerator pedal Figure 14 3 Pa...

Page 131: ...nk shaft as shown Figure 14 5 Page 14 7 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 accele...

Page 132: ...ction 10 Page 10 1 4 Disconnect the governor cable 2 at the carburetor throttle Figure 14 1 Page 14 3 5 Disconnect the governor cable 2 from the governor lever arm 15 6 Remove the governor cable 2 fro...

Page 133: ...and loosen the cable housing retaining nuts Figure 14 4 Page 14 7 3 Disconnect cable 1 from cam 17 in the electrical box Figure 14 6 Page 14 9 4 Disconnect the spring 16 from the engine governor arm 5...

Page 134: ...he electrical box cover and tighten the retaining screw to 18 in lb 2 0 N m 8 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 N m See Figure 10 1 Section 10 Page 10 3 C...

Page 135: ...the tachometer should read Turf 2 with two wheel brakes 3170 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...

Page 136: ...OKE CABLE REMOVAL 1 Turn the key switch to the OFF position and remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect the battery cables as instruct...

Page 137: ...and Service Supplement Page 14 13 14 Figure 14 8 Turf 2 Carryall 2 and Carryall 2 Plus Air Intake and Choke Assemblies REFERENCE CARBURETOR 25 31 26 30 25 26 26 24 16 15 15 13 12 18 4 17 5 6 11 10 9...

Page 138: ...nce and Service Supplement 14 Figure 14 9 Turf 6 Carryall 6 TransPorter and Villager Air Intake and Choke Assemblies 27 26 25 24 21 20 19 TYPICAL 3 PLACES 28 TYPICAL 3 PLACES 22 23 14 REFERENCE CARBUR...

Page 139: ...b 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 on page 14 12 5 Connect battery cables positive cable first and...

Page 140: ...een the round crossmember and the floorboard moving it to the rear along the underside of the floorboard Insert the end of the intake duct through the slot in the front of the air box mounting plate 2...

Page 141: ...length or has a round shaped hole no greater than 1 2 inch 13 mm in diameter it may be repairable with an Air Duct Repair Kit CCI P N 101971001 This kit includes repair materials and procedures for sm...

Page 142: ...14 11 Page 14 19 Fuel filters fuel lines and the fuel tank vent should be inspected periodically for leaks The fuel filters should be replaced when necessary but under no circumstance should the peri...

Page 143: ...4 FUEL LINE NO 3 FUEL LINE NO 1 FUEL LINE 16 1 5 NO 5 CARBURETOR AIR VENT TUBE 23 14 21 24 16 20 16 FUEL LINE No ROUTING 1 2 3 4 5 6 7 Fuel tank to primary fuel filter Primary fuel filter to fuel pump...

Page 144: ...ure 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...

Page 145: ...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 the...

Page 146: ...7 to the inlet nipple on the pump Direction of fuel flow is indicated by the arrows on the fuel pump Figure 14 11 Page 14 19 See also Figure 14 13 Page 14 21 2 Connect to the output side of the fuel p...

Page 147: ...7 4 Turn the key switch to the OFF position and remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 5 Disconnect the battery cables as instructed See WARNING T...

Page 148: ...k with water to remove any remaining fuel 3 In a well ventilated area set the tank upside down so that the water can drain out of it To make sure that the tank dries completely allow the tank to sit f...

Page 149: ...anual 4 Connect the vent tube 6 to the fuel tank vent Figure 14 11 Page 14 19 5 Connect the fuel line 1 to the fuel tank shut off valve 15 Use a new clamp 16 Figure 14 11 Page 14 19 6 Connect the blac...

Page 150: ...line to ensure that the lines are not cracked cut or worn FUEL LINES See General Warning Section 10 Page 10 1 The fuel lines must be properly routed and all hose clamps must be tight The fuel lines sh...

Page 151: ...procedures Fully Open Position The valve s open position differs from standard valve configurations For the valve to be fully open it must be turned approximately 120 from the closed OFF position unt...

Page 152: ...14...

Page 153: ...uffler clamp 6 from the muffler bracket 2 6 Remove the muffler 1 from the vehicle MUFFLER INSTALLATION NOTE Any time the muffler is removed from the vehicle install a new muffler clamp 6 CCI P N 10176...

Page 154: ...Reverse handle in the NEUTRAL position and the neutral lockout cam in the SER VICE MAINTENANCE position Start the engine and check for exhaust leaks and proper engine oper ation See following DANGER D...

