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NOTE - Metro Golf Cars

1. 14 50 1455 1460 1465 14 70 14 75 14 80 Measurement A Measurements in Millimeters Figure 13 101 Crankshaft Shim Table 13 44 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Crankshaft Axial Play Adjustment Camshaft Installation A CAUTION WHEN INSTALLING THE CAMSHAFT MAKE SURE THAT THE TANG 1 ON THE OIL PUMP ROTOR SEATS IN THE SLOT 2 IN END OF THE CAMSHAFT FIGURE 13 103 PAGE 13 46 IF THE OIL PUMP TANG IS NOT SEATED IN THE SLOT IN THE CAMSHAFT SERIOUS ENGINE DAMAGE WILL RESULT 1 Installation is the reverse of removal See Page 13 26 Figure 13 102 Align Timing Marks between Camshaft Figure 13 103 Proper Seating of Tang into and Crankshaft Camshaft Slot 2 Apply a light film of engine oil to the camshaft journals and cam lobes 3 Align the timing marks 3 Figure 13 102 Page 13 46 NOTE e IF THE OUTSIDE EDGES OF THE CAMSHAFT AND CRANKSHAFT GEARS ARE NOT FLUSH AND THE CRANKCASE COVER WILL NOT EASILY MAKE FULL CONTACT WITH THE CRANKCASE MAKE SURE THE TANG ON THE OIL PUMP ROTOR IS SEATED IN THE CAMSHAFT SLOT CRANKCASE COVER INSTALLATION CAUTION e BEFORE ASSEMBLY MAKE SURE PARTS ARE CLEAN DO NOT REUSE THE GASKET INSTALL A NEW ONE INSTA
2. entres nenne aE snnt 16 23 Intermediate Gear Assembly nnne trennen nennen en 16 23 Synchronizer Gear Assembly entren 16 23 shifter Fork Assembly B eerte Iber dee e eset ats 16 25 Differential Gear Case Assembly enne tenete nnn 16 26 Governor Gear Assembly sss nennen nennen 16 28 Unitized Transaxle Assembly sssssssssssseeeenenen 16 28 Unitized Transaxle Installation 16 34 Forward Reverse F amp R Shifter Cable ssssssssssssssesseseeennnen tenerent nnns 16 39 F amp R Shifter Cable Removal ceo tee inde ean ead e ed 16 39 F amp R Shifter Cable Installatiori 232 c Rede RR Rete e t 16 40 F amp R Shifter Cable Adjustment ssssssssssssssssssessseeenen nennen nennen intet rennen nnne 16 41 SECTION 17 TORQUE CONVERTER General Information eire rester eer era deca ta eaa e reae a deae denen eee dean eee e a d ade 17 1 TroublesFiootlrng zoe ette elt i Ge ano tee 17 3 Drive Belt e H mY 17 3 Drive Belt Removal in e re terii emere todas vate cane tend dao Plead eed ORE Ye Ns 17 3 Driv
3. 16 22 valve guides sees 13 12 Valve Seat noeud di eta 13 13 valve Spring er ioter adeo tee 13 17 valves intake and exhaust 13 16 intake duct InistallatiOri o e ple est 14 15 removal 5 14 15 55 Meee 14 16 intermediate gear assembly i eine 16 23 disassembly 16 20 K key switch engine kill circuit testing 11 32 installation 12 14 removal 12 13 starter circuit cece cc ccceeeeeeeesseseeeeeeeeeeees 11 5 11 7 starter circuit testing 11 12 kill circuit engine 11 9 testing nee 11 28 11 31 11 32 kill limit switch Installatiori seth eee edes 12 16 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement L link rod INSPECTION c oii dte Pedes 13 35 low oil warning circuit 11 5 11 16 low oil warning light 11 5 11 10 installation 12 21 nbi 12 20 Testing cero ER 11 34 lubrication 13 3 cnt e m a tetto 13 3 lubrication system 13 4 periodic lubrication schedule 10 4 M maintenance battery nc cdc nile ce e
4. 11 5 11 10 neutral lockout circuit 11 5 11 10 11 17 see also neutral lockout reverse buzzer circuit 11 5 11 9 11 15 starter and generator circuit 11 12 starter circuit 11 5 11 7 engine assembly eee 13 46 DOPING ed CE 13 29 13 49 ignition CIF Cult 11 5 kill circuit see kill circuit engine e 13 22 CE 13 4 RPM adjustment seeen 14 14 service specifications 13 48 engine mounting plate see engine removal engine oll eene 10 6 exhaust system 14 4 15 1 see also muffler F flywheel removal hice ete estrena ied 13 30 forward reverse cable adj stment 16 41 installation 16 40 removal rk oce roro 16 39 handle lever eese 16 2 fuel filler oboe ke kinases 14 4 Installations oin dert tees 14 18 removal uu eire 14 18 fuel gauge see fuel hour gauge fuel gauge sending unit circuit 11 17 fuel level sending unit 12 22 urne 11 35 fuel lines nce 14 4 14 26 fuel pump n em s 14 4 14 20 assembly i Ui ao aaa nna 14 21 cleaning and inspection 14 21 disassem
5. 2 Reconnect the spark plug wire Page 15 2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement EXHAUST SYSTEM Muffler Figure 15 2 Exhaust System 11 Connect battery cables positive first and tighten terminals to 20 ft lb 27 1 N m Figure 15 1 Page 15 2 Coat terminals with Battery Protector Spray Club Car Part No 1014305 12 Place the Forward Reverse handle in the NEUTRAL 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 DANGER THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS AND DEADLY POISON DO NOT OPERATE THE ENGINE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION 13 After checking the exhaust and engine for proper operation return the neutral lockout cam to the OPERATE position 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 15 3 SECTION 16 UNITIZED TRANSAXLE DANGER GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM VEHICLE AND SERVICE AREA SERVICE ONLY IN A WELL VENTILATED AREA DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON A WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE
6. Figure 14 12 Governor and Accelerator Cables Page 14 12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM Engine Control Linkage ACCELERATOR CABLE Accelerator Cable Removal 1 Remove seat or lift bed to access engine compartment 2 Remove the electrical box retaining screw and cover and loosen the cable housing retaining nuts See Figure 14 9 or 14 10 Page 14 10 3 Disconnect cable 1 Figure 14 12 Page 14 12 from cam in the electrical box 4 Remove the E ring 7 on the spring end of the cable at the accelerator cable bracket 5 Figure 14 12 Page 14 12 Pull the cable housing out of the bracket 5 Disconnect the spring 16 from the engine governor arm by rotating the arm counterclockwise one half turn Remove the cable assembly from the vehicle Figure 14 12 Page 14 12 Accelerator Cable Installation 1 Connect the cable to the cam 17 in the electrical box 2 Insert the cable housing into the mounting slot in the wall of the electrical box with approximately the same 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 Connect the spring 16 to the engine governor arm Figure 14 12 Page 14 12 Install cable in accelerator cable bracket s and secure it with E ring 7 Figure 14 12 Page 14 12 Push the cable dust shield onto the spri
7. 12 26 Charging seinen rete dese cec 12 29 12 31 hydrometer test 11 19 installation ce 12 30 load test iun ce reete ree vae 11 21 maintenance 12 27 mineral content 12 28 removal 52 sen n n umi meii dais 12 29 self discharge eese 12 28 SIOF age 12 30 iis cea pens 11 19 11 34 vibration damage 12 28 Voltage test 11 21 water level reete a clt ca 12 28 belt drive see drive belt boring engine 13 29 breather valve reed valve 13 11 13 20 INSPOCUON tits sse rer bee etit ee ores 13 20 Installatlon z ule 13 21 removal 3 aciertos 13 11 C camshaft INSPECTION 13 25 13 41 installatiOn suce odi a E red tend 13 45 removal rii 13 25 carb retor ine 14 4 choke and fresh air system 14 4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement closed throttle or idle adjustment 14 13 floatisystem eed eres 14 4 Jet main nce ie alee ieee es 14 5 elevation size chart 14 5 main system sooten ia
8. Page 11 17 TROUBLESHOOTING TEST PROCEDURES INDEX OF TEST PROCEDURES PO PM PO PPO PPO NM ND AH AH HH HaHa aa oP WN OA HR O qo ONOaAR WD Fuse Battery Ground Straps Key Switch Starter Circuit Accelerator Pedal Limit Switch Solenoid Neutral Lockout Limit Switch Starter Generator Starter Function Wire Continuity Starter Generator Generator Function Voltage Regulator Disconnected Kill Wire Ignition Spark RPM Limiter Ignition Coil Kill Limit Switch Key Switch Engine Kill Circuit Engine Kill Wire Reverse Buzzer Limit Switch Reverse Buzzer Oil Level Sensor Oil Warning Light Neutral Lockout Cam Battery Test Under Load Fuel Level Sending Unit Fuel Gauge 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 2 Remove the cover on the electrical component box Test Procedures Place the neutral lockout cam in the SERVICE position put the Forward Reverse handle in the NEUTRAL position chock the wheels and disconnect the battery negative cable first 3 Check that the wires are connected correctly and are tight If they are not rewire or tighten as necessary 4 Remove the fuse to be tested from the fuse block See Fuse Removal Section 12 Electrical 11 18 2000
9. 2 Connect to the output side of the fuel pump the fuel line 3 that goes to the carburetor Figure 14 16 Page 14 19 3 Connect the impulse line 7 to the bottom nipple on the fuel pump Use a new clamp 4 Install the fuel pump For DS or Villager 4 vehicles install the fuel pump on the frame and tighten the mounting bolts 26 and locknuts 25 to 60 in Ib 6 8 N m Figure 14 16 Page 14 19 For Carryall vehicles install the fuel pump onto the mounting bracket with two thread rolling screws and tighten to 40 in Ib 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 position and place the neutral lockout cam in the SERVICE position and chock the wheels Start the engine and check for fuel leaks If the fuel pump leaks a rebuild kit must be installed to replace all gaskets and diaphragms See following WARNING A DANGER REPAIR ANY FUEL LEAKS BEFORE OPERATING THE VEHICLE 7 Place the neutral lockout cam in the OPERATE position FUEL TANK Read DANGER and WARNING on page 14 1 GENERAL INFORMATION The gasoline vehicle is equipped with a high impact plastic seven gallon 26 5 liter fuel tank PREPARATION FOR EXTENDED STORAGE If the vehicle is to be placed in extended storage prepare the vehicle as follows 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam
10. FAN SHROUD Figure 12 27 Fan Housing and Shroud Installation Figure 12 28 Coil Installation 12 24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS gnition Coil Ignition Coil Installation NOTE e IF A NEW IGNITION COIL IS BEING INSTALLED THE SPARK PLUG CAP GASKET PROTECTOR TUBE AND GROMMET MUST BE REMOVED FROM THE OLD COIL AND INSTALLED ON THE NEW COIL SEE STEPS 1 THROUGH 8 IF THE EXISTING IGNITION COIL WILL BE RE INSTALLED PROCEED TO STEP 9 1 Remove the rubber gasket 2 on the plug cap by rolling back the gasket onto the spark plug wire 2 Remove the cap 1 from the wire by rotating the cap counterclockwise three or four revolutions while gently pulling it off the wire Figure 12 28 Page 12 24 3 Remove the gasket 2 and protector tube 4 from the old coil 4 Remove the grommet 5 from the old spark plug wire Clean the grommet and place it on the new spark plug wire Figure 12 28 Page 12 24 See following NOTE NOTE e MOISTEN SPARK PLUG WIRE WITH WATER TO MAKE GASKET REMOVAL AND INSTALLATION EASIER Install protector tube 4 onto the new wire Slide the gasket 2 onto the end of the spark plug wire Install the cap onto the new coil by rotating it clockwise three or four revolutions while applying light pressure on the cap Figure 12 28 Page 12 24 Install the gasket 2 on the cap 1 Position the ignition co
11. Figure 11 3 Starter Circuit 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11 7 TROUBLESHOOTING Electrical Circuits GENERATOR CIRCUIT The generator circuit consists of the starter generator voltage regulator solenoid battery and connecting wires Figure 11 4 Page 11 8 When battery power is first supplied to the starter generator the starter generator turns the engine at low RPM approx 700 Once the engine starts running it then drives the starter generator At any engine RPM over 1215 3000 starter generator RPM the starter generator functions as a generator supplying charging 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 battery STARTER GENERATOR SOLENOID 624 Wn Sy LACK VOLTAGE ikg REGULATOR BATTERY Figure 11 4 Generator Circuit ENGINE IGNITION CIRCUIT The engine ignition circuit is independent of all other circuits except the kill circuit It consists of the ignition coil with internal igniter spark plug RPM limiter and connecting wires Figure 11 5 Page 11 8 SPARK PLUG RPM LIMITER N GROUND IGNITION COIL WITH IGNITER BULLET CONNECTOR ENGINE KILL WIRE BULLET CONNECTOR Figure 11 5 Engine Ignition Circuit Page 11 8 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUB
12. ee 16 3 Axle Shalt tt de et ed 16 3 Axle Shaft and Oil Seal a a aaea a aa 16 5 AXING BOATING 1 cte REL 16 5 Axle sorina a aa a esas nnns nnns 16 7 Unitized Transaxle Removal seerias ER 16 7 Unitized Transaxle Disassembly eee 16 14 Gomponent Disassembly 5 2 tre Rte roe ten teat Pe ep d p e ne te reo aee 16 17 Governor Gear Disassembly 1 rnt ei tet ee n i pr prd edens inte iB euro eges 16 17 Differential Gear Case Disassembly 16 17 Shifter Fork Disassembly eceeceecceeeeeeeee eee aeeeeeeeeeceaeeeeeaeeeceaeeeseaaeesaeeeseaaeeseeeeestaaeeseeeeeessaeeseneees 16 20 Synchronizer Gear Disassembly sss eene nennen nnne nnns neni 16 20 Intermediate Gear Disassembly tenere sene en 16 20 Idler Shatt DisaSSembly x eet qe ene ities A ee need AE E EE end 16 21 Unitized Transaxle Component Inspection sse enne nne 16 22 Component Assembly xtti exte AU x ER ce PER eve d Sage diera tuas 16 23 Idler Shaft Assembly
13. 23 Attach the ground wire to the mounting screw on the oil filler tube mounting bracket and tighten to 50 in Ib 5 7 N m Figure 16 98 Page 16 38 24 Connect accelerator cable to actuator cam in the electrical box Position the accelerator cable in mounting slot in the wall of the electrical box and tighten mounting nuts to 18 in Ib 2 0 N m Figure 16 100 Page 16 38 Install electrical box cover and tighten mounting screw 25 Pull fuel line from impulse 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 Figure 16 101 Page 16 39 27 Connect air intake hose to carburetor and secure hose clamp Figure 16 102 Page 16 39 28 Connect carburetor vent tube to carburetor and secure with hose clamp Figure 16 103 Page 16 39 29 Install transaxle drain plug and tighten to 21 ft lb 28 5 N m 30 Fill transaxle with 27 oz 8 liter 80 90 Wt API Class GL 3 or 80 90 Wt AGMA Class EP gear lube Install and tighten the level indicator hole plug to 21 ft Ib 28 5 N m WIRE 7 gt BLACK Connect shock absorbers WIRE to lower mounts Figure 16 93 Shock Absorber Vo STARTER aS GENERATOR NO P Su NSIT Yeow NIJ OIL SENDING UNIT JUMPER WIRE Fi
14. ALLOW FOR SHRINKAGE FROM THE FINAL SIZE OF 0 0003 0 0004 INCH 0 0076 0 0102 MM WHICH WILL OCCUR WHEN THE CYLINDER COOLS DOWN 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 0807 inches 78 230 78 250 mm The final honed bore diameter for a 0 020 inch over standard size bore is 3 0898 3 0906 inches 78 480 78 500 mm See Specification for Resizing Cylinder Bore Page 13 50 See following NOTE NOTE IMPORTANT THE CYLINDER WALL FINISH SHOULD HAVE A 40 TO 60 CROSS HATCH PATTERN FIGURE 13 60 PAGE 13 30 DO NOT USE SOLVENTS OR GASOLINE TO CLEAN CYLINDER AFTER HONING 3 After honing clean the cylinder wall thoroughly using soap warm water and clean rags 4 Dry the cylinder and coat with engine oil 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 13 29 FE290 ENGINE Ignition Coil and Flywheel A CAUTION THE CYLINDER MUST BE THOROUGHLY CLEANED AFTER HONING TO ELIMINATE ALL GRIT IGNITION COIL AND FLYWHEEL Ignition Coil and Flywheel Removal 1 Loosen three screws and remove the remaining four screws attaching the flywheel housing as shown then remove the housing Figure 13 61 Page 13 31 2 Disconnect the ignition coil 1 from its primary lead wire at the connector 2 Remove the two bolts 3 and take out the ignition coil Figure 13 62 Page 13 31 3 Hold the flywheel 4 not
15. Club Car Jg 2000 MAINTENANCE SERVICE SUPPLEMENT FE290 GASOLINE VEHICLES MANUAL NUMBER 102067508 EDITION CODE 0500A00000 FOREWORD Club Car vehicles are designed and built to provide the ultimate in performance efficiency however proper main tenance 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 FE290 gasoline vehicles and should be used in conjunction with the appropriate maintenance and service manual 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 2000 DS Golf Car Maintenance and Service Manual Publication Part No 102067501 2000 Turf Carryall Vehicle Maintenance and Service Manual Publication Part No 102067502 2000 Villager TransPorter Vehicle Maintenance and Service Manual Publication Part No 102067503 This supplement and corresponding maintenance and service manual should be thoroughly reviewed prior to servicing the vehicle The procedures provided herein must be properly implemented and the DANGER WARNING and CAUTION statements must be heeded This manual was written for the trained technician who already possesses knowledge and skills in electrical and mechanical repair f the technician does not have such knowledge and skills attempted service or
16. Connect the blue wire from the key switch to the 2 terminal the orange wire from the fuel level send ing unit to the 1 terminal the black wire from the frame ground to the 3 terminal and the white wire from the solenoid to the 4 terminal Reinstall the center dash in reverse order of removal Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place Connect battery cables positive cable first and tighten terminals to 20 ft Ip 27 1 N m Figure 12 1 Page 12 2 Coat terminals with Battery Protector Spray Club Car Part No 1014305 FUEL 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 tank and should never be removed Thoroughly test the fuel level sending unit before replacing the fuel tank RPM LIMITER Read DANGER and WARNING on page 12 1 Testing the RPM Limiter See Test Procedure 14 Section 11 Page 11 29 RPM Limiter Removal 1 2 Disconnect the battery cables as shown Figure 12 1 Page 12 2 Disconnect the white black wire from the black wire at the bullet connector located near the RPM limiter 2 Figure 12 24 Page 12 23 3 Disconnect the other black wire from the bullet connector near the RPM limiter 4 Remove the two flange head bolts from the RPM limiter band and remove the
17. 1 Disconnect the battery cables negative first 2 Close the fuel shut off valve on fuel tank See Section 14 Figure 14 21 Page 14 26 3 Detach all wires hoses etc connecting the powertrain to the vehicle 3 1 Disconnect the carburetor vent tube from the carburetor Figure 16 9 Page 16 7 3 2 Disconnect the air intake hose from the carburetor Figure 16 10 Page 16 8 3 3 Disconnect impulse line from fuel pump Figure 16 11 Page 16 8 Loosen hose clamp then pull fuel vent tube from carburetor Figure 16 9 Fuel Vent Tube 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 7 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal Continued Remove air intake hose clamp 3 4 3 5 3 6 3 7 3 8 3 9 3 10 Page 16 8 Squeeze clamp to remove impulse line IMPULSE LIN Figure 16 11 Impulse Line Loosen retaining nuts to remove throttle Remove fuel line cable from electric box Figure 16 12 Fuel Line Figure 16 13 Throttle Cable Loosen the hose clamp and then disconnect the fuel line from the carburetor To prevent spilling fuel the disconnected end of the line can be pushed onto the impulse line fitting of the fuel pump Figure 16 12 Page 16 8 Remove the cover from the electrical component box Then loosen the hardware securing the accelerator cable to the box
18. 14 2 slow speed system 14 2 choke choke and air intake system 14 4 14 14 choke button 14 15 removal 14 14 clutch torque converter troubleshooting 17 3 clutch drive see drive clutch clutch driven see driven clutch connecting rod INSPECHON soil nee et 13 28 iristallatlOr trentaine 13 42 removal ote ise BEER EE 13 25 separation from piston 13 26 ndersiz amp d 2 eggs 13 38 counterbalance disassembly esee 13 34 guide shaft INSPOCHON cree ede ec cete 13 37 removal 13 34 counterbalance weight inspection s ie EE eia 13 36 crankcase cover ball bearing INSPECTION 12i e CREME 13 39 removal ic sies eg epe ERES 13 39 ERR 13 45 oil seal installation e 13 40 r moVal 4 dte etre des 13 40 removal toe BRI 13 23 crankshaft axial play adjustment 13 43 disassembly 5 erri eco es 13 34 INSPOCHON eee eee ede 13 37 installato 2 13 41 5 e ee Us 13 34 cylinder block INSPOCHON jee iip tee pigs 13 28 cylinder bore resizing cylinder bore 13 49 cylinder head 13 7 clea
19. Breather Reed Valve Valve Tip Air Gap 0 008 inch 0 2 mm Valve Stem IN and EX Stem Bend 0 0012 inch 0 03 mm Push Rod Rod Bend Valve Guide IN and EX 1 0 Standard SPECIFICATIONS FOR RESIZING CYLINDER BORE ITEM OVER SIZE LIMITS 0 012 inch 0 30 mm 0 2756 to 0 2762 inch 7 00 to 7 015 mm 0 010 inch 0 25 mm Final Boring Bore Diameter 0 020 inch 0 50 mm 3 0791 to 3 0799 inches 78 210 to 78 230 mm 3 0890 to 3 0898 inches 78 460 to 78 480 mm 0 010 inch 0 25 mm Final Bore Diameter 0 020 inch 0 50 mm TORQUE SPECIFICATIONS ITEM 3 0799 to 3 0807 inches 78 230 to 78 250 mm 3 0898 to 3 0906 inches 78 480 to 78 500 mm SPECIFICATIONS Cylinder Head Bolts 220 in Ib 24 N m Valve Clearance Adjustment Nuts 90 in Ib 10 N m Connecting Rod Bolts Coat Threads with Engine Cil 180 in Ib 20 N m Flywheel Retaining Nut 63 ft lb 86 N m Crankcase Cover to Block Bolts 250 in lb 28 3 N m Torque Specifications continued on next page 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 49 FE290 ENGINE ITEM Service Specifications SPECIFICATIONS Starter Generator Bracket to Block Bolts 200 in Ib 23 N m Oil Drain Plug 20 ft lb 27 1 N m Fan Housing Screws 90 in Ib 10 N m Fan Shroud Screws 25 in lb 2 8 N m Bolts Marked
20. CLUTCH 8 DRIVE CLUTCH Q Figure 17 2 Drive Belt Removal DRIVE BELT REMOVAL 1 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and disconnect the bat tery negative cable first Disconnect the spark plug wire from the spark plug 2 Grasp the belt midway between the drive and driven clutches Lift upward on the belt to force the sheaves of the DRIVEN clutch apart then roll the belt off the DRIVEN clutch by rotating the clutch counterclockwise Figure 17 2 Page 17 3 See following CAUTION CAUTION e MAKE SURE FINGERS ARE NOT UNDERNEATH THE BELT WHEN ROLLING THE BELT OFF THE DRIVEN CLUTCH 3 Remove the belt from the drive clutch 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 17 3 TORQUE CONVERTER Drive Clutch DRIVE BELT INSTALLATION 1 Position the new belt on the drive clutch then start the belt over the top of the driven clutch 2 With the belt started onto the driven clutch rotate the driven clutch counterclockwise and roll the belt over the driven clutch sheaves and onto the clutch Use Club Car clutch holder VEHICLE BODY while tightening or loosening drive REMOVED FOR clutch retaining bolt CLARITY DRIVEN CLUTCH DRIVE CLUTCH N DRIVE CLUTCH RETAINING BOLT Hook clutch holder on boss of pully located behind drive clutch push down on adjacent boss with holder A fa THREE BOSSES Insert drive clutch puller int
21. IGNITION COIL Read DANGER and WARNING on page 11 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 first 1 2 2 3 2 Using a multimeter set on 200 ohms measure the primary coil resistance 2 1 Disconnect both of the bullet terminals at the RPM limiter Place the black probe of the meter on the male bullet terminal of the wire connecting the coil 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 If the resistance is not between 0 6 1 7 Q ohms remove the coil from the engine See Ignition Coil Removal Section 12 Electrical Components Page 12 23 Retest with a multimeter set on 200 ohms Place the black probe of the meter into the terminal on the coil 1 and place the red probe on the core 2 Figure 11 39 Page 11 31 If the resistance is still not between 0 6 1 7 Q ohms replace the coil Using a multimeter set to 20k Q ohms measure the secondary coil resistance 3 1 Remove the spark plug wire from spark plug Place red probe of the meter into the end of the spark plug wire and place black probe on a clean unpainted surface of the engine or frame If the resistance is not between 6 0 11 0 k Q ohms remove the coil from the engine See Ignition Coil Remova
22. INDEX ignition coil installation eeeeess 12 25 13 31 removal 2 cccccccccececeeeeeesscceeeeeeeeeeneeeens 12 23 13 30 testing ee hee in 11 30 inspection breather valve 13 20 camshaft eer 13 25 13 41 Connecting od iniret etit cie 13 28 counterbalance guide shaft 13 37 counterbalance weight 13 36 crankcase cover ball bearing 13 39 crankshaft iet RARE 13 37 cylinder head esee 13 12 drive clutch E pede 17 5 drive clutch parts 17 8 driver clutch ms 17 14 TUG PUMP hie veering iie te ce repe 14 21 WINK TOG oe denote RARE 13 35 oil pressure relief valve 13 33 Gil DUMP sis c 13 32 PISTON ettet RE aight 13 26 DIET sie Ee He 13 27 pre operation safety checklist daily 10 2 pushitod inae eain 13 18 rocker arri 13 18 rocker shaft ice cu e t dieere 13 18 Spark pl g rti ARR 13 6 starter generator armature uo oot eee etes 12 7 bearirig ideo ue 12 6 brush Spring 12 4 eere tte eben 12 4 COMMUTATION reci ia metet ee 12 8 fleld Coils 1 renes 12 9 unitized transaxle components
23. Tester light is out Meter read 1 Figure 11 32 Test Neutral Lockout Switch 4 Check to be sure the lobes on the cam are depressing the neutral lockout limit switch as the Forward Reverse handle is being shifted The limit switch should make an audible click as it is depressed If it does not check for wear on the cam lobes Be sure the cam snaps fully back into place If the cam lobes still do not activate the limit switch replace the cam TEST PROCEDURE 8 STARTER GENERATOR STARTER FUNCTION Read DANGER and WARNING on page 11 1 NOTE ENGINE ROTATION CLOCKWISE IS AS VIEWED FROM THE CLUTCH SIDE OF THE ENGINE 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 first 2 Check that wires are connected correctly and are tight If they are not rewire or tighten as necessary 3 Disconnect the wires from all the terminals on the starter generator Then place the black probe of a multimeter set to 200 O ohms on the starter generator housing scratch through the paint to ensure a good ground While holding the black probe against the housing place the red probe on the A1 A2 F1 F2 and DF terminals respectively Figure 11 33 Page 11 26 The readings should be NO continuity If the readings are incorrect the starter generator will need to be removed from the v
24. The gasoline vehicle is equipped with an impulse fuel pump If the fuel pump is not operating properly per form the following tests Make sure all hose clamps are tight Inspect the impulse line and fuel lines for damage or clogging Make sure the air vent on the fuel pump is not clogged with dirt Make sure fuel filters are not clogged To clean the air vent the fuel pump must be disassembled FUEL PUMP REMOVAL 1 Turn 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 Figure 14 16 Page 14 19 3 Remove the clamp and impulse line 7 from fuel pump 4 Disconnect the fuel lines 2 and 3 from the pump and plug them to prevent gasoline leakage See following WARNING A WARNING e CAREFULLY DRAIN ANY FUEL REMAINING IN THE PUMP INTO A CONTAINER ADD DRAINED FUEL BACK INTO GAS TANK OR DISPOSE OF PROPERLY FUEL PUMP DISASSEMBLY NOTE A FUEL PUMP REBUILD KIT IS AVAILABLE FROM CLUB CAR CLUB CAR PART NO 1014524 THIS KIT INCLUDES ALL GASKETS DIAPHRAGMS AND VALVES 1 Remove four screws 24 and lock washers 25 from front of the fuel pump Figure 14 17 Page 14 21 2 Remove the front cover of the fuel pump while holding the rest of the pump intact 3 Note the orientations of the impulse gasket 27 the diaphragm 28 and the gasket
25. Valve Seat Cutter 30 and 45 x 35 mm Diameter 1016554 Valve Seat Cutter Guide 1016552 BEFORE SERVICING To eliminate unnecessary work carefully read the applicable information and instructions before beginning engine service Diagrams DANGER WARNING CAUTION and NOTE statements and detailed descriptions have been included wherever necessary Nevertheless even a detailed account has limitations Therefore any one attempting engine service should have knowledge and experience in small engine service and repair MECHANICAL SYSTEMS Adjustments All adjustments shall be made in accordance with Section 10 Periodic Maintenance Edges WARNING WATCH FOR SHARP EDGES ESPECIALLY DURING MAJOR ENGINE DISASSEMBLY AND ASSEMBLY PROTECT YOUR HANDS WITH GLOVES OR A PIECE OF THICK CLOTH WHEN LIFTING THE ENGINE OR TURNING IT OVER Force Common sense should dictate how much force is necessary for assembly and disassembly If a part seems especially difficult to remove or install stop and determine what may 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 order to avoid damaging the heads Page 13 2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE General Information Dirt Clean the engine thoroughly before servicing it See following CAUT
26. 3 Measure camshaft journals and cam lobes with a micrometer at the points shown Figures 13 49 and 13 50 4 If camshaft journal diameter is less than 0 9026 inch 22 927 mm at either end of the shaft replace camshaft 5 Ifthe 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 WARNING on page 13 1 NOTE THE CONNECTING ROD AND CAP MUST STAY TOGETHER AS A SET DO NOT MIX WITH PARTS FROM ANY OTHER ENGINE Piston and Connecting Rod Removal 1 Turn crankshaft to expose the two connecting rod cap bolts 1 Figure 13 51 Page 13 27 2 Loosen the cap bolts and take them out together with the connecting rod cap 2 3 With cylinder head removed push the piston connecting rod assembly out of the cylinder 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 25 FE290 ENGINE Piston and Connecting Rod Piston and Connecting Rod Separation 1 Remove two retaining rings holding the piston pin in place 2 Remove the piston pin Piston Inspection and Repair 1 Remove all deposits from the piston 2 Clean the carbon from the piston ring grooves See following CAUTION A CAUTION e NEVER CLEAN THE PISTON HEAD WITH THE ENGINE ASSEMBLED CARBON PARTICLES WILL FALL BETWEEN THE PISTON AND CYLINDER WALL AND MAY CAUSE SEVERE CYLINDER WEAR 3 Be sure the oil return passages i
27. CONTENTS SECTION 10 PERIODIC MAINTENANCE General Information coc tti d corte etu tbe rti eL EI AR Ete EAE SERE EAR NX ER Feo er MAR e Eyed ro qu indt 10 2 Daily Pre Operation Safety Checklist sess eene 10 2 Periodic Service Schedule octies a ee beue teas ee apa 10 3 Periodic Lubrication Schedule esses EEEE ENKEN KEEA EN ANKE 10 4 Vehicle Capacities ede A te d C e d Eit etas 10 5 PAGING Ol aet e tod Un etude 10 6 Oil MISCOSIEY 10 6 Fuelirig Instr ctioris ne cet 10 7 Battery LET 10 7 SECTION 11 TROUBLESHOOTING AND ELECTRICAL SYSTEM General Informati h e erede o ee dieere adie da e tee toda at ea 11 2 Troubleshooting Guide tire be alte D do 11 2 Electrical System cure oa esee rtr redde atq aseo nte tnt eius 11 5 E err 11 7 Starter Gute 3 2 es ne hte er er 11 7 Generator CIECUIE a td re bet die De OR te c us 11 8 Engine CIEGDIE sna oit cited b e e re RR haere rst uua e teta UE REGE 11 8 Engine ING IFOUI orto eur etre cat ELLE Let ufo aa 11 9 Reverse Buzzer Circui
28. Figure 14 3 Page 14 3 14 2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM How The Carburetor Works from the carburetor float chamber The combustible mixture of air and fuel is then delivered into the venturi through the pilot outlet and bypass When the engine is operating at low speed fuel is supplied mainly through the pilot outlet Figure 14 3 Page 14 3 The air fuel mixture is adjusted by the pilot screw needle valve Figure 14 3 Page 14 3 BYPASS HOLES TOP VIEW THROTTLE VALVE MIXTURE TO CYLINDER CARBURETOR BORE TO ENGINE PILOT OUTLET Pa PILOT AIR SCREW PILOT JET SIDE VIEW CARBURETOR BORE TO ENGINE MIXTURE TO CYLINDER 1 5 THROTTLE VALVE BLEED PIPE FLOAT FUEL INLET FLOAT CHAMBER Figure 14 3 Carburetor MAIN AIR JET MAIN NOZZLE INTAKE MAIN AIR PASSAGE PILOT AIR JET AIR FUEL MIXTURE MAIN AIR PASSAGE MAIN AIR JET INTAKE AIR MAIN NOZZLE MAIN JET FUEL INLET 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14 3 FUEL SYSTEM Carburetor CHOKE AND FRESH AIR SYSTEM The choke system aids in starting the engine in cold weather When starting a cold engine the spring loaded choke cover 1 Figure 14 4 Page 14 4 is pushed in by hand This restricts the air flow to the venturi caus ing a very high vacuum that draws fuel into the venturi at a high rate
29. Inlet valve or seat is leaking dirty worn or damaged Section 14 Fuel System 2 Float is damaged and filled with gaso Section 14 Fuel System line 3 Float needle valve not functioning Section 14 Fuel System properly 4 Carburetor vent is clogged Section 14 Fuel System Starter fails to operate 1 Neutral lockout cam is in the wrong Section 11 Troubleshooting position Neutral Lockout Circuit Page 11 10 2 Fuse is blown Section 11 Troubleshooting Test Procedure 1 3 Battery is dead Section 11 Troubleshooting Test Procedure 2 4 Starter control circuit is Section 11 Troubleshooting not operating Starter Circuit Page 11 12 5 Starter generator failed Section 11 Troubleshooting Test Procedure 8 6 Starter solenoid failed Section 11 Troubleshooting Test Procedure 6 7 Accelerator pedal limit switch failed Section 11 Troubleshooting Test Procedure 5 8 Key switch failed Section 11 Troubleshooting Test Procedure 4 9 Neutral lockout limit switch failed Section 11 Troubleshooting Test Procedure 7 10 Loose or broken wire in Section 12 Electrical Components starter generator circuit Starter Generator page 12 2 11 Cylinder and or crankcase flooded Section 14 Fuel System with fuel Starter generator does not 1 Loose or broken wire in the starter Section 11 Troubleshooting charge battery generator circuit
30. Install the governor guard 8 flat washer and nylon lock nut Tighten to 30 in Ib 3 4 N m Figure 13 43 Page 13 23 Apply a light film of clean engine oil onto the seal of the new oil filter and install the filter Tighten the fil ter 2 3 turn after gasket contact Fill crankcase with the correct level of oil Figure 13 106 Page 13 48 See Section 10 Periodic Maintenance Run the engine for three minutes to check for leaking oil Figure 13 42 Oil Filler Tube and Ground Wire Figure 13 43 Governor Cable Connection CRANKCASE Read DANGER and WARNING on page 13 1 ENGINE REMOVAL To perform repairs on crankcase components the engine must be removed from the vehicle A CAUTION e BEFORE REMOVAL AND DISASSEMBLY CLEAN THE ENGINE Remove the powertrain by performing steps 1 through 14 pages 16 7 through 16 10 in Section 16 Unitized Transaxle Remove starter generator See Section 12 Electrical System Remove drive belt See Section 17 Torque Converter Remove drive clutch See Section 17 Torque Converter and following NOTE NOTE THE CRANKSHAFT HAS LEFT HAND THREADS AT THE CLUTCH MOUNTING HOLE 5 Remove muffler See Section 15 Exhaust System Page 13 22 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Crankcase 6 Remove engine mounting hardware Items 1 2 5 and 6 Figure 13 48 Page 13 25 7 Lift engine from the mounting plate
31. TEST PROCEDURE 26 FUEL GAUGE 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse handle in NEUTRAL chock the wheels and disconnect the battery negative cable first Remove the center dash assembly to gain access to the back of the fuel gauge See Key Switch Removal Section 12 Electrical Components Page 12 13 Place a sheet of insulating material between the front frame and the electrical connections on the rear of the center dash assembly to prevent contact between the two Disconnect the orange wire from the fuel gauge Set a multimeter to 20 volts DC and place the red probe of the multimeter on the positive post of the battery Place the black probe on the negative post of the battery Record the voltage reading Seta 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 probe on the 3 terminal of the fuel gauge with the black wire Figure 11 44 Page 11 36 11 36 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Test Procedures 7 Reconnect the battery cables positive terminal first and tighten to 20 ft lb 27 1 N m 8 Turn the key switch ON The voltage reading should be the same as the battery voltage reading recorded earlier If not check the continuity of the blue and black wires Figure 11 44 Page 11 36 9 Plac
32. THE RINGS ARE INSTALLED INSTALL THE CHROME EDGED RING INTO THE TOP RING GROOVE 5 Tighten the two connecting rod bolts to 16 5 ft lb 23 N m E SHAFT je CENTER LINE Sem KE E wo Figure 13 97 Piston Connecting Rod Figure 13 98 Position Piston Ring Gaps 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 measurement A Figure 13 99 Page 13 45 2 Measure from the crankcase cover 3 mounting face to the crankshaft bearing inner end 4 Record measurement B Figure 13 99 Page 13 45 3 Locate the measurements on the Crankshaft Shim Table Follow lines to where the recorded measure ments intersect Figure 13 101 Page 13 45 4 Choose the next smaller shim from the table Example Measurement A is 15 87 mm and B is 17 66 mm The correct crankshaft shim 5 is 1 53 mm 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 43 FE290 ENGINE Crankshatt Axial Play Adjustment Crankshaft Axial Play Adjustment Continued 5 Install the shim 5 on the crankshaft 6 Figure 13 100 Page 13 45 NOTE CRANKSHAFT SHIM SIZES FOR FE290 ENGINES RANGE FROM 1 13 TO 1 53MM Figure 13 99 Determine Crankshaft Shim Size Figure 13 100 Install Shim on Crankshaft
33. 13 32 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 31 FE290 ENGINE Pump Oil Pump Inspection 1 Check the clearance between the inner and outer rotors 5 with a feeler gauge 6 Measure the clearance between the high point of the inner rotor and the high point of the outer rotor Figure 13 66 Page 13 33 2 Replace both rotors as a set if the measurement exceeds 0 012 inch 0 3 mm 3 Remove inner and outer rotors 5 4 Inspect the inner and outer oil pump rotors If the rotors are worn or damaged replace them 4 1 Measure the pump shaft bearing surface Replace both rotors as a set if the measurement is less than 0 4971 inch 12 627 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 replace both rotors 4 4 Using a micrometer measure the thickness of the outer rotor Figure 13 69 Page 13 33 4 5 f the rotor thickness is less than 0 3905 inch 9 920 mm replace both rotors Measure two places 90 apart Figure 13 66 Check Clearance Between Rotors Figure 13 67 Measure Pump Shaft Bearing Surface Measure two places 90 apart Figure 13 68 Measure O D of Outer Rotor Figure 13 69 Measure Thickness of Outer Rotor OIL PRESSURE RELIEF VALVE Cil Pressure Relief Valve Removal 1 Remove the oil pump cover See Oil Pump Cover Remo
34. 13 and 22 Figure 16 35 Page 16 14 into the left driver side case Use an oil seal installation tool Club Car Part No 1014160 to install a new oil seal 55 Figure 16 42 Page 16 18 into the right passenger side case See also Figure 16 67 Page 16 29 3 Position the governor gear shaft installation tool Club Car Part No 101933101 over the shaft bore in the inside of the left driver side case and insert the governor gear shaft into the tool long end from the groove first as shown Figure 16 68 Page 16 29 Make sure the shaft is started into the bore and then using a plastic or rubber hammer carefully tap the governor gear shaft into the bore until the end being tapped is flush with the end of the tool Remove installation tool 4 Install the washer governor gear and sleeve together onto the governor shaft Figure 16 69 Page 16 30 Make sure the sleeve is properly positioned within the flyweight brackets of the gear as shown Figure 16 70 Page 16 30 and then push 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 Figure 16 71 Page 16 30 Install the exterior washer and cotter pin on the pivot arm outside the case as shown Figure 16 71 Page 16 30 Bend the legs of the cotter pin 6 Install the shifter shaft into the left driver side case as shown Figure 16 72 Pag
35. 17 Page 14 21 2 Install the valve assembly in the pumping chamber 30 Figure 14 17 Page 14 21 A CAUTION e IF THE VALVE ASSEMBLY IS NOT INSTALLED EXACTLY AS SHOWN FIGURE 14 17 PAGE 14 21 THE IMPULSE FUEL PUMP WILL NOT OPERATE PROPERLY 3 Install the pumping chamber 30 on top of the fuel diaphragm 34 Be sure the fuel inlet and the fuel outlet align with the arrows on the front of the front cover Figure 14 17 Page 14 21 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 14 21 EZ FUEL SYSTEM Fuel Tank Fuel Pump Assembly Continued 4 Install the gasket 29 clear impulse diaphragm 28 and the paper impulse gasket 27 to the pumping chamber 30 5 Install the front cover and then the lock washers 25 and four screws 24 on the assembly Figure 14 17 Page 14 21 Be sure the arrows on the front cover point from the fuel inlet to the fuel outlet Figure 14 18 Page 14 21 Tighten the screws to 26 in Ib 3 0 FUEL PUMP INSTALLATION NOTE BE SURE TO CONNECT THE FUEL LINE 2 THAT COMES FROM THE PRIMARY FUEL FILTER 17 TO THE INLET NIPPLE ON THE PUMP FIGURE 14 16 PAGE 14 19 DIRECTION OF FUEL FLOW IS INDICATED BY THE ARROWS ON THE FUEL PUMP FIGURE 14 18 PAGE 14 21 1 Connect to the fuel pump the fuel line 2 that comes from the primary fuel filter 17 Install a new clamp 16 Figure 14 16 Page 14 19 See Page 14 19 for proper routing of fuel lines
36. 1783 inches 29 930 mm Crankshaft Balancer Link Rod Journals 1 8474 inches 46 924 mm Camshaft Axial Play 0 0137 inch 0 35 mm Camshaft PTO Side Journal 0 9026 inch 22 927 mm Camshaft Flywheel Side Journal 0 9026 inch 22 927 mm Camshaft Cam Lobes IN and EX 1 287 inches 32 70 mm Connecting Rod Big End Bearing 1 4003 inches 35 567 mm Connecting Rod Small End Bearing 0 7500 inch 19 051 mm Counterbalancer Rod Big End Bearing Counterbalancer Rod Small End Bearing 1 0 MAX 1 8554 inches 47 126 mm 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 Groove Clearance and End Gap Visual inspection only Piston Pin O D MIN 0 7470 inch 18 975 mm Piston Pin Hole 1 0 MAX 0 7493 inch 19 033 mm Crankcase Cover Camshaft bearing I D MAX 0 9079 inch 23 063 mm Cylinder Bore Cylinder Bore 1 0 Standard 1 0 MAX 3 0700 to 3 0708 inches 77 980 to 78 000 mm 3 0735 inches 78 067 mm Cylinder Bore out of round MAX 0 0022 inch 0 056 mm Crankshaft Bearing 1 0 MAX 1 1841 inches 30 075 mm Camshaft Bearing 1 0 MAX 0 9080 inch 23 063 mm Oil Pump Housing 1 0 MAX 1 6050 inches 40 7
37. 29 then remove them from the pump Figure 14 17 Page 14 21 Page 14 20 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM Fuel Pump CAUTION FUEL PUMP GASKETS AND DIAPHRAGMS MUST BE REINSTALLED IN EXACTLY THE SAME POSITIONS AND ORIENTATIONS THEY WERE IN BEFORE DISASSEMBLY OR THE PUMP COULD LEAK IF LEAKING OCCURS ALL NEW GASKETS AND DIAPHRAGMS MUST BE INSTALLED 4 If the impulse gasket 27 the diaphragm 28 come off with the front cover note their orientations and remove them Figure 14 17 Page 14 21 5 Remove the pumping chamber 30 6 Remove the back cover 36 the fuel diaphragm 34 and gasket 35 Figure 14 17 Page 14 21 2 PUMPING ane XE D 30 CHAMBER FUEL _ VENT Ae e OUTLET ue c5 VALVE ASSEMBLY DIRECTION OF FUEL FLOW IMPULSE LINE BACK COVER Figure 14 17 Fuel Pump Figure 14 18 Fuel Pump Orientation FUEL PUMP CLEANING AND INSPECTION 1 Using a nonflammable solvent clean the front cover pumping chamber and back cover Be sure the vent on the front cover is clean both inside and out Figure 14 17 Page 14 21 2 Inspect the valve assemblies 31 32 and 33 and all gaskets and diaphragms for damage 3 If a valve assembly is damaged the rubber retaining plug 33 and valve assembly must be replaced FUEL PUMP ASSEMBLY 1 Install the fuel gasket 35 and diaphragm 34 on the back cover 36 Figure 14