Page 155: ...prevents a driver 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 i...

Page 156: ...the lower plug for draining When draining lubricant remove both plugs to allow the lubricant to drain faster Clean and reinstall the drain plug and gasket before filling the transaxle with new lubric...

Page 157: ...key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Sectio...

Page 158: ...rs 0 047 in tip to remove the retaining ring 74 Place a bearing puller wedge attachment CCI P N 1012812 on the axle shaft between the wheel mounting flange and the bearing Figure 16 6 Page 16 5 See al...

Page 159: ...e and Service Supplement Page 16 5 16 Figure 16 6 Differential Gear Case Axle Tubes 74 73 70 71 ClubCar REFERENCE PASSENGER SIDE CASE 74 73 70 68 69 78 77 76 79 87 86 90 89 85 91 84 82 89 85 88 81 80...

Page 160: ...aring was removed from the shaft replace it with a new one Do not tighten the bearing puller wedge attachment against the axle shaft This could damage the axle shaft when the bearing and collar are pr...

Page 161: ...assembly and other components Loss of vehicle control could result in severe personal injury or death UNITIZED TRANSAXLE REMOVAL See General Warning Section 10 Page 10 1 1 Turn the key switch to the...

Page 162: ...16 9 Page 16 8 4 2 Disconnect the air intake hose from the carburetor Figure 16 10 Page 16 8 4 3 Disconnect impulse line from fuel pump Figure 16 11 Page 16 8 4 4 Loosen the hose clamp and then disco...

Page 163: ...able to shifter cable mounting bracket Then disconnect the shifter cable rod end from the shifter arm on the unitized transaxle and remove the cable from the cable mounting bracket Figure 16 15 Page 1...

Page 164: ...0 4 11 Cut away the wire ties securing the engine kill wire at the lower right front of the engine below the exhaust header the wire harness at the governor cable bracket and the wire harness to the p...

Page 165: ...ch mount Figure 16 21 Page 16 11 9 Raise vehicle just enough to relieve tension from leaf springs then remove the bolts securing the leaf springs to the shackles Figure 16 22 Page 16 11 10 Remove the...

Page 166: ...s to support the vehicle Figure 16 25 Page 16 12 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 lowe...

Page 167: ...idway between drive and driven clutch and pull up on belt to force the driven clutch sheaves apart Roll the belt counterclockwise while pulling it off driven clutch Figure 16 29 Page 16 13 18 Remove t...

Page 168: ...elerator cable should remain attached to the governor arm 23 Remove the six bolts mounting the unitized transaxle to the engine 23 1 Remove four transaxle mounting bolts and flat washers one at each c...

Page 169: ...2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page 16 15 16 Figure 16 35 Transaxle Gear Casing and Brackets 30 29 3 4 9 6 5 7 8 10 17 18 19 16 11 12 13 21 22 20 31 14 15 23 24 28 27 2...

Page 170: ...ds to 17 ft lb 23 1 N m Figure 16 36 Page 16 16 7 Install the accelerator cable bracket on transaxle case Tighten the mounting screws to 134 in lb 15 1 N m Figure 16 33 Page 16 14 8 Install the govern...

Page 171: ...16 40 Page 16 17 Make sure the vehicle is stable on the jack then remove the jack stands 15 After the jack stands are removed lower the vehicle to approximately its normal height Position the leaf spr...

Page 172: ...to the bullet connector at the lower right front of the engine Figure 16 43 Page 16 18 21 Install three wire ties to secure the engine kill wire to the accelerator cable where they both route togethe...

Page 173: ...tighten the mounting nuts to 22 ft lb 29 8 N m Connect shifter cable rod end to the shifter arm Figure 16 46 Page 16 19 26 Attach the ground wire to the mounting screw on the oil filler tube mounting...

Page 174: ...e clamp Figure 16 51 Page 16 20 31 Connect carburetor vent tube to carburetor and secure with hose clamp Figure 16 52 Page 16 20 32 Install transaxle drain plug and tighten to 21 ft lb 28 5 N m 33 Fil...

Page 175: ...key switch to the OFF position and remove the key and place the Forward Reverse handle in the NEUTRAL position 2 Disconnect battery cables as instructed See WARNING To avoid unintentionally starting i...

Page 176: ...ing WARNING WARNING 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 p...

Page 177: ...ION CAUTION 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 Fo...

Page 178: ...16...