38. 8 Remove crankcase oil drain plug and filler tube Tip the engine slightly to allow all of the oil to drain from the crankcase Dispose of engine oil properly TYPICAL 2 PLACES Figure 13 46 Oil Level Sensor Wire Figure 13 47 Oil Level Sensor CRANKCASE COVER REMOVAL 1 Remove yellow jumper wire 11 from cord connector 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 NOTE NOTE IF THE CRANKCASE COVER STICKS TAP LIGHTLY WITH A PLASTIC MALLET ON ALTERNATE SIDES NEAR THE DOWEL PINS 5 FIGURE 13 44 PAGE 13 24 4 Remove the crankcase cover gasket completely It may stick to the flanged surface of the crankcase 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 13 23 FE290 ENGINE Crankcase OIL LEVEL SENSOR Testing the Oil Level Sensor See Section 11 Test Procedure 21 Page 11 33 Oil Level Sensor Removal 5 If not already removed remove crankcase cover See Crankcase Cover Removal Page 13 24 Disconnect the oil level sensor wire 2 from the cord connection 1 Figure 13 47 Page 13 24 Remove the screw 3 from the wire clamp 4 Remove the two mounting screws from the inside of the crankcase cover and remove the oil level sensor and bracket If necessary r
39. 90 from the differential gear carrier case Figure 16 5 Page 16 4 4 Remove the differential pin 88 Figure 16 5 Page 16 4 by pushing it through from one side Figure 16 46 Page 16 21 Remove the two differential idler gears 89 and two idler gear thrust plates 85 Figure 16 5 Page 16 4 as the pin is driven through NOTE IT MAY BE NECESSARY TO DRIVE THE DIFFERENTIAL PIN OUT WITH HAMMER AND PUNCH 5 Remove the differential gear 91 from the carrier case Figure 16 5 Page 16 4 6 If the bearings 79 are to be removed place a bearing puller wedge attachment Club Car Part No 1012812 between 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 following CAUTION A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THIS COULD DAMAGE THE SHAFT 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 16 19 UNITIZED TRANSAXLE Component Disassembly SHIFTER FORK DISASSEMBLY 1 Push the shift rod 33 out of the shifter fork 34 Figure 16 42 Page 16 18 2 Shake the shifter fork to remove the spring 35 and ball 36 Figure 16 42 Page 16 18 SYNCHRONIZER GEAR DISASSEMBLY A CAUTION e MARK PARTS FOR IDENTIFICATION AS THEY ARE DISASSEMBLED PARTS MUST BE REASSEMBLED IN THEIR ORIGINAL
40. A tae a a Sia ee Cylinder Shroud Removal ccccceeeccceeeneeeeesceeceaeeeeeaaeecaeeeeeaaesesaeeeeeaaeesseeeeesaeesseaaeesseeeeseaaeenines Rocker Arm and Push Rod Removal esses eene Cylinder Head Removal iii teet pee iced aee pei a cele dents Vave e ete e itta ea Breather Valve Reed Cylinder Head Cleaning and Inspection sssssssssseeeeneeenee ennemis Valve Guides t e t odi tte o d eed ads Valve Seats oa age dd ree ay eee Page iv 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Rocker Arm and Rocker Shaft Inspection nnne 13 18 Push Rod Inspection oet banca 13 18 Cylinder Head Installation 2 1 2 m ste c er ie e Po dE e ERE Beda 13 19 Valve Clearance Check and Adjustment sess 13 20 Breather Valve Reed Valve 13 20 Installation Of Remaining Engine Components sse 13 21 GrankCcase 55 6 cte ttd att fo ume ete t t en ts 13 22 Engine Hemovals iie e E EB p ete te M nt tib by 13 22 Grankcase Gover Hemoval aep iu bete eese 13 23 Gili bevel Sensor xu ettam e sede c uds 13 24 GCamshaft and T Appels 2 5 e
41. APPROVED JACK STANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE GENERAL INFORMATION All gasoline powered Club Car vehicles manufactured since the beginning of the 1997 model year are equipped with heavy duty fully synchronized Unitized Transaxles The unitized transaxle utilizes fully syn chronized internal gearing to change vehicle direction Because the unitized transaxle is used to reverse vehicle direction the engine drive clutch belt and driven clutch rotate in the same direction therefore the engine and clutches are not subjected to reversing loads This reduces maintenance requirements on the engine and clutches With the unitized transaxle power is transferred from the engine through the drive clutch the drive belt the driven clutch and then through the unitized transaxle to the wheels 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 1 UNITIZED TRANSAXLE General Information Shifter Lever A shifter lever connected to a shifter arm on the unitized transaxle is used to change the gears to one of three shift positions FORWARD F NEUTRAL N or REVERSE R Figure 16 1 Page 16 2 The vehicle should come to a complete stop before changing FORWARD or REVERSE direction Neutral Lockout During normal vehicle operation the neutral lockout feature prevents the engine from running when the For word Reverse handle is in the NEUTRAL position If a vehicle is started in FORWARD or REVERSE
42. AS THEY ARE DISASSEMBLED PARTS MUST BE REASSEMBLED IN THEIR ORIGINAL LOCATIONS AND ORIENTATIONS 1 Remove eight ring gear retaining bolts 80 Figure 16 5 Page 16 4 then remove the ring gear from the assembly It may be necessary to tap the ring gear off with a plastic or rubber mallet Figure 16 45 Page 16 19 See following NOTE NOTE BECAUSE LOCTITE WAS APPLIED TO THE BOLTS DURING ASSEMBLY IT MAY BE NECESSARY TO PLACE THE DIFFERENTIAL GEAR CASE IN A VISE TO REMOVE THE BOLTS 2 Pull the cover 87 and thrust plate 86 from the differential gear carrier case Figure 16 5 Page 16 4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 16 17 UNITIZED TRANSAXLE Component Disassembly Differential Gear Case Disassembly Continued REFERENCE DRIVER SIDE PASSENGER SIDE CASE Figure 16 42 Unitized Transaxle Page 16 18 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Component Disassembly Pry governor gear assembly from shaft using two small screwdrivers Using a hammer and drift punch lightly tap governor gear and washer from case Figure 16 44 Pry Gear from Shaft Remove eight ring gear retaining bolts Then turn differential gear assembly over and tap around ring gear with a rubber or plastic mallet to loosen and remove the ring gear Figure 16 45 Remove Ring Gear 3 Remove the differential gear
43. CABLE INSTALLATION 1 From the F amp R shifter route the cable toward the driver side of the vehicle so it lies against the side of the front body turns 90 and passes to the driver side of air intake box over the battery beside the fender and then turns again to connect with the shifter arm on the transaxle Figure 16 104 Page 16 40 Make sure cable does not touch muffler Secure the cable with a retaining nut 5 on each side of the shifter cable support bracket at the tran saxle Figure 16 106 Page 16 41 Tighten nuts to 22 ft lb 29 8 N m Secure the cable with a retaining nut 5 on each side of the shifter cable support bracket at the F amp R assembly Figure 16 106 Page 16 41 Tighten nuts to 22 ft lb 29 8 N m Install the ball joint socket 10 on the shifter lever ball stud 11 on the transaxle Figure 16 106 Page 16 41 Install the ball joint socket 2 on the F amp R shifter assembly ball stud 3 Figure 16 106 Page 16 41 Attach F amp R cable at cable retainer 7 Install wire tie 8 to secure wire harness to cable at the support bracket near the F amp R shifter assembly Figure 16 106 Page 16 41 See following WARNING A WARNING IF WIRES ARE REMOVED OR REPLACED MAKE SURE WIRING AND WIRING HARNESS IS PROPERLY ROUTED AND SECURED TO VEHICLE FRAME FAILURE TO PROPERLY ROUTE AND SECURE WIRING COULD RESULT IN VEHICLE MALFUNCTION PROPERTY DAMAGE OR PERSONAL INJURY Page 16
44. CRANKSHAFT FROM DROPPING TO THE FLOOR AFTER THE GEAR HAS BEEN REMOVED Page 13 34 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Crankshaft and Counterbalance A CAUTION ALWAYS USE A PRESS WHEN REMOVING THE SPUR GEAR AND HELICAL GEAR FROM OR INSTALLING THEM ON THE CRANKSHAFT 5 Remove the woodruff key 6 Slide the remaining link rod off the crankshaft TYPICAL 4 PLACES Figure 13 76 Crankshaft and Counterbalance Figure 13 77 Inspect Link Rod Link Rod Inspection 1 Clean and inspect the link rod 1 bearing surfaces If the bearing surface of the small end is scored or damaged replace the link rod If the large end bearing is scored or damaged the bearing must be replaced Figure 13 77 Page 13 36 1 1 Using a telescoping gauge and micrometer measure both inside bearing surfaces at several points 1 2 If the inside diameter of the small end is greater than 0 4746 inch 12 057 mm replace the link 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 NOTE DO NOT REMOVE THE LINK ROD ON THE PTO POWER TAKE OFF SIDE UNLESS LINK ROD ON THE OPPOSITE END NEEDS REPLACEMENT THE CRANK GEAR IS VERY TIGHTLY FITTED TO THE CRANKSHAFT SO THAT IT CAN TRANSFER ENGINE TORQUE TO THE CAMSHAFT WHICH ALSO FUNCTIONS AS A POWER TAKE OFF SHAFT FIGU
45. Disconnect the cable from the actuator cam and remove it from the box Figure 16 13 Page 16 8 Disconnect the engine ground wire from oil filler tube mounting bracket Figure 16 14 Page 16 9 Loosen nuts securing shifter cable to shifter cable mounting bracket Then disconnect the shifter cable rod end from the shifter arm on the unitized transaxle and remove the cable from the cable mounting bracket Figure 16 15 Page 16 9 Mark for proper reconnection and then disconnect the 6 gauge white wire F2 post 6 gauge black ground wire A2 post and 16 gauge yellow DF post from starter generator Figure 16 16 Page 16 9 Disconnect the oil level sensor wire 18 gauge yellow at the connector just to the rear of the starter generator Figure 16 17 Page 16 9 Disconnect the engine kill switch wire 18 gauge white black stripe from the bullet connector at the lower right front of the engine Figure 16 18 Page 16 10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Unitized Transaxle Removal Remove engine ground TOP VIEW retaining nut Pull spring release back to remove shifter Loosen nuts cable from lever Figure 16 14 Engine Ground Wire Figure 16 15 Shifter Cable Remove yellow wire Remove ground wire at A2 terminal Remove white wire ll veLLOW NE OIL SENDING UNIT JUMPER WIRE Mark wires for
46. FE290 Gasoline Vehicle Maintenance and Service Supplement Components Page 12 15 Using a multimeter set on 200 Q ohms place the red probe on one fuse terminal and the black probe on the other fuse terminal The reading should be continuity If the reading is incorrect determine and repair the cause of the fuse failure Replace the fuse with a properly rated new one TROUBLESHOOTING Test Procedures TEST PROCEDURE 2 BATTERY Read DANGER and WARNING on page 11 1 DANGER DUE TO THE DANGER OF AN EXPLODING BATTERY WEAR A FULL FACE SHIELD AND RUBBER GLOVES WHEN WORKING AROUND A BATTERY BATTERY EXPLOSIVE GASES KEEP SPARKS AND FLAMES AWAY FROM VEHICLE AND SERVICE AREA VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR EYE PROTECTION WHEN WORKING ON OR NEAR BATTERY FOR ADDED PROTECTION COVER TOP OF THE BATTERY WHEN SERVICING THE VEHICLE BATTERY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING EXTERNAL FLUSH WITH WATER CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF WATER FOLLOW WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL A PHYSICIAN IMMEDIATELY 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Check for loose or corroded battery terminal connections Clean t
47. FOR PROPER LOCATION OF ALL VEHICLE WARNING DECALS AND MAKE SURE THEY ARE IN PLACE AND ARE EASY TO READ WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST SYSTEM FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS 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 TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE FRAME ENGINE OR OTHER METAL COMPONENT TURN THE KEY SWITCH TO OFF REMOVE THE KEY CHOCK THE WHEELS AND PLACE THE FORWARD REVERSE HANDLE IN NEUTRAL PRIOR TO SERVICING THE VEHICLE WARNING CONTINUED ON NEXT PAGE 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10 1 PERIODIC MAINTENANCE General Information A WARNING 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 FIGURE 10 4 PAGE 10 6 DO NOT WORK ON VEHICLE POWERTRAIN OR UNDER THE CARGO BED WHEN IT IS L
48. FROM PASSENGER SIDE OF VEHICLE FRONT _ VEHICLE p Remove negative Na AOR cable first BEFORE WORKING ON VEHICLE Figure 10 1 Battery Cable Removal DAILY PRE OPERATION SAFETY CHECKLIST Inspect and drive the vehicle using the Pre operation Checklist and Performance Inspection in Section 3 in the appropriate maintenance and service manual as a guide to check the following items Vehicle warning decals Brake system Page 10 2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement PERIODIC MAINTENANCE Periodic Service Schedule Park brake Reverse warning buzzer Steering and linkages Proper acceleration and maximum speed In addition check the items listed below Tires Visually inspect for wear damage and proper inflation Exhaust system Check for leaks Forward Reverse shifter Check for proper operation See Controls Section 3 in the appropriate maintenance and service manual Fuel system Check fuel tank lines cap pump fuel filters and carburetor for fuel leakage PERIODIC SERVICE SCHEDULE A WARNING e SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE MAINTENANCE AND SERVICE MANUAL AND THIS SUPPLEMENT NOTE e IF THE VEHICLE IS CONSTANTLY SUBJECTED TO HEAVY USE OR SEVERE OPERATING CONDITIONS THE PREVENTIVE MAINTENANCE PROCEDURES SHOULD BE PERFORMED MORE OFTEN THAN RECOMMENDED IN THE PERIODIC SERVICE AND LUBRICATION SCHE
49. IGNITION OF FUEL AND SERIOUS PERSONAL INJURY OR DEATH NEVER TRY TO START THE ENGINE WITH PLUG REMOVED FROM ENGINE Page 13 6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Engine Mounting Plate Testing the Spark Plug Check the sparking ability of a cleaned and regapped plug on a sparking comparator if possible Spark should be blue and strong and able to jump a 5 16 inch 8 mm gap Setting the Spark Gap 1 Before setting the spark gap on a used plug pass a contact point file between the electrodes to pro duce flat parallel surfaces to facilitate accurate gauging 2 Use a wire type gauge Bend the outside or ground electrode so only a slight drag on the gauge is felt when passing it between the electrode Never make an adjustment by bending the center electrode Set gap A to 0 027 0 031 inch 0 69 0 79 mm Figure 13 4 Page 13 7 Spark Plug Installation NOTE e BEFORE INSTALLING THE PLUG CHECK THE CONDITION OF THE THREADS IN THE CYLINDER HEAD SOFTEN DEPOSITS IN CYLINDER HEAD THREADS WITH PENETRATING OIL AND CLEAN THE THREADS WITH A TAP IF NECESSARY 1 Install the spark plug and thread it in until finger tight then 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 repairs to the cylinder assembly a cylind
50. 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 SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD REVERSE HANDLE IN THE NEUTRAL POSITION AND REMOVE KEY BEFORE SERVICING THE VEHICLE HOT DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST SYSTEM FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS MOVING PARTS DO NOT ATTEMPT TO SERVICE 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 TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRICAL WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR ANY OTHER METAL COMPONENT TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING SET THE PARK BRAKE WHEN LIFTING THE FRONT OF THE VEHICLE UNLOAD THE CARGO BED AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LB 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION USE
51. LOCATIONS AND ORIENTATIONS DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THIS COULD DAMAGE THE SHAFT 1 Place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing 38 and spur governor drive gear 40 Figure 16 42 Page 16 18 then press the bearing off the input shaft as shown Figure 16 48 Page 16 21 See preceding CAUTION 2 Pull the spring washer 39 spur gear 40 dowel pin 50 thrust plate 41 input gear assembly 42 large needle bearing 43 small needle bearing 44 synchronizer ring 45 and thrust plate 41 from the input shaft Figure 16 42 Page 16 18 3 Place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing 54 and input gear assembly 52 Figure 16 42 Page 16 18 then press the bearing off the input shaft as shown Figure 16 49 Page 16 21 See following CAUTION A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THIS COULD DAMAGE THE SHAFT 4 Pull the spring washer 39 thrust washer 53 input gear assembly 52 two needle bearings 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 synchronizer clutch hub 49 from the input shaft 51 Figure 16 42 Page 16 18 NOTE THERE ARE THREE SYNCHRONIZER INSER
52. LS 02 in 0 5 mm Turn idler shaft over and press bearing on other end Figure 16 54 Synchro Ring Figure 16 55 Idler Shaft 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 16 23 UNITIZED TRANSAXLE Component Assembly Synchronizer Gear Assembly Continued Install springs on top and bottom of synchronizer sleeve as shown SYNCHRONIZER SLEEVE ci Top of spline pressed SYNCHRONIZER f level with machined INSERT SLOTS 74 insert slots fece FRONT VIEW Figure 16 56 Synchro Gear Assembly Figure 16 57 Synchro Springs Install the three synchronizer inserts 48 into the slots in the sleeve Figure 16 42 Page 16 18 Make sure the notched surfaces of the inserts are facing outward as shown Figure 16 58 Page 16 25 Install the synchronizer clutch hub 49 Figure 16 42 Page 16 18 onto the synchronizer sleeve Make sure the chamfered end of the hub is oriented toward the long end of the input shaft as shown Figure 16 59 Page 16 25 On the long end of the shaft install the synchronizer ring 45 Figure 16 42 Page 16 18 with the smooth collar of the ring towards the clutch hub Make sure the three notches in the collar mate with the synchronizer inserts in the synchronizer sleeve as shown Figure 16 60 Page 16 25 Install the thrust washer 41 and two bearings 43 as shown Figure 16 42 Page 16 18 Install the input gear assembly 5
53. NO CONTINUITY REPLACE WIRE Figure 11 18 Testing the Engine Kill Circuit Chart 3 Page 11 14 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Circuit Testing TESTING THE REVERSE BUZZER CIRCUIT Read DANGER and WARNING on page 11 1 Use the following chart Figure 11 19 to begin troubleshooting the reverse buzzer circuit REVERSE BUZZER WILL NOT FUNCTION CHECK FUSE TEST PROCEDURE 1 GOOD FUSE DETERMINE CAUSE REVERSE BUZZER REVERSE BUZZER OF THE BLOWN FUSE WILL NOT FUNCTION AND WILL NOT FUNCTION AND ENGINE WILL NOT CRANK ENGINE WILL CRANK REPLACE FUSE CHECK BATTERY CHECK REVERSE BUZZER TEST PROCEDURE 2 LIMIT SWITCH TEST PROCEDURE 19 USE MULTIMETER TO TEST LIMIT SWITCH TEST PROCEDURE 3 CHECK GROUND STRAPS CORRECT INCORRECT CONTINUITY READING CONTINUITY READING CHECK WIRE CONNECTION REPLACE LIMIT SWITCH TO THE REVERSE BUZZER TEST PROCEDURE 20 WIRES CORRECTLY WIRES INCORRECTLY CONNECTED CONNECTED CHECK CONTINUITY RECONNECT WIRES OF CIRCUIT WIRES TO REVERSE BUZZER NO CONTINUITY CONTINUITY REPLACE WIRE REPLACE REVERSE BUZZER Figure 11 19 Testing the Reverse Buzzer Circuit 2000 FE290 Gasoline Vehicle Maintenan
54. NOTE NOTE CONTACT YOUR LOCAL WATER DEPARTMENT FOR MINERAL CONTENT ANALYSIS Page 12 28 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS IMPURITY Battery ALLOWABLE CONTENT IN PARTS PER MILLION SUSPENDED MATTER TRACE TOTAL SOLIDS 100 0 CALCIUM AND MAGNESIUM OXIDES 40 0 IRON 5 0 AMMONIA 8 0 ORGANIC MATTER NITRATES NITRITES CHLORIDE Battery Removal Read DANGER and WARNING on page 12 1 and DANGER on Page 12 26 1 Disconnect the battery cables negative first as shown Figure 12 1 Page 12 2 2 Remove the clamp from the battery 3 Lift the battery from the vehicle See following WARNING A WARNING e KEEP THE BATTERY IN AN UPRIGHT POSITION TO PREVENT ELECTROLYTE LEAKAGE TIPPING THE BATTERY BEYOND A 45 ANGLE IN ANY DIRECTION CAN ALLOW A SMALL AMOUNT OF ELECTROLYTE TO LEAK OUT THE VENT HOLE DO NOT EXCEED THIS 45 ANGLE WHEN LIFTING CARRYING OR INSTALLING BATTERY THE BATTERY ACID COULD CAUSE SEVERE PERSONAL INJURY WHEN ACCIDENTALLY COMING IN CONTACT WITH THE SKIN OR EYES AND COULD DAMAGE CLOTHING Charging the Battery Read DANGER and WARNING on page 12 1 and DANGER on Page 12 26 1 Charge the battery using an automotive type 12 volt battery charger Follow all warnings and proce dures supplied by the battery charger manufacturer 2 Attach the positive charger cabl
55. Page 13 6 and Figure13 2 Page 13 6 Oil can build up excess pressure in a lubrica tion system To prevent build up of excess oil pressure which could possibly force oil past the seals and damage the engine the pump is fitted with a pressure relief valve 8 Figure 13 1 Page 13 6 that is made of a ball and a spring When the pressure increases beyond the pressure 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 preset limit the spring holds the ball against its seat to keep the oil from draining back into the sump crankcase Excess oil pressure could otherwise force the oil past seals and cause engine damage 1 Oil Sump 2 Oil Filter Screen 4 Camshaft Bearing 6 Passage 3 Oil Pump 9 Tappet 5 Oil Filter 8 Pressure 7 Relief Valve 10 Crankshaft Main Bearing 11 Link Rod Bearing 12 Connecting Rod Bearing 13 Link Rod Bearing Figure 13 2 Lubrication System Figure 13 3 Lubrication System Flow Chart 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 5 FE290 ENGINE General Information SPARK PLUG Spark plugs are selected to suit specific engine design and vehicle operating conditions The spark plug Club Car Part No 101881101 is designed to give maximum
56. RPM limiter and damper Figure 12 24 Page 12 23 RPM Limiter Installation 1 2 3 Place the RPM limiter damper on the front of the mounting bracket Figure 12 24 Page 12 23 Place the RPM limiter on the damper squarely so that limiter fits tightly against damper Place the band over the RPM limiter and align the holes Install the brown wire with the ring connector onto the flange head bolt and secure the left side driver side of the band Use another flange head bolt to secure the other side of the band Make sure the band holds the RPM limiter securely in place 12 22 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS gnition Coil BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL WHITE BLACK FEMALE BULLET KILL CIRCUIT WIRE TERMINAL Figure 12 24 RPM Limiter Assembly BROWN WIRE BLACK WIRE 4 Mount the RPM limiter to the engine 4 1 Secure the extra wire with the clamp mounted on the back side of the RPM limiter mounting bracket Figure 12 24 Page 12 23 Install the RPM limiter assembly onto the 2 ended bolts on the engine Slide a wire clamp onto one of the bolts then secure the limiter assembly with two M6 nuts and tighten to 50 in Ib 5 6 N m Figure 12 24 Page 12 23 5 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 Battery Protector Spray Club Car Pa
57. TANK AVOID SPILLING FUEL 1 Lift and remove seat bottom 2 The fuel tank is located on passenger side of vehicle Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only See following NOTE NOTE WHENEVER POSSIBLE AVOID USING OXYGENATED FUELS AND FUELS THAT ARE BLENDED WITH ALCOHOL VEHICLES TO BE STORED FOR EXTENDED PERIODS SHOULD BE PREPARED FOR STORAGE AS INSTRUCTED IN SECTION 3 IN THE APPROPRIATE MAINTENANCE AND SERVICE MANUAL 3 Replace the fuel cap on the tank Make sure cap is tightened securely 4 Replace seat bottoms BATTERY For periodic battery maintenance see Battery Section 12 Page 12 26 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10 7 SECTION 11 TROUBLESHOOTING AND ELECTRICAL SYSTEM DANGER BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE VEHICLE AND SERVICE AREA VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR A FULL FACE SHIELD AND RUBBER GLOVES WHEN WORKING ON OR NEAR BATTERIES BATTERY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF WATER FOLLOW WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL A PHYSICIAN IMMEDIATELY GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOK
58. WARNINGS STATED IN THIS MANUAL WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF REMOVE THE KEY AND PLACE FORWARD REVERSE HANDLE IN THE NEUTRAL POSITION MOVING PARTS DO NOT ATTEMPT TO SERVICE 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 TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRICAL WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR ANY OTHER METAL COMPONENT TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FOR VEHICLES WITH CARGO BEDS REMOVE ALL CARGO BEFORE RAISING THE BED DO NOT CLOSE BED UNTIL ALL PERSONS ARE CLEAR OF CARGO BED AREA KEEP HANDS CLEAR OF CRUSH AREA BETWEEN BED AND SEAT BACK SUPPORT DO NOT DROP CARGO BED LOWER GENTLY AND KEEP ENTIRE BODY CLEAR FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SEVERE PERSONAL INJURY LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING SET THE PARK BRAKE WHEN LIFTING THE FRONT OF THE VEHICLE UNLOAD THE CARGO BED AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LB 454 K
59. WHEN WORKING ON OR NEAR BATTERIES BATTERY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF WATER FOLLOW WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR FIFTEEN MINUTES CALL A PHYSICIAN IMMEDIATELY GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM VEHICLE AND SERVICE AREA SERVICE ONLY IN A WELL VENTILATED AREA DO NOT OPERATE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON A WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN ELECTRICAL AND MECHANICAL REPAIR FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS SUPPLEMENT AND HEED ALL DANGER WARNING AND CAUTION 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 PERSONAL INJURY ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY OR HANDLING OF THE VEHICLE OR INCREASES MAXIMUM VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH CHECK THE OWNER S MANUAL
60. and then shifted to NEUTRAL the engine will stop running For the convenience of the trained 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 inch 10 mm and then rotated one half turn until it snaps into place the cam will be in the SERVICE position When the cam is in the SERVICE position it will allow the technician to run the engine in NEUTRAL for cer tain maintenance procedures With the cam in this position 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 inch 10 mm and rotate it one half turn until it snaps into place See Neutral Lockout Circuit Section 11 Page 11 10 Governor System The governor system is a flyweight type and regulates vehicle ground speed It is mounted inside the unit ized transaxle and is driven by transaxle gears Because the governor is mounted inside the transaxle it is protected from abuse and damage common to externally mounted governor systems If any of the governor linkages are removed in order to service other components readjustment of the governor linkage is required See Governor Cable Installation and Adjustment Section 14 Page 14 11 Unitized Transaxle Service The unitized transaxle is extremel
61. and A r Intake System TYPICAL 2 PLACES NN TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 14 15 Air Intake and Choke Assemblies 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 14 17 FUEL SYSTEM Fuel Filters Air Filter Replacement Continued 6 Install new air filter by inserting back edge first and pushing down using the palm of your hand to seat filter evenly onto inside lip of air box Ensure filter fits correctly and that the wire latches are not caught between lid and air box Close the lid 7 Fasten wire latches 3 Make sure latches securely engage the bottom half of the box See following CAU TION A CAUTION ENGINE DAMAGE WILL OCCUR IF THE AIR BOX COVER IS NOT PROPERLY SECURED e IF AIR BOX IS EXTREMELY DIRTY REMOVE AIR BOX FROM VEHICLE AND CLEAN THOROUGHLY USE ONLY CLUB CAR REPLACEMENT AIR FILTERS CLUB CAR PART NO 1015426 THE USE OF OTHER AIR FILTERS COULD RESULT IN ENGINE DAMAGE IF THE AIR FILTER IS TOO THIN THE COVER WILL SEAT BEFORE THE FILTER CAN SEAL LEAVING SPACE FOR DIRT TO PASS INTO THE ENGINE ON ALL SIDES OF THE ELEMENT THIS WILL DAMAGE THE ENGINE AND VOID THE WARRANT Y 8 Reinstall hose 16 and hose clamp 15 If equipped with screw clamp tighten to 17 in Ib 1 9 N m Make sure clamp ends are located in the 12 00 o clock position FUEL FILTERS Read DANGER and WARNING on page 14 1 GENERAL INFORMATION Fuel is supplied to the fuel pump and
62. and thus creates a fuel rich mixture The choke cover is held in until the engine starts and then released An air duct provides the engine with clean cool air from outside the engine compartment This feature increases engine horsepower and greatly extends air filter life FLOAT SYSTEM The carburetor is a float bowl type with the float chamber located just below the carburetor body The float system keeps the fuel in the float chamber at the correct level while the engine is running Figure 14 5 Page 14 4 Fuel is supplied to the carburetor 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 The fuel entering the bowl causes the float 4 Figure 14 4 Page 14 4 to rise until it shuts off the inlet valve preventing the fuel from exceeding a level predetermined by the float level setting SIDE VIEW dn FUEL END VIEW da T IY AIR FUEL MIXTURE 2 Figure 14 4 Choke System Figure 14 5 Float System CARBURETOR Read DANGER and WARNING on page 14 1 Before suspecting the carburetor as the cause of poor engine performance make sure the fuel and ignition systems are in proper operating condition Check the following items Spark Plug and Gap Condition See Section 13 Page 13 6 Air Filte
63. be 14 to16 Q ohms If the reading is not within limits replace the solenoid 5 Making sure the battery is disconnected remove the 6 gauge white wire and the 16 gauge red 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 28 Page 11 22 6 Set the multimeter to 200 Q ohms Connect the red probe to one of the large posts of the solenoid and connect the black probe to the other large post Figure 11 30 Page 11 24 7 Connect the battery positive cable first 8 Place the Forward Reverse handle in NEUTRAL and place the neutral lockout cam in the SERVICE position Turn the key switch to the ON position With the accelerator in the UP position the reading on the multimeter should be NO continuity 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 still in NEUTRAL and the neutral lockout cam in the SERVICE position set the multimeter to volts DC DC V and place the red probe on the large post that does not have wires connected to it Place the black probe on the frame of the vehicle Turn key switch to the ON position depress accelerator pedal and listen for solenoid click The meter should read full battery voltage If the reading is incorrect replace the solenoid Figure 11 31 Page 11 24 10 Disconnect
64. by poor performance or lack of power under heavy load conditions A dirty or clogged main jet will cause 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 symptoms of overly rich or lean fuel mix after all maintenance and adjustments are cor rectly performed the main jet should be replaced A smaller numbered jet gives a leaner mixture and a larger numbered jet gives a richer mixture It is recommended that any change be limited to one jet size difference from the standard jet STANDARD JETTING Pilot Air Screw Middle of Travel Pilot Jet 45 x1 100 Main Jet 82 x1 100 Throttle Valve Stop Screw 3 4 Turn Open VENTURI FUEL TANK ENGINE AIR CLEANER FLOAT MAIN AIR CARBURETOR E CHAMBER PASSAGE BORE INTAKE STROKE OF PISTON CARBURETOR MAIN Hmm FUEL MAIN JET BLEED PIPE mn AIR FUEL MIXTURE Figure 14 1 Fuel Flow Sequence Figure 14 2 Air Fuel Mixture SLOW SPEED SYSTEM The slow speed system supplies fuel during low speed running Low speed running without load requires very low intake airflow The throttle valve 2 Figure 14 3 Page 14 3 is almost closed when this is the case and as high negative pressure is created on the back side of the throttle valve intake air is drawn in and metered through the pilot air jet The intake air draws fuel metered by the pilot jet 6
65. cam TEST PROCEDURE 24 BATTERY TEST UNDER LOAD Read DANGER and WARNING on page 11 1 NOTE KEEP THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 24 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Set a multimeter to 20 volts DC and place the red probe on the F2 white wire terminal on the starter generator Place the black probe on the negative terminal post on the battery 3 Turn the key switch to the ON position leave the Forward Reverse shifter in the NEUTRAL position and depress the accelerator pedal with the accelerator pedal depressed the battery is under load 3 1 If the voltage reading is over 9 6 volts at 70 F 21 C electrolyte temperature see following NOTE check the starter generator See Starter Generator Page 11 2 3 2 If the reading is below 9 6 volt at 70 F 21 C electrolyte temperature see following NOTE check the battery See Test Procedure 2 Page 11 19 11 34 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Test Procedures 3 3 If the reading is zero there may be NO continuity across the large posts of the solenoid See Test Procedure 6 Page 11 23 NOTE e THE VOLTAGE READING LISTED IS FOR ELECTROLYTE AT 70 F 21 AT LOWER ELECTROLYTE TEMPERATURES THE VOLTAGE READING WILL BE LOWER 4 If all of the test resul
66. can be removed from the case Then remove the idler shaft assembly Figure 16 38 Page 16 16 Remove the synchronizer gear assembly and shifter fork assembly as a unit from the case Figure 16 38 Page 16 16 Use a seal puller Club Car Part No 1012809 or rolling head prybar to remove the input shaft oil seal from the case Figure 16 39 Page 16 16 Remove the oil flow guide from the case Figure 16 40 Page 16 17 Remove the shifter shaft and oil seal from the case Figure 16 40 Page 16 17 13 1 Loosen nut 3 and bolt 7 on transmission shifter lever and remove lever from shaft Figure 16 35 Page 16 14 13 2 Remove woodruff key 10 from shaft Figure 16 35 Page 16 14 13 3 Use snap ring pliers 047 tip to remove the retaining ring 11 on the shifter shaft 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 transaxle Figure 16 35 Page 16 14 13 5 Use a seal puller to remove the shifter shaft oil seal 13 from the case Figure 16 35 Page 16 14 Remove the breather 31 from the case Figure 16 35 Page 16 14 Remove the governor assembly from the case 15 1 Remove the cotter pin 20 and flat washer 21 from the pivot arm 24 Figure 16 35 Page 16 14 15 2 Remove the pivot arm 24 by pulling it through the wall to the interior of the case 15 3 Use a
67. center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 12 7 Page 12 5 3 Install the commutator end cover 23 onto the armature shaft Align the locating pin with the pin hole in the cover Install two M6 x 1 x 180mm bolts 20 and tighten to 100 in Ib 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 hole in it next to the A2 terminal Install the remaining three brush covers 29 in the openings in the commutator end cover 23 Figure 12 4 Page 12 4 BRUSH BEING HELD BY BRUSH SPRING Figure 12 7 Pull Brushes Away from Center of the Commutator End Cover Disassembly of the Starter Generator to Service the Armature Commutator 1 If the brushes are not removed contact between the brushes and commutator as the commutator end cover is being removed or installed could damage the brushes 1 1 Lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 12 7 Page 12 5 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 12 5 ELECTRICAL COMPONENTS Starter Generator Disassembly of the Starter Generat
68. dash out approximately one inch from the frame and then bend the top right corner of the center dash inward while pulling the top of the panel out and down Figure 12 17 Page 12 14 NOTE BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD WHILE REMOVING IT WILL PREVENT THE CONTACTS ON THE REAR OF THE KEY SWITCH FROM TOUCHING THE METAL FRAME AROUND THE DASH 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 12 13 ELECTRICAL COMPONENTS Solenoid Key Switch Removal Continued 2 5 Slide center dash panel up the steering column by snapping out the top and then rotating the panel out and up There is sufficient slack in the wiring to allow for this 3 Disconnect the wires from the key switch Do not allow wires to touch 4 Remove the key switch 4 1 Remove the key switch cap with a small flat blade screwdriver 4 2 Remove key switch from the dash by holding the key switch and turning the nut on the outside of the dash with a one inch socket wrench Remove the keyed washer with key switch Key Switch Installation 1 Reconnect wires to key switch See Section 11 Figure 11 2 Page 11 6 Coat the connectors with Battery Protector Spray Club Car Part No 1014305 to prevent corrosion Reverse removal procedures to install key switch in the dash Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place 1 Remove plastic cap and loosen screw on e
69. dip stick VENT until fully seated SHUT OFF Oil must be in Z the Safe Level Figure 10 3 Checking Engine Oil Figure 10 4 GasolineTank OIL VISCOSITY Choose the viscosity according to the temperature as shown Figure 10 5 Page 10 6 20 C 10 C 0 C 40 C SAE UWaUSAE 10W 40 gt ATTE m 40 Sy PF 14 F 32F 50 F 68 F 86 F 104 Figure 10 5 Oil Viscosity Chart NOTE e USING MULTI GRADE OILS 5W 20 10W 30 AND 10W 40 WILL INCREASE OIL CONSUMPTION CHECK OIL LEVEL MORE FREQUENTLY WHEN USING MULTI GRADE OILS Page 10 6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement PERIODIC MAINTENANCE Fueling Instructions FUELING INSTRUCTIONS Read DANGER and WARNING on pages 10 1 and 10 2 DANGER TURN KEY SWITCH TO OFF BEFORE REFUELING NEVER POUR GASOLINE INTO THE FUEL TANK WHEN THE 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 THE PUMP BEFORE AND DURING THE FUELING OPERATION IF THE VEHICLE HAS AN ALL WEATHER ENCLOSURE INSTALLED THE GAS TANK MUST BE PROPERLY VENTED AS SHOWN FIGURE 10 4 PAGE 10 6 TO AVOID THE POSSIBILITY OF FIRE CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE VEHICLE CAUTION TO ALLOW FOR EXPANSION DO NOT FILL HIGHER THAN ONE INCH FROM TOP OF THE FUEL
70. governor gear assembly snap into place CR 0 OG C NJ ore Insert shifter shaft from inside of left side casing Figure 16 72 Insert Shifter Shaft 10 Install and finger tighten the fifteen bolts 27 Figure 16 35 Page 16 14 that secure the left and right sides of the case together Then in sequence shown tighten the bolts to 17 ft lb 23 1 N m Figure 16 81 Page 16 33 11 Install axle tubes 75 and 76 and brake cluster assemblies if removed on the transaxle case Figure 16 5 Page 16 4 11 1 Make sure the mating surfaces of the axle tubes and the transaxle case are clean and free of oil grease or residue of any kind Page 16 30 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Unitized Transaxle Assembly Install differential bore in the let oy Insert the idler gear side case assembly into casing bore gears do not mesh Figure 16 73 Differential Gear Assembly Figure 16 74 Idler Gear Assembly Position shifter fork on synchronizer sleeve Mate tabs on oil guide with slots in casing and insert oil guide Cutaway view of shifter fork and synchronizer gear assembly being inserted as a unit into Figure 16 75 Oil Guide Figure 16 76 Synchronizer Ring Gear 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 31 UNITIZED TRANSAXLE Uni
71. in the SERVICE position Turn the fuel shut off valve to closed OFF and run the engine until fuel remaining in the carburetor and fuel lines is used up and the engine stalls Return the neutral lockout cam to the OPERATE position Page 14 22 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM Fuel Tank 2 Loosen do not remove the carburetor drain screw 11 Figure 14 7 Page 14 7 and drain fuel remaining in the carburetor bowl into an approved container then pour the fuel from the container into the fuel tank 3 Disconnect the fuel tank vent tube 6 Figure 14 16 Page 14 19 from the fuel tank vent nipple 4 Plug the fuel tank vent nipple so that it is air tight A slip on vinyl cap is recommended See following WARNING and CAUTION A WARNING e IF THE FUEL TANK IS DAMAGED REPLACE IT DO NOT ATTEMPT TO REPAIR IT SEE FOLLOWING TANK REMOVAL AND DISPOSAL PROCEDURE A CAUTION ADD ONLY UNLEADED GASOLINE TO THE TANK DO NOT PUT OIL INTO THE FUEL TANK FUEL TANK REMOVAL 1 Remove seat or lift bed to access engine compartment 2 Remove the rear body DS vehicle or the seat back support Carryall vehicle See Section 4 Body and Trim in the maintenance and service manual 3 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the SERVICE position 4 Turn fuel shut off valve to the closed OFF position Figure 14 21 Page 14 26 and ru
72. lightly with a plastic mallet until the cam seats against the retaining ring See following CAUTION A CAUTION DO NOT USE A METAL HAMMER TO TAP THE FIXED FACE HUB A METAL HAMMER WILL DAMAGE THE SHAFT DRIVEN CLUTCH INSTALLATION 1 To 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 yellow side facing out Figure 17 16 Page 17 12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 17 15 INDEX A accelerator cable installato 2 2 tes 14 13 rete randi Br iaa 14 13 pedal limit switch installation eeesceeeeeeeeeee 12 16 removal nter rates 12 16 TOSUING iced ii neci te tette 11 23 rod installation and adjustment 14 9 removal ns tate ee EM EE 14 9 air box Installation o eaput eun 14 15 removal asser eh ed Ho ce chs 14 15 air filler oon eset tee ee a ee 14 4 14 16 replacement 14 16 axle bearing installation nci cerco ct eee 16 6 removal 22 3 nie 16 5 shaft installation 16 7 tomen n 16 5 FEMOVA tee 16 5 ball bearing installation reor TER 13 3 battery e
73. lower hole at the back of the stiffener 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 A CAUTION MAKE SURE WIRE HARNESS IS ROUTED AWAY FROM MUFFLER 19 Place the governor guard 1 onto the throttle bracket and the 2 ended bolt Install the two torx screws 4 through the governor guard into the throttle bracket and tighten to 15 in Ib 1 7 N m Place the 3 8 flat washer 3 onto the 2 ended bolt and secure with nylon locknut 2 Tighten the nut to 50 in Ib 5 7 N m Figure 12 25 Page 12 24 20 Connect the spark plug wire to the spark plug 21 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 Battery Protector Spray Club Car Part No 1014305 OIL LEVEL SENSOR Read DANGER and WARNING on page 12 1 Testing the Oil Level Sensor See Test Procedure 21 Section 11 Page 11 33 Oil Level Sensor Removal See Oil Level Sensor Removal Section 13 FE290 Engine Page 13 24 Oil Level Sensor Installation See Oil Level Sensor Installation Section 13 FE290 Engine Page 13 24 BATTERY Read DANGER and WARNING on page 12 1 Page 12 26 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Battery DANGER DUE TO THE DANGER OF AN EXPLODING BATTERY WEAR A FULL