Page 179: ...he ratio of drive clutch to driven clutch is 0 92 to 1 On steep grades or when the vehicle is heavily loaded higher torques are achieved through the use of a torque sensing ramp device on the driven c...

Page 180: ...g Section 10 Page 10 1 The drive belt should be inspected semiannually for wear and or glazing If it is excessively worn frayed or glazed replace the belt As the drive belt wears the engine RPM will i...

Page 181: ...counterclock wise Figure 17 2 Page 17 3 See following CAUTION CAUTION Make sure fingers are not underneath the belt when rolling the belt off the driven clutch 4 Remove the belt from the drive clutch...

Page 182: ...ter generator mounting and adjusting hardware and then remove the starter belt See WARNING Moving parts Do not in General Warning Section 10 Page 10 2 Figure 17 3 Loosen Retaining Bolt Figure 17 4 Dri...

Page 183: ...ing bolt has left hand threads The crankshaft has left hand threads at the clutch mounting hole 5 Lubricate the threaded portion of the clutch puller tool with a light oil and thread the clutch puller...

Page 184: ...E CONVERTER Drive Clutch Page 17 6 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement 17 Figure 17 5 Drive Clutch Assembly 2 1 3 13 4 5 6 7 11 12 12 16 15 14 22 20 21 17 19 TYPICAL 3 PLACE...

Page 185: ...ter bolt of the Drive Clutch Hub Puller CCI P N 1014497 into clutch until the stop nut touches the clutch then back the bolt out one half turn Figure 17 7 Page 17 7 2 3 Thread the three small bolts of...

Page 186: ...s of the wave washer and of the primary and secondary weights to one another Figures 17 10 and 17 11 Page 17 8 Remove the plastic washers weights and wave washer from the pin Retain all parts Figure 1...

Page 187: ...17 5 Page 17 6 See also Figure 17 13 Page 17 9 Discard the rings INSPECTION OF DRIVE CLUTCH PARTS 1 Inspect the idler bearing 6 for smooth rotation or seal damage Figure 17 5 Page 17 6 See follow ing...

Page 188: ...face assembly 7 CAUTION To avoid damaging the spiral back up rings be very careful when installing the moveable face 6 1 Rotate the moveable face assembly clockwise while installing it onto the shaft...

Page 189: ...clock position as shown Figure 17 15 Page 17 11 14 Compress each take up spring and install the drive button over the rib and take up spring Figure 17 8 Page 17 8 15 Install a no 10 24 button retaini...

Page 190: ...als with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 6 Connect the spark plug wire to the spark plug 7 Drive the vehicle and check for proper operation DRIVEN CLUTCH See Gen...

Page 191: ...aring 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 sh...

Page 192: ...TORQUE CONVERTER Driven Clutch Page 17 14 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement 17 Figure 17 18 Driven Clutch Assembly 2 3 4 5 6 7 8 11 12 1 10 9 TYPICAL 3 PLACES...

Page 193: ...ing ring can be reused if the O D does not exceed 1 607 inches 40 82 mm otherwise it must be replaced with a new ring CCI P N 1014080 5 1 4 While holding onto the cam tap the end of the fixed face sha...

Page 194: ...yed shaft Advance the press hub until it is firm against the shaft end 5 2 8 Remove the cam press hub 6 and installation tool and install the retaining ring NOTE The retaining ring can be reused if th...

Page 195: ...11 44 brake pedal limit switch installation 12 35 removal 12 35 testing 11 51 breather valve reed valve 13 3 C carburetor 14 1 closed throttle or idle adjustment 14 10 jet main 14 2 elevation size ch...

Page 196: ...on 14 25 removal 14 23 storage 14 24 fueling instructions 10 7 fuse installation 12 16 removal 12 16 testing 11 17 G governor governor system 16 2 governor cable installation and adjustment 14 8 remov...

Page 197: ...3 6 removal 13 6 testing 11 37 oil engine 10 6 P park brake limit switch installation 12 34 removal 12 34 park brake pedal limit switch testing 11 51 periodic lubrication schedule 10 5 periodic servic...

Page 198: ...1 24 11 starter generator 11 25 12 voltage regulator 11 25 13 engine kill circuit 11 26 14 ignition test 11 27 15 RPM limiter 11 28 16 ignition coil 11 28 17 kill limit switch 11 34 18 key switch engi...

Page 199: ...X 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page i 5 testing 11 48 voltage regulator installation 12 12 removal 12 12 testing 11 25 W wire continuity testing 11 24 wiring diagram...

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Page 204: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808...

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