74. nuts to 25 in Ib 2 8 N m 3 Install the rear body on the vehicle if removed Install seat back support if removed See Section 4 Body and Trim in the maintenance and service manual 14 24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM Fuel Tank 4 Connect the vent tube 6 to the gas tank vent Figure 14 16 Page 14 19 Connect the fuel line 1 to the fuel tank shut off valve 15 Use a new clamp Figure 14 16 Page 14 19 6 Connect the black wire to one of the fuel level sending unit screws Connect the orange wire to the cen ter stud Figure 14 19 Page 14 24 and install flat washer lock washer and nut Tighten to 18 in Ib 2 0 N m 7 Slide the rubber boot over the stud Figure 14 19 Page 14 24 8 Add gasoline to the tank 9 Reconnect the battery positive cable first Tighten the terminals to 20 ft lb 27 1 N m e 10 Ensure that the wheels are chocked the Forward Reverse handle is in the NEUTRAL position and that the neutral lockout cam is in the SERVICE position 11 Check to be sure the fuel shut off valve on top of the gas tank is in the open ON position Figure 14 22 Page 14 26 12 Turn the key switch to the ON position and press the accelerator pedal to start the engine See following DANGER DANGER AFTER INSTALLING THE FUEL TANK AND ADDING GASOLINE CAREFULLY CHECK ALL FUEL LINES AND CONNECTIONS FOR LEAKS REPAIR ANY FUEL LEAKS BEFORE OPERA
75. 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 next scheduled oil change See Section 10 Periodic Maintenance Check all hardware for proper torque tightness Remove dip stick and clean Reinsert dip stick Oil must be in until fully seated the Safe Level Figure 13 106 Check Engine Oil Level Check engine oil level Figure 13 106 Page 13 48 15 1 Vehicle should be on a level surface when checking oil Do not overfill with oil Install a new or cleaned spark plug gap 0 027 to 0 031 inch 0 686 to 0 787 mm and connect plug wire to plug Connect battery cables positive cable first and tighten terminals to 20 ft lb 27 1 N m Adjust engine RPM setting See Engine RPM Adjustment Section 14 Fuel System Page 14 14 If initial checks indicate the engine is functional place the neutral lock out cam in OPERATE position Test drive vehicle to ensure all systems are functional and correctly adjusted 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 13 47 Service Specifications FE290 ENGINE SERVICE SPECIFICATIONS ITEM SERVICE LIMIT Crankshaft Axial Play 0 0137 inch 0 35 mm Crankshaft Crankpin Journal 1 3954 inches 35 444 mm Crankshaft PTO Side Journal 1 1783 inches 29 930 mm Crankshaft Flywheel Side Journal 1
76. on its outer or inner cir cumference contact surface so that it will go into place smoothly Oil Seal 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 installation Before a shaft passes through a seal apply a small amount of lubricant preferably high temperature grease to the lip to reduce rubber to metal friction Gasket O Ring When in doubt as to the condition of a gasket or O ring replace it with a new one To avoid leaks the mating surface around the gasket or O rings should be free of foreign matter and perfectly smooth Liquid Gasket and Non permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage Certain compounds can lead to premature gasket failure Use the non permanent locking agent Loctite Lock n Seal Blue or approved equivalent Ball Bearing Installation When installing a ball bearing the bearing race which has a press fit should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents damage Press on the inner race if the ball bearing is being pressed onto a shaft or on the outer race if the ball bearing is being pressed into a housing Press the ball bearing until it is
77. 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 technician It is the policy of Club Car Inc to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efficient service for vehicle owners Regional techni cal representatives 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 GA 30917 Attention Technical Services or contact a Club Car Technical Service Representative at 706 863 3000 ext 3580 2000 Club Car Inc Club Car Carryall ArmorFlex and Tranquility are registered trademarks of Club Car Inc This manual effective July 26 1999 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page A WARNING READ SECTION 1 SAFETY IN THE MAINTENANCE AND SERVICE MANUAL BEFORE ATTEMPTING ANY SER
78. replace the entire set of rings 4 Using a micrometer measure the thickness of both piston rings at several points around the rings Figure 13 54 Page 13 28 5 f either ring thickness is less than 0 0566 inch 1 438 mm replace the entire set of rings NOTE IT IS DIFFICULT TO MEASURE EXACTLY THE OIL RING THICKNESS REPLACE THE OIL RING WHENEVER THE COMPRESSION RINGS TOP AND SECOND ARE REPLACED Piston Pin Inspection 1 Using a micrometer measure the outside diameter of the piston pin at several points along its length Figure 13 55 Page 13 28 2 f 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 the piston at several points Figure 13 56 Page 13 28 4 Ifthe inside diameter exceeds 0 7439 inch 18 895 mm replace the piston Y Measure each position in 2 places 90 apart C 1 1 Measure each D D side in 2 places 90 apart Figure 13 55 Measure O D of Piston Pin Figure 13 56 Measure 1 0 of Piston Pin Hole 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 13 27 FE290 ENGINE Cylinder Block Connecting Rod Inspection 1 Clean and inspect the bearing surfaces of the connecting rod and cap Replace parts if scored 2 Using an inside micrometer or a telescoping gauge measure the inside diameter of the connecting rod
79. screw 17 and adjust the choke positioner 18 on the choke lever 6 Figure 14 15 Page 14 17 Move the positioner toward the choke button to increase choke engagement and away from the choke button to reduce choke engagement AIR BOX REMOVAL 1 Remove seat or lift bed to access engine compartment 2 Remove the air intake box from the vehicle by removing intake hose 16 and three screws 24 and washers 23 that mount the intake box to the vehicle Figure 14 15 Page 14 17 AIR BOX INSTALLATION NOTE THE INTAKE DUCT MUST BE IN PLACE BEFORE THE AIR BOX CAN BE INSTALLED 1 Check to be sure the intake seal 14 is seated correctly Figure 14 15 Page 14 17 The seal fits tightly onto the bottom side of the air box If seal is not in place moisture will enter the air intake sys tem 2 Place the air box assembly into vehicle and install three flat washers 22 and screws 23 from under side of air box mounting plate into air box Figure 14 15 Page 14 17 Tighten to 33 in Ib 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 intake duct 1 Remove the front body See Section 4 Body and Trim in the appropriate maintenance and ser vice manual 2 Remove the front left wheel See Section 8 Wheels and Tires in the appropriate maintenance and service manual Remove t
80. service limit of 0 4704 inch 11 949 mm replace the shaft STANDARD PITCH SPRING COILS NARROW PITCH SPRING f COLS TT Figure 13 35 Variable Pitch Valve Spring Figure 13 36 Cylinder Head Installation PUSH ROD INSPECTION 1 Support the rod in V blocks at each end of rod Position a dial gauge perpendicular to the rod Figure 13 34 Page 13 19 2 Turn the rod slowly and read the variation on the gauge 3 If the push rod is bent more than 0 012 inch 0 3 mm replace the push rod Page 13 18 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Cylinder Head CYLINDER HEAD Figure 13 37 Cylinder Head Installation Figure 13 38 Bolt Torque Sequence CYLINDER HEAD INSTALLATION Read DANGER and WARNING on page 13 1 1 Installation is the reverse of removal See Cylinder Head Removal Page 13 11 2 Making sure that each push rod 5 is in place between the rocker arm 3 and the tappet 6 as shown put the rocker shaft 2 into the posts through the rocker arm 3 and washer 4 Figures 13 36 and 13 37 3 Slide the washer 4 against 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 torque wrench tighten t
81. servicing or replacing axle shafts axle bearings or axle shaft oil seals If the unitized transaxle is to be removed from the vehicle then 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 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 3 UNITIZED TRANSAXLE Axle Shaft Axle Shaft Continued Kal e f E Figure 16 5 Differential Gear Case Axle Tubes Page 16 4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UNITIZED TRANSAXLE Axle Shaft AXLE SHAFT AND OIL SEAL REMOVAL 1 Loosen the lug nuts on the wheel to be removed 2 Place chocks at the front wheels and lift the rear of the vehicle with a floor jack Then place jack stands under the axle tubes to support the vehicle See WARNING on page 16 1 3 Remove the rear wheel and brake drum 4 Using 90 internal snap ring pliers 090 tip remove internal retaining ring 1 from axle tube Figure 16 3 Page 16 3 5 Carefully pull the axle shaft 2 straight out of the axle tube 6 Use a 16 inch 40 cm rolling head prybar Figure 16 4 Page 16 3 to remove the oil seal Insert the prybar under the seal and pull oil seal out Figure 16 6 Page 16 5 See following CAUTION A CAUTION DO NOT SCAR OR DAMAGE THE INSIDE SURFACES OF THE TUBE WHEN REMOVING THE OIL SEAL A DAMAGED TUBE MIGHT HAVE TO BE REPLACED Insert
82. shifter handle in the NEUTRAL position chock the wheels and disconnect battery negative cable first 2 Check for proper wiring and tight connections Figure 11 3 Page 11 7 3 Set the multimeter to 200 ohms Place the red probe on the common COM terminal green wire of the limit switch and place the black probe on the normally closed NC terminal orange wire of the limit switch 4 Make sure the battery is disconnected With the key switch in the OFF position the Forward Reverse handle in NEUTRAL and the accelerator pedal in the UP position the reading should be NO continuity With the accelerator pedal depressed the reading should be continuity If readings are incorrect replace the switch TEST PROCEDURE 6 SOLENOID Read DANGER and WARNING on page 11 1 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 first 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 11 23 TROUBLESHOOTING Test Procedures Test Procedure 6 Continued 2 Remove the electrical component box cover 3 Check that the wires are connected correctly and are tight If they are not rewire or tighten as necessary 4 Seta multimeter to 200 Q ohms Place the red probe on one of the small posts of the solenoid and place the black probe on the other small post The reading should
83. switch Figure 11 42 Page 11 32 5 Reconnect wires to key switch Make sure wires are connected correctly and are tight If they are not rewire or tighten as necessary 6 Reinstall dash panel in reverse order of removal KEY SWITCH ENGINE KILL V Figure 11 42 Test Key Switch Engine Kill Circuit TEST PROCEDURE 18 ENGINE KILL WIRE Read DANGER and WARNING on page 11 1 1 Place the neutral lockout cam in the OPERATE position put the Forward Reverse shifter handle in the NEUTRAL position chock the wheels and disconnect battery negative cable first 2 Disconnect white black wire bullet connector located at the engine RPM limiter Figure 11 35 Page 11 28 3 Connect red probe of multimeter to the male bullet terminal on the white black wire and connect the black probe to the vehicle frame Page 11 32 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Test Procedures 4 Turn the key switch ON place the Forward Reverse handle in FORWARD and depress the accelerator pedal There should be NO continuity If there is continuity check for worn insulation on the white black wire that is allowing the wire to ground to the vehicle frame TEST PROCEDURE 19 REVERSE BUZZER LIMIT SWITCH Read DANGER and WARNING on page 11 1 NOTE KEEP THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 19 The reverse buzzer limit switch is located on the For
84. the Forward Reverse shifter assembly which is activated by a neutral lockout cam and a limit switch that is located in the electrical component box which is activated by the accelerator pedal Figure 11 9 Page 11 10 M FORWARD REVERSE M ASSEMBLY we gt NEUTRAL LOCKOUT KEY PO LIMIT SWITCH SWITCH 2 p ACCELERATOR PEDAL LIMIT SWITCH ORANGE SOLENOID Figure 11 9 Neutral Lockout Circuit For the convenience of the trained 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 inch 10 mm and then rotated one half turn until it snaps into place the cam will be in the SERVICE position Figure 11 10 Page 11 11 When the cam is in the SERVICE position it will allow the technician to run the engine in NEUTRAL for certain maintenance procedures With the cam in this position the vehicle will not operate if the Forward Reverse handle is placed in either the FORWARD or REVERSE position To put the neutral lockout cam back into the OPERATE position pull the cam out approximately 3 8 inch 10 mm and rotate one half turn until it snaps back into place Figure 11 11 Page 11 11 See following WARNING and NOTE A WARNING WITH THE CAM IN THE SERVICE POSITION AND THE ENGINE RUNNING THE VEHICLE MAY MOVE SUDDENLY IF THE FORWARD REVERSE HANDLE IS SHIFTED OR ACCID
85. the connections are good and the reading is incorrect repair or replace the wire 11 22 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Test Procedures SWITCH STARTER CIRCUIT N Figure 11 29 Test Key Switch Engine Starter Circuit TEST PROCEDURE 4 KEY SWITCH STARTER CIRCUIT Read DANGER and WARNING on page 11 1 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 first 2 Remove the center dash assembly See Key Switch Removal Section 12 Electrical Components Page 12 13 3 Ensure that the wires are connected correctly and are tight If they are not rewire or tighten as necessary 4 Insert the key and turn the switch to ON Place the red probe of the multimeter on the No 2 terminal and the black probe on the No 1 terminal of the key switch The reading should be continuity If the reading is incorrect replace the key switch Figure 11 29 Page 11 23 TEST PROCEDURE 5 ACCELERATOR PEDAL LIMIT SWITCH Read DANGER and WARNING on page 11 1 The accelerator pedal limit switch is the top switch located in the electrical component box There is an 18 gauge green wire and an 18 gauge orange wire connected to this limit switch 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse
86. vehicle then lift snubber into the snubber bracket Figure 16 89 Driven Clutch Position floorjack under TRAILER HITCH trailer hitch bracket then BRACKET lower vehicle until front spring and shackles are in alignment Continue using floorjack to lower or raise the vehicle in order to align the rear shackles and leaf springs before installing bolts washers and nuts Insert bolts through SV leaf springs and A front mounts on both sides of vehicle Install washers and nuts on bolts Figure 16 91 Leaf Springs Figure 16 92 Leaf Springs and Shackles 19 Connect the engine kill switch wire 18 gauge white black stripe to the bullet connector at the lower right front of the engine Figure 16 94 Page 16 37 20 Connect the oil level sensor wire 18 gauge yellow to the jumper wire Figure 16 95 Page 16 37 21 Connect the 6 gauge white wire to the F2 post the 6 gauge black ground wire to the A2 post and tighten to 48 in Ib 5 4 N m Connect the 16 gauge yellow wire to the DF post on the starter generator and tighten to 30 in Ib 3 4 N m Figure 16 96 Page 16 37 Page 16 36 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Unitized Transaxle Installation 22 Position the shifter cable in the shifter cable mounting bracket on the transaxle and tighten the mounting nuts to 22 ft lb 29 8 N m Connect shifter cable rod end to the shifter arm Figure 16 97 Page 16 38
87. wear line replace all four brushes Figure 12 5 Page 12 4 Brush Spring Inspection and Replacement 1 Visually inspect springs Replace all four springs if any spring is discolored from heat straw or bluish in color 2 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 replace all four springs Figure 12 6 Page 12 5 See following CAUTION A CAUTION WHEN CHECKING BRUSH SPRING TENSION DO NOT PUSH SPRINGS BEYOND THE POINT THEY WOULD NORMALLY BE IF THERE WERE NEW BRUSHES INSTALLED EXERTING EXCESSIVE FORCE OR PUSHING BRUSH SPRINGS BEYOND THEIR NORMAL MAXIMUM EXTENSION POINT WILL DAMAGE SPRINGS 12 4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Starter Generator Replace springs which apply a force of less than 24 ounces Figure 12 6 Brush Spring Tension Test Starter Generator Assembly 1 Connect the brush wires to the holders using four lockwashers 26 and four screws 25 making sure the crossover leads are connected also Tighten the screws to 31 in Ib 3 5 N m Figure 12 4 Page 12 4 2 To prevent contact between the brushes and commutator as the commutator is installed and possible damage to the brushes lift the brush springs out of the notches in the brushes and pull the brushes back from the
88. wires from the reverse buzzer limit switch 4 located on the back of the Forward Reverse shifter assembly Figure 12 19 Page 12 18 3 Remove the two nuts 2 and washers 6 from the neutral lockout limit switch 5 then remove the neu tral lockout limit switch Do not disconnect the wires 4 Remove the spacers 9 from the screws 4 and then remove the reverse buzzer limit switch Reverse Buzzer Limit Switch Installation 1 Install the reverse buzzer limit switch 4 and then install two spacers 9 Figure 12 19 Page 12 18 2 Install the neutral lockout limit switch 5 two washers 6 and two nuts 2 Torque to 4 in Ib 0 5 N m A WARNING DO NOT OVER TIGHTEN THE RETAINING NUTS IF THE NUTS ARE OVER TORQUED THE LIMIT SWITCHES COULD BE DAMAGED 3 Place the Forward Reverse handle in REVERSE 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 12 19 Page 12 18 5 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 Battery Protector Spray Club Car Part No 1014305 6 Turn the key switch ON and shift the Forward Reverse handle to REVERSE The buzzer should sound OIL WARNING LIGHT Read DANGER and WARNING on page 12 1 Testing the Oil Warning Light See Test Procedure 22 Secti
89. with the weight pins on the secondary weights pointing away from the primary weights The wave washers should be between the primary and sec ondary weights Figure 17 13 Page 17 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 Figure 17 14 Page 17 10 Install the weight assemblies into the slots in the hub casting Figure 17 9 Page 17 8 Make sure the mounting pin protrudes an equal amount on each side of the weights when the assemblies are in posi tion Figure 17 14 Page 17 10 Install white washers on each side of pin Pin should protrude an equal amount on each side Figure 17 14 Install White Washers 12 Install the 1 4 20 screws and washers 2 and tighten them to 10 ft lb 13 N m Figure 17 5 Page 17 6 17 10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TORQUE CONVERTER Drive Clutch NOTE MAKE SURE THERE IS AT LEAST A MINIMUM GAP OF 0 020 INCH 0 51 MM BETWEEN EACH END OF THE MOUNTING PIN AND THE MOUNTING SCREW 13 Install one drive button take up spring 13 1 Install spring on right side of any one of the three button mounting posts when looking into the interior of the clutch cover with the rib at the twelve o clock position as shown Figure 17 15 Page 17 11 14 While compressing the take up spring install the drive b
90. with two washers 6 and nuts 2 Figure 12 19 Page 12 18 Tighten to 5 in Ib 0 6 N m Place the Forward Reverse handle in REVERSE to make sure that both switches actuate See following WARNING A WARNING DO NOT OVER TIGHTEN THE RETAINING NUTS IF THE NUTS ARE OVER TORQUED THE LIMIT SWITCHES COULD BE DAMAGED 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 12 17 ELECTRICAL COMPONENTS Neutral Lockout Cam Neutral Lockout Limit Switch Installation Continued 2 Connect the black wire to common COM terminal the green wire to the normally open NO terminal and the white wire to the normally closed NC terminal of the neutral lockout limit switch Figure 12 20 3 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 Battery Protector Spray Club Car Part No 1014305 4 Place the Forward Reverse handle in NEUTRAL The neutral lockout cam should be in the OPERATE posi tion Make sure everyone is clear of the vehicle Turn the key switch ON The engine should not crank when depressing the accelerator If the engine does crank turn the key switch OFF and re adjust the shift linkage 5 Test drive the vehicle in both FORWARD and REVERSE for proper operation FORWARD REVERSE ASSEMBLY FORWARD REVERSE ASSEMBLY REVERSE BUZZER NEUTRAL LOCKOUT LIMIT SWITCH LIMIT SWITCH O IX Vig Ee Figure 12 19 Forward
91. 1 N m Figure 16 86 Page 16 35 Install the governor cable bracket on transaxle case Tighten the mounting screws to 134 in Ib 15 1 Figure 16 87 Page 16 35 Install governor lever arm on governor shaft Figure 16 88 Page 16 35 With the governor lever arm loose on the governor shaft turn the governor arm shaft counterclockwise until it stops Then pull the governor lever arm rearward until the carburetor throttle is in the wide open throttle WOT position Figure 16 88 Page 16 35 While holding the arm and shaft in the fully counterclockwise position tighten the governor arm lever nut to 35 in Ib 4 0 N m Install the key onto the input shaft Figure 16 89 Page 16 36 Position the driven clutch on the transaxle input shaft and install the washer yellow side facing out and mounting bolt Tighten the mounting bolt to 14 ft lb 19 0 N m Figure 16 89 Page 16 36 Install the drive belt See Section 17 Torque Converter Page 16 34 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Unitized Transaxle Installation 13 Remove the blocks from under the engine and roll the powertrain into position under the vehicle Then lift the front of the powertrain and place the snubber into the snubber bracket in the vehicle frame Figure 16 90 Page 16 36 14 Position the floor jack under the rear frame crossmember and raise the jack high enough to support the vehicle Make sure the ve
92. 13 15 NOTE THE VALVE STEM AND GUIDE MUST BE IN GOOD CONDITION OR STEP 5 WILL NOT BE VALID 6 Ifthe valve seating surface is not correct repair the seat 7 Pitted or worn valve seats can be resurfaced See Valve Seat Repair Make sure to lap the valves to the seats after refacing 0 0197 0 0433 ee 50 1 10 mm mm Resurface valve seat with 45 cutter 32mm exhaust 35mm intake Figure 13 23 Check Mark on Valve Head Figure 13 24 Recondition Valve Seat Valve Seat Repair A CAUTION e IF YOU ARE UNFAMILIAR WITH THE FOLLOWING PROCEDURES CLUB CAR SUGGESTS THAT THE CYLINDER HEAD BE TAKEN TO A PROFESSIONAL ENGINE MACHINE SHOP FOR RECONDITIONING 1 Clean the cylinder head thoroughly See Cylinder Head Cleaning Page 13 13 2 Recondition the valve seats with the valve seat cutters 45 x 32 mm Exhaust Seat 45 x 35 mm Intake Seat 2 1 Using Prussian Blue check the seats for good contact all 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 more than 0 079 inch 2 0 mm the seating surface should be resurfaced 2 4 Resurface the valve seat with a 45 cutter 1 32mm Exhaust Valve Seat Cutter Club Car Part No 1016553 and 35mm Intake Valve Seat Cutter Club Car Part No 1016554 removing only eno
93. 13 88 Page 13 39 2 The final finishing dimensions are as follows Figure 13 88 Page 13 39 A 1 3775 1 3779 inches 34 989 35 00 mm B 0 110 0 126 inch 2 80 3 20 mm radius two places C 1 12 inches maximum 28 4 mm D 1 1811 1 1831 inches 30 0 30 05 mm 3 The connecting rod journal A must be concentric and cylindrical within 0 0002 inch 0 005 mm at full indicator reading Figure 13 88 Page 13 39 4 Finish should be very smooth Use a super fine finishing stone Figure 13 88 Crankshaft Finishing Dimensions Page 13 38 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Crankshaft and Counterbalance OIL SCREEN Cil Screen Removal 1 Remove the two bolts 1 to take out the oil screen plate 2 and the oil screen 3 Figure 13 89 Page 13 40 2 Clean the oil screen thoroughly with a high flash point solvent then dry the screen Oil Screen Installation 1 To install the oil screen reverse the removal procedure 2 Tighten bolts to 30 in Ib 3 4 N m Figure 13 89 Oil Screen Removal Figure 13 90 Ball Bearing Removal BALL BEARING Ball Bearing Removal 1 Remove the oil seal in the crankcase cover See following NOTE NOTE NEVER REUSE AN OIL SEAL REPLACE THE OIL SEAL WITH A NEW ONE 2 Place 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
94. 16 33 See following CAUTION Install shifter shaft and governor shaft seals into their seats Position the governor gear shaft tool Club Car Part No 101933101 over the shaft bore in the case then insert long end of the governor gear shaft through tool and into bore tap governor gear shaft through the Press oil seal tool and into bore into right side in left side case until end of shaft E 4 YON EON is even with end 4 fp 7 of tool O v Figure 16 67 Install Seals Figure 16 68 Governor Gear Shaft 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 16 29 UNITIZED TRANSAXLE Unitized Transaxle Assembly Continued Unitized Transaxle Assembly A CAUTION USE ONLY THREE BOND NO 1215 SEALANT TO SEAL CASE DO NOT USE A SUBSTITUTE e IF THE TWO SIDES OF THE CASE CANNOT BE EASILY CLOSED OR DO NOT MAKE COMPLETE CONTACT DO NOT FORCE THEM TOGETHER CHECK THAT ALL INTERNAL COMPONENTS ARE PROPERLY SEATED AND THEN TRY AGAIN SLEEVE Position sleeve between T x flyweight brackets C GOVERNOR GEAR WASHER Insert washer and governor gear complete with sleeve onto governor shaft INTERIOR WASHER GOVERNOR ARM EXTERIOR WASHER INSIDE VIEW OF LEFT SIDE CASING Figure 16 71 Pivot Arm KW 0 e gt EOE y NS WOO 0 Push onto shaft until you hear the
95. 16 64 Page 16 27 6 Position the output ring gear 81 Figure 16 5 Page 16 4 on the carrier case visually aligning the dowel hole in the carrier case with the dowel pin in the ring gear Then using a plastic or rubber mallet tap the ring gear into place on the dowel pin as shown Figure 16 65 Page 16 27 7 Apply Loctite 277 on the threads of the eight mounting bolts and install them through the ring gear car rier case and into the carrier case cover Tighten the bolts to 18 ft lb 24 4 N m in the sequence shown Figure 16 66 Page 16 27 Position idler gear and thrust plate in carrier case Insert differential gear into differential gear carrier case DIFFERENTIAL GEAR CARRIER CASE x then tap differential pin into carrier case through thrust plate and idler gear then continue to tap differential pin about another inch past idler gear Figure 16 61 Differential Gear Figure 16 62 Idler Gear Page 16 26 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Position second thrust plate and second idler gear in differential gear carrier case then continue tapping pin through second idler gear and thrust plate until pin is flush with outside of housing Figure 16 63 Second Idler Gear Align the dowel pin in the ring gear with dowel pin hole in differential gear case DOWEL PIN then tap ring gear onto the differential gear case Figure
96. 16 65 Ring Gear Component Assembly Position differential gear and thrust plate in carrier case cover then while holding gear and thrust plate in position rotate cover and position it on carrier case Apply a few drops of loctite to the ends of the eight retaining bolts before installing them In sequence shown below torque retaining bolts to 18 ft Ib 24 4 N m Figure 16 66 Retaining Bolts 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 16 27 UNITIZED TRANSAXLE Unitized Transaxle Assembly GOVERNOR GEAR ASSEMBLY The governor gear is not assembled before installing it in the unitized transaxle case The governor gear shaft is installed into the case and then the rest of the governor gear assembly is installed on the shaft Pro ceed with unitized transaxle assembly UNITIZED TRANSAXLE ASSEMBLY Read DANGER and WARNING on page 16 1 NOTE ALTHOUGH THE FOLLOWING DRAWINGS SHOW THE TRANSAXLE BEING ASSEMBLED IN AN UPRIGHT POSITION LAYING THE TRANSAXLE ON ITS LEFT DRIVER SIDE WILL SIMPLIFY THE ASSEMBLY PROCESS 1 Make sure both parts of the case are clean and free of any contaminants Make sure the machined mating surfaces are free of residue and are not scratched or damaged in any way 2 Puta light coating of clean transmission oil on the outside edge of the seal to make installation easier Press two new oil seals
97. 2 with the smooth collar toward the synchronizer ring as shown Figure 16 42 Page 16 18 The input gear should seat in the synchronizer ring Install the thrust washer 53 and then the spring washer 39 The spring washer should be oriented with the raised center toward the end of the shaft Figure 16 42 Page 16 18 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 A CAUTION e APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRESSURE ANYWHERE ELSE WILL DAMAGE THE BEARING 10 11 12 13 On the other end of the input shaft install the thrust washer 41 and the synchronizer ring 45 The smooth collar of the synchronizer ring should be oriented toward the clutch hub and the notches in it should mate with the synchronizer inserts as shown Figure 16 42 Page 16 18 Install the narrow bearing 44 wide bearing 43 and input gear 42 onto the shaft The smooth collar of the input gear should be oriented toward the synchronizer ring as shown Figure 16 42 Page 16 18 The gear should seat inside the ring Install thrust plate 41 onto the shaft and the dowel pin 50 into the shaft as shown Figure 16 42 Page 16 18 Install the spur governor drive gear 40 onto the shaft with either side down Mate the notch in the gear with the dowel pin as shown Figure 16 42 Page 16 18
98. 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11 31 TROUBLESHOOTING Test Procedures Test Procedure 16 Continued 3 Disconnect wires from the limit switch and test the limit switch for continuity Place the red probe of the multimeter the common COM terminal white black wire of the limit switch Place the black probe on the normally open NO terminal black wire of the limit switch Without the lever depressed the reading should be NO continuity Depress the lever and the reading should be continuity If either reading is incorrect replace the limit switch Figure 11 41 Page 11 31 4 Reconnect wires to limit switch and check for tight connections TEST PROCEDURE 17 KEY SWITCH ENGINE KILL CIRCUIT Read DANGER and WARNING on page 11 1 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 first 2 Remove the center dash assembly See Key Switch Removal Section 12 Electrical Components Page 12 13 3 Disconnect wires from the M and M terminals 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 switch turned ON the reading should be NO continuity If the either reading is incorrect replace the key
99. 23 disassembly rre t ees 16 20 T test procedure accelerator pedal limit switch 11 23 batiery s neq euo 11 19 11 34 engine kill circuit 11 28 11 31 engine kill circuit wire eseese 11 32 T el gauge uite diee trt irn 11 36 fuel level sending unit 11 35 TUS ose otis 11 18 ground straps sssssse 11 21 hour gauge RR 11 37 ignition Coll 11 30 ignitiori test meten 11 29 key switch engine kill circuit 11 32 low oil warning light esses 11 34 neutral lockout M 11 34 ligit SWITCH iere reinen 11 24 oil level sensor eene 11 33 reverse bUZZer 11 33 reverse buzzer limit switch 11 33 RPM limiter i iet 11 29 SOlenold uir RR ERRARE 11 23 Fage 4 2000 FE290 Gasoline Vehicle Maintenance and Service Manual INDEX starter generator 11 25 11 27 voltage regulator 11 27 Wire CODLtIDUlly riot tee n tete 11 27 test procedures index of 11 18 testing circuit testing 11 12 engine ignition circuit seeeeeeee 11 12 fuel gauge sending unit Circuit 11 1
100. 3 6 gap adjustment 13 7 14 4 installation i iit RR Ds 13 7 removal hs dana nies aneir 13 6 TESTING audiet ec cmt eed er cer epe teda 13 7 specifications engine service eese 13 48 liquid capacities 10 5 Torque ect pee ear 13 49 starter generator atmalure RR 12 5 ground test 12 9 armature inspection 12 7 assembly taie ere 12 5 12 10 bearing clearilng wii een RR 12 6 INSPOCHON iicet e A 12 6 eie RI 12 7 belt tension adjustment 12 12 brush spring INSPECCION 12 4 replacement 12 4 le Ui 12 3 Inspection 3 0 ute tee 12 4 replacement seen 12 4 COmmb ltator 3 rer earn de 12 5 armature replacement 12 8 cleanirig pieno 12 8 inspection 12 8 disassembly 5 09 2 e inte 12 3 12 5 field coil iriSDection deeds 12 9 removal cese RI 12 7 installation 2 cte zs 12 11 removal 5 12 2 IGWOIK iude etel pei 12 9 TOSUNG 11 25 11 27 storage vehicle storage 2e reete Ree 14 22 synchronizer gear assembly enn nomeo re 16
101. 4 and retainer 5 into the cup of the idler bearing 6 Figure 17 5 Page 17 6 Install the spacer 13 onto the shaft of the fixed face Figure 17 5 Page 17 6 RON Install a new spiral backup ring 12 in each end of the bore of the moveable face assembly 14 Figure 17 5 Page 17 6 6 Install the moveable face assembly 14 onto the shaft of the fixed face assembly 7 Figure 17 5 Page 17 6 CAUTION TO AVOID DAMAGING THE SPIRAL BACK UP RINGS BE VERY CAREFUL WHEN INSTALLING THE MOVEABLE FACE 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 17 9 TORQUE CONVERTER Drive Clutch Drive Clutch Assembly Continued Insert pin through primary weight then install wave washer onto pin P PRIMARY WEIGHT Install the secondary weight onto pin installed on same side as small pin CR Ed EI 9 yn Figure 17 12 Install Pin and Washer Figure 17 13 Install Secondary Weight 6 1 Rotate the moveable face assembly clockwise while installing it onto the shaft 6 2 Install the retaining ring 3 Figure 17 5 Page 17 6 Install the primary weights on the mounting pins Figure 17 12 Page 17 10 8 Install a wave washer on each mounting pin Make sure that the concave side of the washer faces the 10 11 side of the primary weight with the small guide pin protruding from it Figure 17 12 Page 17 10 Install the secondary weights onto the mounting pins
102. 40 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Forward Reverse F amp H Shifter Cable TRANSMISSION SHIFTER LEVER REFERENCE TRANSMISSION CABLE SUPPORT BRACKET Figure 16 106 F amp R Shifter Cable F amp R SHIFTER CABLE ADJUSTMENT With the shifter lever of the unitized transaxle in the NEUTRAL position Figure 16 106 Page 16 41 the Forward Reverse handle 21 should be straight up For minor adjustments the nut 1 may be loosened and the ball joint socket 2 rotated to get the proper adjustment Figure 16 106 Page 16 41 See following CAUTION CAUTION e 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 F amp R SHIFTER WILL NOT OPERATE PROPERLY For 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 shift lever of the transaxle will also be in the NEUTRAL position Figure 16 105 Page 16 40 Retighten nuts to 22 ft lb 29 8 N m 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 41 SECTION 17 TORQUE CONVERTER DANGER e GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM VEHICLE AND SERVICE AREA SERVICE ONLY IN A WELL VENTILATED AREA DO NOT OPERATE VEHICLE
103. 4162 Axle Shaft 17 mm Socket 3 8 inch Drive 7 16 inch Combination Wrench 1 2 inch Combination Wrench 9 16 inch Combination Wrench 11 16 inch Combination Wrench 2 17 mm Combination Wrench Small Flat Blade Screwdriver Medium Flat Blade Screwdrivers 2 No 2 Phillips Head Screwdriver 1 4 inch Nut Driver 5 16 inch Nut Driver Small Knife or Wire Snippers Governor Gear Shaft Installation Tool Club Car Part No 101933101 LUBRICATION There are two plugs located on the right driven clutch side of the unitized transaxle Figure 16 2 Page 16 2 When the vehicle is on a level surface the upper plug is used as a lubricant level indicator Lubricant level should be even with the bottom of level indicator hole The lower plug is used for draining lubricant from the transaxle When draining lubricant both plugs should be removed to allow the lubricant to drain faster Be sure the drain plug and gasket are cleaned and reinstalled before filling the transaxle with new lubricant Tighten the plug to 20 ft lb 27 1 N m Use a funnel when filling the transaxle through the lubricant level indi cator hole Fill with 27 oz 8 liter 80 90 WT API Class GL or 80 90 WT AGMA Class 5 EP gear lubricant or until lubricant begins to run out of the level indicator hole Figure 16 3 Retaining Ring AXLE SHAFT Figure 16 4 Rolling Head Prybar Read DANGER and WARNING on page 16 1 Removal of the unitized transaxle is not required for
104. 6 The unitized transaxle is equipped with a slot for prying the housing apart Use the slot to open the case Pull the housing apart making sure all gear assemblies inside the transaxle stay together in one either side of the case See following CAUTION A CAUTION TO PREVENT DAMAGE TO THE MATING SEAL SURFACES OF THE CASE USE CARE WHEN SEPARATING THE HALVES 7 Turn the case section containing the gearing on edge as shown Figure 16 36 Page 16 15 While holding it in this position gently rock all the gear assemblies to slightly loosen them in their seating A CAUTION TO PREVENT DAMAGE TO THE GEARS USE EXTREME CARE WHEN HANDLING THEM 8 When all the gear assemblies are slightly loosened remove the differential gear case assembly by gently rocking it while pulling it from the case Figure 16 37 Page 16 15 Hold case upright and gently rock each gear assembly until all are DIFFERENTIAL slightly loosened in their seatings GEAR CASE ASSEMBLY While gently rocking intermediate gear assembly pull it from its seating Figure 16 36 Loosen Gears Figure 16 37 Remove Differential Gear Case 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 15 UNITIZED TRANSAXLE Unitized Transaxle Disassembly Unitized Transaxle Disassembly Continued 9 10 11 12 13 14 15 Continue to rock and loosen the remaining gear assemblies until the intermediate gear assembly
105. 66 mm Oil Pump Housing Depth MAX 0 4004 inch 10 170 mm Oil Pump Shaft Bearing 1 0 MAX 0 5028 inch 12 770 mm Rocker Shaft MIN 0 4704 inch 11 949 mm Rocker Arm Bearing 1 0 MAX 0 4754 inch 12 074 mm Valve Seat Angle IN EX Standard 45 Valve Seat Width Standard 0 0197 to 0 0433 inch 0 50 to 1 10 mm Valve Seat Width MAX 0 075 inch 1 9 mm Service Specifications Chart continued on next page Page 13 48 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE ITEM SPEC Service Specifications SERVICE LIMIT Valve Face Angle IN EX Standard 45 Valve Margin IN EX MAX 0 024 inch 0 6 mm Valve Clearance IN EX Standard 0 0047 inch 0 12 mm Intake Valve Stem O D MIN 0 2728 inch 6 930 mm Exhaust Valve Stem Valve Guide Hole Intake O D MIN 0 2722 inch 6 915 mm 0 2781 inch 7 065 mm Valve Guide Hole Exhaust 0 2781 inch 7 065 mm Valve Spring Free Length 1 2894 inches 32 75 mm Oil Pump Shaft 0 4971 inch 12 627 mm Outer Rotor 1 5932 inches 40 467 mm Outer Rotor Width 0 3905 inch 9 92 mm Relief Valve Spring Free Length 0 748 inch 19 0 mm Counterbalancer Weight Bearing 1 0283 inches 26 118 mm Support Shaft 1 0199 inches 25 907 mm
106. 7 Torque Converter 5 Damaged drive clutch Section 17 Torque Converter 6 Damaged driven clutch Section 17 Torque Converter T Damaged starter generator pulley Section 12 Electrical Components Starter Generator Page 12 2 8 RPM setting is incorrect Section 14 Fuel System see Engine RPM Adjustment Page 14 14 Torque converter does not 1 Drive belt is worn cracked Section 17 Torque Converter shift smoothly glazed or frayed 2 Drive clutch malfunction Section 17 Torque Converter 3 Driven clutch malfunction Section 17 Torque Converter 4 Governor is sticking Section 16 Unitized Transaxle Engine won t stop running 1 Kill circuit wire is disconnected Section 11 Troubleshooting from the ignition coil Test Procedure 12 2 Accelerator pedal linkage out of adjust Section 14 Fuel System ment causing engine kill limit switch not to operate 3 Carburetor is too lean check main and Section 14 Fuel System pilot jet sizes 4 Carburetor throttle stop screw misadjusted Section 14 Fuel System AS SEEN FROM PASSENGER SIDE OF VEHICLE negative eT Cable first BEFORE WORKING ON VEHICLE Figure 11 1 12 Volt Battery Disconnect ELECTRICAL SYSTEM The electrical system on the FE290 gasoline vehicle is 12 volts DC with negative ground to frame and consists of seven readily identifiable circuits Starter Circuit Reverse Buzzer Circuit Gener
107. 7 low oil warning circuit esses 11 16 neutral lockout circuit csecsen 11 17 reverse buzzer circuit 11 15 Spark plug ettet 13 7 starter circuit and generator circuit 11 12 starter generator ground test 12 9 tires pressule repere ex m gutes 10 5 tools See service tools torque converter troubleshooting 2 2 17 3 transaxle see unitized transaxle troubleshooting torque converter 17 3 vehicle troubleshooting guide 11 2 U unitized transaxle assembly 3 peint amete 16 28 diSassembly erii ctt tees 16 14 inspection of components 16 22 installation Sete 16 34 l bricatiori 2 eee hee 16 3 removal 2 24 dni udis 16 7 CI ue T EIE 16 2 V valve quides tct 13 12 INSPOCHON 3 nit n orbe het 13 12 replacement 13 12 valve seat INS POCUON are 13 13 ET TEE 13 14 valve spring INSPOCUON iieri arae aana 13 17 valve intake and exhaust clearance check and adjustment 13 20 INSPOCUON et tace eed 13 16 inSt llatiori zoo aa 13 17 rertioval sent einn 13 10 voltage regulator inistallatior ei DEI 12 12 removal etae 12 12 testing eh odere D toes 11 27 wire continu
108. 811 to the wedge attachment tool and pull the bearing off of the end of the armature shaft Support the armature so that it will not drop when the bear ing is removed Figure 12 10 Page 12 7 2 Discard the bearings 3 Slide the bearing retainer 32 off of the output end of the shaft Figure 12 8 Page 12 6 PULLER Support A of bearing I Press on armature LS P 7 H WEDGE D ATTACHMENT Pai PRESSRAM TS TOOL Use a 1 2 inch woe 2 Socket or pipe Use a 1 2 inch ATTACHMENT socket or pipe TOOL BEARING IS SECTIONED FOR CLARITY Figure 12 10 Bearing Removal Field Coil Removal 1 Remove the retaining nut from each field coil terminal and slide the insulator out of the slots in the housing Remove the four pole piece screws from the housing Remove the four pole pieces from inside the housing Remove the field coils from the inside of the housing Figure 12 11 Page 12 8 See following NOTE NOTE DO NOT REMOVE THE INSULATORS OR THE FIELD COILS UNLESS AN ELECTRICAL TEST INDICATES THAT IT IS NECESSARY FIGURE 12 11 PAGE 12 8 SEE SECTION 11 TEST PROCEDURE 8 PAGE 11 25 Visual Inspection of Armature Obvious defects can be seen by examining the armature If an armature has frayed or charred insulation b
109. AISING THE BED DO NOT CLOSE BED UNTIL ALL PERSONS ARE CLEAR OF CARGO BED AREA KEEP HANDS CLEAR OF CRUSH AREA BETWEEN BED AND SEAT BACK SUPPORT DO NOT DROP CARGO BED LOWER GENTLY AND KEEP ENTIRE BODY CLEAR FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SEVERE PERSONAL INJURY WARNING CONTINUED ON NEXT PAGE 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11 1 General Information TROUBLESHOOTING A WARNING LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING SET THE PARK BRAKE WHEN LIFTING THE FRONT OF THE VEHICLE UNLOAD THE CARGO BED AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LB 454 KG MINIMUM 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 GENERAL INFORMATION Section 11 contains the information required to correctly troubleshoot the vehicle A troubleshooting guide is provided for general troubleshooting For issues pertaining solely to the electrical system proceed to Circuit Testing on page 11 12 In addition to troubleshooting this section contains general information on the electrical system and the nine circuits of the electrical system TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difficulties should they occur The guide
110. CE position put the Forward Reverse handle in NEUTRAL chock the wheels and disconnect the battery negative cable first 2 Remove the access panel on a DS Golf Car or Villager 4 vehicle lift the cargo bed on a Turf or Carryall vehicle See WARNING on Page 12 1 3 Make sure the two pivoting screws 5 on the mounting bracket are finger tight The carriage bolt 11 and hex nut 12 are to be finger tight also Figure 12 14 Page 12 11 4 Push the starter generator down so it is at the lowest part of its adjustment travel With the starter gen erator belt fully in place around the drive clutch pulley install 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 starter generator by passing the pry bar under the exhaust header 6 While holding the pry bar measure the belt tension using a Krikit gauge 1 available at NAPA Auto Parts stores or equivalent Proper tension for a new starter generator 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 ft lb 16 3 N m Tighten the two pivot bolts 5 and hex nuts 7 to 23 ft lb 31 2 N m Figure 12 14 Page 12 11 See following CAUTION A CAUTION REMOVE PRY BAR BEFORE STARTING ENGINE 8 Connect
111. CH ring pliers remove retaining ring CAM PULLER Figure 17 17 Remove Retaining Ring Figure 17 18 Driven Clutch Disassembly 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 17 13 TORQUE CONVERTER Driven Clutch Driven Clutch Disassembly Continued 3 Remove the spring 5 Figure 17 16 Page 17 12 4 Retain the key 3 5 Slide the moveable face 7 off the fixed face shaft 8 Figure 17 16 Page 17 12 DRIVEN CLUTCH INSPECTION 1 Inspect the cam 4 for excessive wear Replace it if necessary Figure 17 16 Page 17 12 2 Inspect the drive buttons 6 for excessive wear Replace if necessary To remove the drive buttons remove the socket head cap screws and then the buttons Figure 17 16 Page 17 12 3 Inspect the smooth surface on the fixed and moveable face assemblies Assemblies must be replaced if surfaces are worn more than 0 060 inch 1 5 mm 4 Inspect the bronze bearing in the moveable face If the bearing bore diameter is more than 1 384 inches 35 15 mm the entire moveable face assembly must be replaced 5 Inspect the shaft of the fixed face assembly There should be no measurable wear Replace the shaft if itis worn scratched or damaged DRIVEN CLUTCH ASSEMBLY 1 Place the three drive buttons 6 in position Apply one drop of Loctite 222 to each of the socket head cap screws and then install and tighten them to 8 in Ib 0 9 N m Figure 17 16 Page 17 12 Slide the movea
112. CTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR ANY OTHER METAL COMPONENT TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FOR VEHICLES WITH CARGO BEDS REMOVE ALL CARGO BEFORE RAISING THE BED DO NOT CLOSE BED UNTIL ALL PERSONS ARE CLEAR OF CARGO BED AREA KEEP HANDS CLEAR OF CRUSH AREA BETWEEN BED AND SEAT BACK SUPPORT DO NOT DROP CARGO BED LOWER GENTLY AND KEEP ENTIRE BODY CLEAR FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SEVERE PERSONAL INJURY GENERAL INFORMATION The exhaust system is designed to provide quiet vehicle operation If the muffler should ever need to be removed for repairs or replacement follow the instructions below 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 15 1 Muffler AS SEEN FROM PASSENGER SIDE OF VEHICLE FRONT OF VEHICLE 5 REMOVE ib NEGATIVE 1p zioni 7 waa zi Mer VEIBZCE CABLE FIRST BEFORE WORKING ON VEHICLE Figure 15 1 FE350 Battery MUFFLER MUFFLER REMOVAL 1 Disconnect the battery cables negative cable first Disconnect the spark plug wire from the spark plug Remove the hex nuts 10 and lock washers 11 Figure 15 2 Page 15 3 Remove the hex head cap screw 7 lock washer 8 and flat washer 9 Remove the retaining bolts 5 lock washers 4 and
113. CTITE 271 TO THE INSIDE OF THE COLLAR ONLY NOT TO THE SHAFT SO THAT THE LOCTITE WILL BE PUSHED AWAY FROM THE BEARING AS THE COLLAR AND BEARING ARE PRESSED ON IF LOCTITE GETS ON OR IN THE BEARING THE BEARING MUST BE REPLACED THE COLLAR SHOULD BE REMOVED NO MORE THAN TWO TIMES IF A COLLAR IS REMOVED A THIRD TIME THE SHAFT AND COLLAR WILL NOT FIT PROPERLY 3 Install collar 73 Figure 16 5 Page 16 4 onto axle shaft Place axle assembly on bearing puller wedge attachment and press collar onto axle 4 Use external snap ring pliers 047 tip to install retaining ring 74 Figure 16 5 Page 16 4 5 Place a new sealed bearing 71 and collar 73 on shaft 67 or 68 Figure 16 5 Page 16 4 6 Place the bearing 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 A CAUTION IF THE BEARING WAS REMOVED FROM THE SHAFT REPLACE IT WITH A NEW ONE DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE AXLE SHAFT THIS COULD DAMAGE THE AXLE SHAFT WHEN THE BEARING AND COLLAR ARE PRESSED ON BEARING PULLER WEDGE ATTACHMENT PRESS RAM AXLE SEAL 7 Y AXLE SEAL 7 Figure 16 7 Bearing and Collar Figure 16 8 Axle Seal Tool Page 16 6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Unitized Transaxle Removal AXLE SHAFT I
114. CUIT WIRES WIRES CORRECTLY WIRES INCORRECTLY CONNECTED CONNECTED CHECK CONTINUITY CONNECT WIRES CORRECTLY OF CIRCUIT WIRES TEST PROCEDURE 9 NO CONTINUITY REPLACE WIRE Figure 11 16 Testing the Engine Kill Circuit Chart 1 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 11 13 TROUBLESHOOTING Circuit Testing ENGINE WILL NOT STOP RUNNING WHEN KEY SWITCH IS IN OFF POSITION CHECK KEY SWITCH TEST PROCEDURE 17 CORRECT Y READING INCORRECT CONTINUITY READING CONTINUIT CHECK CONNECTIONS OF CIRCUIT WIRING REPLACE KEY SWITCH WIRES INCORRECTLY CONNECTED WIRES CORRECTLY CONNECTED CHECK CONTINUITY CONNECT WIRES CORRECTLY OF CIRCUIT WIRES TEST PROCEDURE 9 NO CONTINUITY REPLACE WIRE Figure 11 17 Testing the Engine Kill Circuit Chart 2 ENGINE WILL NOT STOP RUNNING WHEN SHIFTER IS IN NEUTRAL POSITION CHECK NEUTRAL LOCKOUT LIMIT SWITCH TEST PROCEDURE 7 CORRECT INCORRECT CONTINUITY READING CONTINUITY READING REPLACE LIMIT SWITCH CHECK CONNECTIONS OF CIRCUIT WIRING WIRES CORRECTLY WIRES INCORRECTLY CONNECTED CONNECTED CONNECT WIRES CORRECTLY CHECK CONTINUITY OF CIRCUIT WIRES TEST PROCEDURE 9
115. DULES BOTH THE PERIODIC SERVICE SCHEDULE AND THE PERIODIC LUBRICATION SCHEDULE MUST BE FOLLOWED TO KEEP THE VEHICLE IN OPTIMUM OPERATING CONDITION PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Check engine oil level Change as required See Lubrication Schedule on page 10 4 Engine Dispose of used oil properly Check engine cooling air intake clean as necessary Monthly Service by Visually inspect the unshrouded area around engine Owner or exhaust for grass and debris and clean as necessary Trained Technician Tires Check air pressure and adjust as necessary See Vehicle Capacities Chart on page 10 5 Wash engine compartment and underside General Vehicle of vehicle Do not wash engine when hot Dispose of waste water properly Clean terminals and wash dirt from casing Check elec Semiannual Battery trolyte level Service by See Battery in Section 12 on page 12 26 Trained Technician Only Every 50 hours of operation or every 100 rounds for golf cars Check and adjust as required Front Wheel Alignment and Camber See Section 7 in the appropriate maintenance and service manual Electrical wiring and connections Check for tightness and damage Periodic Service Schedule continued on next page 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10 3 PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC SERVICE SCHEDULE REGULA
116. E KEEP SPARKS AND FLAMES AWAY FROM VEHICLE AND SERVICE AREA SERVICE ONLY IN A WELL VENTILATED AREA DO NOT OPERATE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON A WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN ELECTRICAL 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 SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE TURN KEY SWITCH OFF PLACE FORWARD REVERSE HANDLE IN THE NEUTRAL POSITION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE 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 TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FRAME GROUND DO NOT ALLOW TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR ANY OTHER METAL COMPONENT FOR VEHICLES WITH CARGO BEDS REMOVE ALL CARGO BEFORE R
117. E STOPS RUNNING 5 If the engine fails to run proceed to Test Procedure 13 Ignition Spark 11 28 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Test Procedures TEST PROCEDURE 13 IGNITION SPARK Read DANGER and WARNING on page 11 1 NOTE KEEP THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 13 SOLENOID VOLTAGE REGULATOR IGNITION GAP TEST TOOL SPARK PLUG WIRE SPARK PLUG FRAME BATTERY Figure 11 36 Test Voltage Regulator Figure 11 37 Ignition Spark Test 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Remove the plug wire from the spark plug Using an ignition spark gap test tool Thexton 4049 or equivalent check for correct spark Figure 11 37 Page 11 29 2 1 Adjust the tester probes to approximately to 18 000 volts 18 Kv setting SE small engine set ting 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 Turn the key switch to the ON position and crank the engine by depressing the accelerator There should be a strong blue spark between the probes of the spark gap tester If there is no spark or if the spark is a faint yellow or red color test components of the ignition circuit 3 If the spark gap tester tool indicates a strong blue spark it is po
118. ENTALLY BUMPED TO PREVENT THIS CHOCK THE FRONT AND REAR WHEELS AND FIRMLY SET THE PARK BRAKE BEFORE SERVICING OR LEAVING THE VEHICLE 11 10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Flectrical Circuits NOTE e BE SURE TO RETURN THE CAM TO THE OPERATE POSITION AFTER SERVICING THE VEHICLE OR THE VEHICLE WILL NOT RUN FUEL GAUGE AND SENDING UNIT CIRCUIT NEUTRAL FORWARD NEUTRAL FORWARD SERVICE POSITION OPERATE POSITION Figure 11 10 Neutral Lockout Cam Service Figure 11 11 Neutral Lockout Cam Operate The fuel gauge and sending unit circuit consists of the fuel hour gauge fuel level sending unit key switch and connecting wires The fuel gauge sending unit picks up power from the key switch when the key switch is turned to the ON position The power goes through the gauge to the fuel level sending unit at the fuel tank The sending unit tells the gauge how much fuel is in the tank Figure 11 12 Page 11 11 KEY SWITCH CC ue FUEL HOUR GAUGE GAUGE SOLENOID WHITE Figure 11 12 Fuel Gauge and Sending Unit Circuit Figure 11 13 Hour Meter Circuit 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 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 11 11 TROUBLESHOOTING Circuit Testing CIRCUIT TESTING Read DANGER and WARN
119. ES WITH CARGO BEDS REMOVE ALL CARGO BEFORE RAISING THE BED DO NOT CLOSE BED UNTIL ALL PERSONS ARE CLEAR OF CARGO BED AREA KEEP HANDS CLEAR OF CRUSH AREA BETWEEN BED AND SEAT BACK SUPPORT DO NOT DROP CARGO BED LOWER GENTLY AND KEEP ENTIRE BODY CLEAR FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SEVERE PERSONAL INJURY GENERAL INFORMATION The torque converter consists of a drive clutch a driven clutch and a drive belt The drive clutch which is mounted to the engine is in the open position when the engine is at idle At this point the belt is riding at a low position smaller diameter on the drive clutch The driven clutch is mounted on the transaxle It is in the closed position and the drive belt is riding at a high position large diameter on it when the engine is at idle 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 17 1 TORQUE CONVERTER General Information At the point of clutch engagement the speed ratio of the drive clutch to the driven clutch is 3 5 to 1 This ratio provides excellent starting and low speed torque As engine speed increases centrifugal force on internal weights close the drive clutch pushing the belt up to a higher position on the clutch increasing the diameter of the belt loop As the diameter of the belt loop increases at the drive clutch the driven clutch is forced open as the diameter of its belt loop decreases At governed top speed the ratio of drive clutc
120. FACE SHIELD WHEN WORKING AROUND A BATTERY BATTERY EXPLOSIVE GASES KEEP SPARKS FLAMES CIGARETTES AWAY FROM THE VEHICLE AND SERVICE AREA VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR EYE PROTECTION WHEN WORKING ON OR NEAR BATTERY FOR ADDED PROTECTION COVER TOP OF THE BATTERY WHEN SERVICING THE VEHICLE BATTERY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING EXTERNAL FLUSH WITH WATER CALL PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOW WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY General Information See preceding DANGER statement Club Car gasoline vehicles are equipped with 12 volt low maintenance batteries When changing a 12 volt battery in any Club Car gasoline powered vehicle the same size battery with adequate amperage ratings should be used as a replacement Club Car recommends a group 70 side post battery Club Car Part No 1012328 with a 615 cranking amp rating at 32 F 0 C 500 CCA at 0 F 17 8 C and a reserve capacity of at least 105 minutes The group 70 classification indicates battery size 8 1 4 inch W x 6 1 2 inch D x 7 1 4 inch H It is important to use the proper size to ensure that the battery clamp will fit correctly Testing the Battery See Test Procedure 2 Section 11 Page 11 19 Preventive
121. G MINIMUM 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 GENERAL INFORMATION The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment The car buretor atomizes the fuel mixes it with air and feeds the combustible mixture into the cylinder 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14 1 FUEL SYSTEM How The Carburetor Works HOW THE CARBURETOR WORKS MAIN SYSTEM The main system of the carburetor consists of the main jet the main nozzle and the main air passage The main system meters fuel to the engine during moderate to heavy load conditions Fuel flows through the main jet and into the main nozzle where it meets air from the main air passage The resulting mixture flows out the end of the main nozzle and into the carburetor bore where it is atomized by high speed air flow and then carried into the engine Figure 14 1 Figure 14 2 and Figure 14 3 During the intake stroke of the engine a negative pressure vacuum is created in the venturi of the carbure tor In this venturi tube the intake air has high velocity and low static pressure Subsequently fuel is drawn out of the carburetor float chamber atomized to fine particles then drawn into the cylinder as a combustible mixture Figure 14 2 Page 14 2 Trouble in the main system is usually indicated
122. ICE PLACE RECOMMENDED LUBRICANT Brake pedal shaft bearings T Dry Moly Lube Club Car Part No 1012151 Semiannually by Brake Linkage and Pivots 2 Dry Moly Lube Club Car Part No 1012151 Owner or Trained Technician Accelerator push rod pivots mounts 3 Dry Moly Lube Club Car Part No 1012151 Every 50 hours of and shifter cable pivots operation or every 100 rounds for golf cars Front Suspension 5 fittings 4 Chassis Lube EP NLGI Grade 2 Brake slides 5 Dry Moly Lube Club Car Part No 1012151 Annually by Trained re 6 27 oz 8 liter 80 90 WT API Class GL 3 or 80 Technician Only Every 90 WT AGMA Class EP Gear Lube 100 hours of operation or every 200 rounds for golf Inspect front wheel bearings T _ cars Repack as necessary Chassis Lube EP NLGI Grade 2 Periodic Lubrication Schedule continued on next page Page 10 4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement PERIODIC MAINTENANCE Vehicle Capacities PERIODIC LUBRICATION SCHEDULE 200 Hours of Operation or every 400 rounds for golf Cars or annually which ever comes first REGULAR INTERVAL SERVICE PLACE RECOMMENDED LUBRICANT First Change 100 Hours Additional Change every Change engine oil and oil filter 8 32 oz 97 liter without filter 38 oz 1 16 liters with filter 10W30 above 32 F 0 C or SAE 5W20 below 32 F 0 C API Class
123. IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON A WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE 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 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 NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS USE EXTREME CAUTION TO AVOID SHORTING OF COMPONENTS OR WIRING MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST SYSTEM FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS FRAME GROUND DO NOT ALLOW TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR ANY OTHER METAL COMPONENT TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FOR VEHICL
124. ING on page 11 1 Before testing the electrical circuits to determine the source of an electrical problem test the vehicle battery to determine whether or not it is the source of the problem A hydrometer multimeter and 160 ampere load tester will be required See Test Procedure 2 Battery Page 11 19 TESTING THE STARTER CIRCUIT AND GENERATOR CIRCUIT Read DANGER and WARNING on page 11 1 Use the following chart Figure 11 14 Page 11 12 to begin troubleshooting problems with the starter and generator circuits ENGINE WILL NOT CRANK STARTER DOES NOT ROTATE SOLENOID DOES NOT CLICK SOLENOID DOES CLICK _ CHECK BATTERY TAKE VOLTAGE READING EST PROCEDURE 2 TEST PROCEDURE 24 VOLTAGE ABOVE 9 6 VOLTS CHECK FUSE VOLTAGE LESS THAN NO VOLTAGE READING 9 6 VOLTS TEST PROCEDURE 1 CHECK STARTER GENERATOR CHECK SOLENOID EO Gee TEST PROCEDURE 8 CHECK BATTERY TEST PROCEDURE 6 TEST PROCEDURE 2 CHECK PEDAL CHECK WHITE WIRE ACCELERATOR LIMIT SWITCH CHECK GROUND STRAPS CONTINUITY TEST PROCEDURE 5 TEST PROCEDURE 3 TEST PROCEDURE 9 CHECK NEUTRAL LOCKOUT LIMIT SWITCH TEST PROCEDURE 7 CHECK KEY SWITCH TEST PROCEDURE 4 Figure 11 14 Testing the Starter and Generator Circuits TESTING THE ENGINE IGNITION CIRCUIT Read DANGER and WARNING on page 11 1 Use the
125. ION A CAUTION e BEFORE REMOVAL AND DISASSEMBLY CLEAN THE ENGINE ANY DIRT ENTERING THE ENGINE CARBURETOR OR OTHER PARTS WILL WORK AS AN ABRASIVE AND SHORTEN THE LIFE OF THE ENGINE FOR THE SAME REASON BEFORE INSTALLING A NEW PART CLEAN OFF ANY DUST OR METAL FILINGS Tightening Sequence Where there is a tightening sequence indicated in this Service Manual the bolts nuts or screws must be tightened in the order and by the method indicated When installing a part that is secured with several bolts nuts or screws hand tighten all then tighten to specified torque in the proper sequence This is to avoid dis tortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws loosen all about a quarter of a turn first and then remove them Torque The torque values given in this Service Manual should always be adhered to Applying too little or too much torque may lead to serious damage Lubricant Some oils and greases should only be used in certain applications and may be harmful if used in an applica tion for which they are not intended Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have adequate lubrication During assembly oil or grease whichever is more suitable should be applied to any rubbing surface Press A part installed using a press or driver such as a seal should first be coated with oil
126. KOUT LIMIT SWITCH TEST PROCEDURE 7 INCORRECT CORRECT CONTINUITY READING CONTINUITY READING Circuit Testing REPLACE LIMIT SWITCH CHECK CONNECTION OF BLACK WIRE WIRE CORRECTLY WIRE INCORRECTLY CONNECTED CONNECTED CHECK CONTINUITY RECONNECT WIRE OF BLACK WIRE TEST PROCEDURE 9 NO CONTINUITY REPLACE WIRE Figure 11 21 Testing the Neutral Lockout Circuit TESTING THE FUEL GAUGE AND SENDING UNIT CIRCUIT Read DANGER and WARNING on page 11 1 Use the chart below Figure 11 22 to begin troubleshooting fuel gauge and sending unit circuit NO READING ON FUEL GAUGE CHECK FUEL LEVEL SENDING UNIT TEST PROCEDURE 25 VOLTAGE READING VOLTAGE READING ABOVE 8 VOLTS BELOW 8 VOLTS CHECK GROUND WIRE SEE TABLE IN CONTINUITY TEST PROCEDURE 25 NO CONTINUITY CONTINUITY OK VOLTAGE READINGS VOLTAGE READINGS INCORRECT __ CORRECT REPAIR OR REPLACE WIRE CHECK FUEL GAUGE TEST PROCEDURE 26 REPLACE SENDING UNIT CHECK FUEL GAUGE TEST PROCEDURE 26 INCORRECT VOLTAGE READINGS B 0 VOLTAGE READINGS REPLACE FUEL GAUGE REPLACE FUEL GAUGE Figure 11 22 Testing the Fuel Gauge and Sending Unit Circuit 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement
127. LESHOOTING Flectrical Circuits ENGINE KILL CIRCUIT The ignition coil supplies electrical power for the spark plug therefore the proper way to stop the engine is to run this electrical power to ground bypassing the spark plug Figure 11 6 Page 11 9 The engine kill circuit consists of the key switch a kill limit switch that is activated by the accelerator pedal a neutral lockout limit switch that is activated by a cam located on the back of the Forward Reverse shifter and connecting wires The engine can be stopped by releasing the accelerator pedal turning the key switch to the OFF position or by shifting the Forward Reverse handle to NEUTRAL See Neutral Lockout Circuit Page 11 10 Q FORWARD REVERSE ASSEMBLY Em M BLACK W amp 1 2 FRAME NEUTRAL GROUND LOCKOUT SWITCH LIMIT SWITCH BLACK WHITE A m lt WHITE 3k ZEP 3 KILL LIMIT RPM LIMITER K oe FRAME SWITCH lt GROUND 8 VW 2 S Figure 11 6 Engine Kill Circuit REVERSE BUZZER CIRCUIT The reverse buzzer is a safety warning device that sounds when the Forward Reverse handle is in REVERSE It functions to remind the operator not to leave 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 connecting wires Figure 11 7 Page 11 9 The battery supplies power through the fuse bloc
128. LL AND TIGHTEN CRANKCASE COVER BOLTS AS INSTRUCTED FAILURE TO DO SO COULD CAUSE THE COVER TO BECOME WARPED 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 45 FE290 ENGINE Eng ne Assembly Crankshaft Cover Installation Continued 1 Clean the gasket surfaces on the crankcase cover to fit a new gasket during installation and inspect the oil seal for wear and damage 2 Install crankcase cover Using HANDS ONLY seat cover completely against the crankcase If the cover will not seat the camshaft is not installed correctly 3 Install and finger tighten evenly the eight cover mounting bolts Figure 13 104 Page 13 47 4 Tighten the cover mounting bolts in two steps First in the sequence shown tighten all eight bolts to approximately 130 in lb 14 N m Then repeating the sequence tighten them to 250 in lb 28 2 N m Figure 13 104 Page 13 47 Figure 13 104 Crankcase Cover Installation Figure 13 105 Fan and Flywheel Assembly ENGINE ASSEMBLY Read DANGER and WARNING on page 13 1 A CAUTION e BEFORE ASSEMBLY MAKE SURE PARTS ARE CLEAN 1 Install cylinder head See Cylinder Head Installation Page 13 20 2 Insert the flywheel key into the keyway in the crankshaft Then align the keyway in the flywheel to the key and push the flywheel and fan assembly onto the crankshaft until it seats Install flat washer and nut finger tight 3 Use a strap wrench 3 t
129. Maintenance To keep the battery in good operating condition follow these steps on a regular basis 1 Any corrosion build up on or around the battery should be removed immediately Post connections should be clean and tight Any frayed or worn wires should be replaced After all cables have been connected coat terminals 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 removed Wash the battery with a bristle brush using water and bicarbonate of soda baking soda 1 cup per gallon Rinse with water Do not allow solution to enter battery through the vent cap holes See Self Discharge Page 12 28 3 Maintain proper water level See Water Level Page 12 28l 4 Check battery periodically to see that it is in a full state of charge See Charging the Battery Page 12 29 5 Keep battery clamp tight See Vibration Damage Page 12 28 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 12 27 ELECTRICAL COMPONENTS Battery Self Discharge Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery To pre vent self discharge the battery should always be kept clean Hot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a battery will discharge In hotter climates therefo
130. NE OIL TO THE CRANKSHAFT JOURNALS AND GUIDE SHAFT FIGURE 13 94 PAGE 13 42 1 Installation is the reverse of removal See Crankshaft and Counterbalance Removal Page 13 35 2 Tighten the four nuts 2 for counterbalance guide shaft to 50 in Ib 5 9 N m Figure 13 73 Page 13 34 3 If the link rod was removed from the PTO side of the crankshaft support the crankweb as shown slide the link rod onto the crankshaft and install the key Press the spur gear and helical gear onto the crankshaft Figure 13 95 Page 13 43 and Figure 13 96 Page 13 43 See following CAUTION and NOTE 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 41 FE290 ENGINE Crankshatt and Counterbalance Crankshaft Installation Continued A CAUTION ALWAYS USE A PRESS WHEN REMOVING OR INSTALLING THE SPUR GEAR AND HELICAL GEAR ON THE CRANKSHAFT IF THE SPUR GEAR WAS WARPED WHILE BEING REMOVED INSTALL A NEW ONE NOTE MAKE SURE THE CHAMFERED INSIDE DIAMETERS OF THE SPUR GEAR AND HELICAL GEAR ARE ORIENTED DOWNWARD ON THE CRANKSHAFT AS SHOWN FIGURE 13 95 PAGE 13 43 MAKE SURE THE LINK RODS ROTATE SMOOTHLY AFTER THE GEARS ARE PRESSED ON 4 Slide the link rod then the spacer onto the flywheel end of the crankshaft PRESS HELICAL SLEEVE GEAR NOTE SPUR GEAR CHAMFERED TIMING INSIDE DIAMETER PRESS RAM MARK FACING DOWN PRESS LINK ROD Figure 13 95 Cran
131. NSTALLATION 1 Clean bearing and seal seats in axle tube 75 or 76 Figure 16 5 Page 16 4 2 Place a new seal 72 Figure 16 5 Page 16 4 in axle tube with seal lip facing inside of the axle tube Use an axle seal tool Club Car Part No 1014162 to press it in until it seats firmly in position Figure 16 8 Page 16 6 See following NOTE NOTE THE NEW SEAL CAN BE INSTALLED BY TAPPING THE AXLE SEAL TOOL WITH A MALLET 3 Clean the axle shaft and splines and then insert the shaft splined end first through the seal and into the axle tube Be careful not to damage the seal Then advance the shaft through the inner bearing and rotate it to align the shaft splines with the splined bore of the differential side gear Continue advancing the shaft until the bearing seats against the axle tube shoulder 4 Install the retaining ring 70 Figure 16 5 Page 16 4 in the axle tube See also Figure 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 A WARNING e BE SURE RETAINING RING IS PROPERLY SEATED IN ITS GROOVE IF RING IS NOT PROPERLY INSTALLED THE AXLE ASSEMBLY WILL SEPARATE FROM THE TRANSAXLE AND DAMAGE THE AXLE ASSEMBLY AND OTHER COMPONENTS LOSS OF VEHICLE CONTROL COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH UNITIZED TRANSAXLE REMOVAL Read DANGER and WARNING on page 16 1
132. OADED FOR VEHICLES WITH CARGO BEDS REMOVE ALL CARGO BEFORE RAISING THE BED DO NOT CLOSE BED UNTIL ALL PERSONS ARE CLEAR OF CARGO BED AREA KEEP HANDS CLEAR OF CRUSH AREA BETWEEN BED AND SEAT BACK SUPPORT DO NOT DROP CARGO BED LOWER GENTLY AND KEEP ENTIRE BODY CLEAR FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SEVERE PERSONAL INJURY LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING SET THE PARK BRAKE WHEN LIFTING THE FRONT OF THE VEHICLE UNLOAD THE CARGO BED AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LB 454 KG MINIMUM 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 GENERAL INFORMATION To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program regularly scheduled service even though the vehicle is functional Regular and consistent vehicle maintenance can prevent vehicle down time and expensive repairs that result from neglect Any vehi cle not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local authorized Club Car distributor dealer to perform all repairs and semiannual and annual periodic service AS SEEN
133. ONENT HOT DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST CAN CAUSE SEVERE BURNS ALWAYS ALLOW ENGINE AND EXHAUST TO COOL PRIOR TO SERVICING IF WIRES ARE REMOVED OR REPLACED MAKE SURE WIRING IS PROPERLY ROUTED AND SECURED TO VEHICLE FRAME FAILURE TO PROPERLY ROUTE AND SECURE WIRING COULD RESULT IN VEHICLE MALFUNCTION PROPERTY DAMAGE OR PERSONAL INJURY TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT BATTERY CABLES NEGATIVE FIRST FIGURE 12 1 PAGE 12 2 DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG WARNING CONTINUED ON NEXT PAGE 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12 1 ELECTRICAL COMPONENTS Starter Generator A WARNING e FOR VEHICLES WITH CARGO BEDS REMOVE ALL CARGO BEFORE RAISING THE BED DO NOT CLOSE BED UNTIL ALL PERSONS ARE CLEAR OF CARGO BED AREA KEEP HANDS CLEAR OF CRUSH AREA BETWEEN BED AND SEAT BACK SUPPORT DO NOT DROP CARGO BED LOWER GENTLY AND KEEP ENTIRE BODY CLEAR FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SEVERE PERSONAL INJURY LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING SET THE PARK BRAKE WHEN LIFTING THE FRONT OF THE VEHICLE UNLOAD THE CARGO BED AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LB 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION USE APPROVED JACK STANDS OF PROPER WEIGHT CAPACI
134. OTES EXTERNAL FLUSH WITH WATER CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF WATER FOLLOW WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL A PHYSICIAN IMMEDIATELY GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM VEHICLE AND SERVICE AREA SERVICE ONLY IN A WELL VENTILATED AREA DO NOT OPERATE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON A WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE 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 SERVICING VEHICLE TURN KEY SWITCH OFF PLACE FORWARD REVERSE HANDLE IN THE NEUTRAL POSITION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE 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 TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR ANY OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR ANY OTHER METAL COMP
135. PACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION USE APPROVED JACK STANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE GENERAL INFORMATION Read DANGER and WARNING on page 13 1 Club Car DS gasoline golf cars Turf 1 Carryall 1 and Villager 4 vehicles are powered by 4 cycle overhead valve single cylinder air cooled engines The 4 cycle engine has an oil reservoir crankcase similar to auto mobiles trucks aircraft heavy equipment machinery and other applications designed for reliable heavy duty service The engine has two major component assemblies cylinder assembly and crankcase assembly 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 1 FE290 ENGINE General Information NOTE ENGINE ROTATION IS CLOCKWISE AS VIEWED FROM THE CLUTCH SIDE OF THE ENGINE SPECIAL ENGINE SERVICE TOOLS AVAILABLE FROM CLUB CAR DESCRIPTION PART NUMBER Gear Yoke 1016418 Compression Gauge and Adapter 101641001 and 02 Valve Spring Compressor 101641101 Valve Guide Reamer 101641201 Valve Guide Reamer Arbor 101641202 Piston Ring Compressor Kit 1016414 Piston Ring Pliers 1016415 Bearing Driver Set 1016416 Flywheel Puller Kit 1016627 Valve Clearance Adjuster Screw Holder 1016413 Bearing and Seal Remover Assembly 1016417 Valve Seat Cutter T Wrench 1016551 Valve Seat Cutter 45 x 32 mm Diameter for FE290 engine only 1016553
136. PONENTS Starter Generator 9 Install the commutator end cover 23 onto the armature shaft Align the locating pin with the pin hole in the cover Install two M6 x 180mm screws 20 and tighten to 100 in lb 11 3 N m Figure 12 3 Page 12 4 10 Install the brushes into the holders Place 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 covers 29 in the openings in the commutator end cover 23 Figure 12 4 Page 12 4 11 Slide the spacer 37 onto the end of the shaft Insert the shaft key 34 into the shaft Install the belt pulley 39 onto the shaft and install the lockwasher 40 and nut 41 and tighten to 28 ft lb 38 0 N m Figure 12 8 Page 12 6 Starter Generator Installation 1 Install the green wire from the F1 terminal to the A1 terminal on the Starter Generator Figure 12 2 Page 12 3 Install a flat washer lockwasher and nut onto each terminal and tighten to 48 in Ib 5 4 N m 2 Install the two 3 8 hex head pivot screws 5 into the mounting bracket with the heads of the screws fac ing toward the driver 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 screw Finger tighten the screws and nuts Figure 12 14 Page 12 11 3 Install the adjustment bolt 11 thro
137. POSITION ALWAYS USE APPROVED JACK STANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE 4 Remove the drive clutch retaining bolt 17 and mounting washer 19 Figure 17 5 Page 17 6 See also Figure 17 3 See following NOTE NOTE THE DRIVE CLUTCH MOUNTING BOLT HAS LEFT HAND THREADS THE CRANKSHAFT HAS LEFT HAND THREADS AT THE CLUTCH MOUNTING HOLE 5 Lubricate the threaded portion of the clutch puller tool with a light oil and thread the clutch puller tool into the clutch retaining bolt hole 6 Using a 1 2 inch drive air wrench tighten the clutch puller tool The drive clutch will come free of the crankshaft Figure 17 4 Page 17 4 7 Support the drive clutch assembly in your hand and back the clutch puller tool out of the crankshaft CAUTION DO NOT HIT OR TAP THE CLUTCH WITH A HAMMER DO NOT PRY THE CLUTCH THESE ACTIONS WILL DAMAGE THE CLUTCH DRIVE CLUTCH CLEANING AND INSPECTION 1 Use a dry lint free cloth to clean clutch parts A CAUTION DO NOT LUBRICATE THE DRIVE CLUTCH LUBRICANTS ATTRACT DIRT AND DUST WHICH INTERFERE WITH PROPER CLUTCH OPERATION e USE ONLY A DRY CLOTH TO LIGHTLY WIPE THE SHAFT OF THE FIXED FACE ASSEMBLY 7 FIGURE 17 5 PAGE 17 6 DO NOT USE A BRUSH OR STEEL WOOL THESE WILL DAMAGE THE SURFACE OF THE SHAFT DO NOT USE SOLVENTS SOLVENTS WILL DAMAGE THE LUBRICATING CHARACTERISTICS OF THE BUSHINGS 2000 FE290 Gasoline Vehicle Maintenanc
138. 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 filter If only the cylinder head is to be disassembled proceed without draining the oil or removing the oil filter Page 13 8 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Cylinder Head 11 Disconnect oil filler tube 20 from cylinder shroud by first removing the locknut 18 ground wire 17 and flange nut 10 and then pulling oil filler tube out of the crankcase cover Figure 13 8 Page 13 10 NOTE MAKE SURE VEHICLE IS LEVEL BEFORE REMOVING FILLER TUBE THIS WILL PREVENT OIL FROM SPILLING WHEN FILLER TUBE IS REMOVED TYPICAL 4 Figure 13 9 Rocker Cover Removal Figure 13 10 Rocker Shaft Removal 12 Remove the eight bolts 14 and the two ended bolts 11 and 15 Figures 13 7 and 13 8 Page 13 10 13 Take off the head shroud 13 the upper shroud 23 and the bracket 22 Figures 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 NOTE e MARK THE ROCKER ARMS 6 AND THE PUSH RODS 8 SO THEY CAN BE PUT BACK IN THEIR ORIGINAL POSITIONS FIGURE 13 10 PAGE 13 10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 9 FE290 ENGINE Cylinder Head Rocker Arm and
139. Page 14 17 5 Install front left wheel Tighten the wheel rim mounting nuts to 55 ft lb 75 N m 6 Install front body 7 Check for proper operation Figure 14 14 Compound Steering Joint INTAKE DUCT REPAIR In the event of puncture damage to the intake duct a repair kit is available Club Car Part No 101971001 This kit is designed to repair small cracks or holes If the intake duct is badly torn it will need to be replaced AIR FILTER General Information The air filter should 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 acceleration or an engine which runs roughly with black exhaust smoke Air Filter Replacement 1 Remove seat or lift bed to access engine compartment Lift two latches 3 on the side of the air box Figure 14 15 Page 14 17 Remove the hose clamp 15 from the air hose and remove hose from the air box assembly Standing on driver side of vehicle grasp air hose mounting inlet and open box fully Remove filter element 12 Using a clean cloth wipe away any dust or dirt from inside the air box Remove all dirt build up around the inside lip of the box or the box will not seal properly 14 16 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM Sb gt a REFERENCE CARBURETOR AUT Choke
140. Page 16 24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UNITIZED TRANSAXLE Component Assembly Synchronizer SIDE VIEW inserts overlap springs m CHAMFERED ON END OF CLUTCH HUB SYNCHRONIZER CLUTCH HUB Notched Y SYNCHRONIZER surfaces SLEEVE of synchro inserts face Bis LONG END out SPRINGS TOP AND BOTTOM OF SHART Figure 16 58 Synchronizer Inserts Figure 16 59 Synchronizer Clutch Hub 14 Install the spring washer 39 onto shaft with the raised center toward the end of the shaft Figure 16 42 Page 16 18 15 Press a new bearing 38 onto the end of the shaft until it seats Figure 16 42 Page 16 18 Make sure the input gears turn freely See following CAUTION A CAUTION e APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRESSURE ANYWHERE ELSE WILL DAMAGE THE BEARING SYNCHRONIZER RING SYNCHRONIZER CLUTCH HUB Figure 16 60 Synchro Ring SHIFTER FORK ASSEMBLY 1 Install the spring 35 and ball 36 into the shifter fork 34 as shown Figure 16 42 Page 16 18 2 Use a No 1 tip phillips screwdriver to depress the ball 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 the ball is positioned in the middle detent on the rod Figure 16 42 Page 16 18 2000 FE290 Gasoline Vehicle Maintenance and Ser
141. Push Rod Removal Continued 2 Remove the E ring 4 and pull the rocker shaft 5 out of the cylinder head Figure 13 10 Page 13 10 3 Lift out the rocker arms 6 washer 7 and push rods 8 Figure 13 10 Page 13 10 CYLINDER HEAD REMOVAL 1 Remove the six bolts 1 and remove the cylinder head assembly 2 Figure 13 11 Page 13 11 2 Remove head gasket 3 Note the position of the two dowels 4 as shown Figure 13 12 Page 13 11 Figure 13 11 Cylinder Head Figure 13 12 Head Gasket 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 and take out the upper retainer 7 and the spring 8 3 Remove valve 10 4 Remove valve stem seal 11 with a screwdriver Figure 13 14 Page 13 12 See following CAUTION A CAUTION TO KEEP THE SCREWDRIVER FROM DAMAGING THE CYLINDER HEAD FLANGE SURFACE PLACE A PIECE OF HEAVY CARDBOARD OR WOOD BETWEEN THEM FIGURE 13 14 PAGE 13 12 THE VALVE STEM SEAL CANNOT BE REUSED REPLACE VALVE STEM SEAL WITH A NEW ONE 5 Remove spring seat 9 Figure 13 14 Page 13 12 13 10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Oylinder Head Figure 13 13 Valve Remova
142. R INTERVAL SERVICE Check brake shoes replace if necessary See Section 6 in the appropriate maintenance and Semiannual service manual Service by ee Brake System Lubricate brake slides per Periodic Lubrication Schedule Trained Technician Only S Iso Section 6 in th Continued ee also Section 6 in the appropriate mainte nance and service manual Check brake cables for damage replace as required Check for leaks around gaskets fill plugs etc f Engine Inspect clean and regap spark plug replace if neces Annual Service by sary Trained Technician Only Every 100 hours of Check air filter element clean or replace if necessary operation or every 200 rounds for golf cars Engine Air Intake System Dispose of used filter element properly Check clamps for tightness check hose for cracks General Vehicle Check for loose hardware and tighten as required Two year Service by Trained Technician Only Every 200 Fuel Filters Replace Dispose of used filters properly hours of operation or every 400 rounds for golf cars A WARNING e IF ANY PROBLEMS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH PERIODIC LUBRICATION SCHEDULE See Figure 10 2 Page 10 5 PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERV
143. RE 13 77 PAGE 13 36 IGNORE CRANKSHAFT AND COUNTERBALANCE DISASSEMBLY STEPS 2 THROUGH 6 PAGE 13 35 IF THE LINK ROD OPPOSITE OF THE PTO SIDE PASSES INSPECTION FIGURE 13 77 PAGE 13 36 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 35 FE290 ENGINE Crankshatt and Counterbalance Measure A9 in two places in two places 90 apart 90 apart Figure 13 78 Measure Small Bore I D Figure 13 79 Measure Large Bore I D Figure 13 80 Remove Bearing From Link Rod Figure 13 81 Install New Bearing Into Link Rod Link Rod Bushing Replacement 1 Support the link rod around the entire large end and using a 1 97 inches 50 mm bearing driver 1 drive the bearing 2 out of the rod 3 as shown Figure 13 80 Page 13 37 2 Clean the parts thoroughly in a high flash point solvent and dry them 3 Coat the new bearing with new engine oil 4 Using a 1 97 inches 50 mm bearing driver press the new bearing into the link rod with its seam 6 toward the side of the link rod with the hollow 5 and at right angles to the rod center to a depth of 0 039 inch 0 991 mm from the surface Figure 13 81 Page 13 37 COUNTERBALANCE WEIGHT NOTE THE WRIST PINS ARE TIGHTLY PRESSED INTO THE WEIGHT AND NORMALLY REQUIRE NO MAINTENANCE Counterbalance Weight Inspection 1 Clean the inside of the bore surface and inspect it for wear or damage 2 Using a t
144. RE SHOULD BE TAKEN DURING INSTALLATION TO AVOID CUTTING OR NICKING THE O RING SEAL FIGURE 13 42 PAGE 13 23 3 Install oil filler tube 6 and O Ring 7 into the large hole in the crankcase cover Install the upper end of the oil filler tube 6 onto the two ended bolt 2 Install flange nut 8 and tighten to 50 in Ib 5 7 N m Connect the ground wire 3 to the two ended bolt and install and tighten the locknut 4 to 50 in Ib 5 7 N m Insert the dip stick 5 Figure 13 42 Page 13 23 4 Connect muffler See Section 15 Exhaust System 5 Install carburetor 11 throttle spring 12 and throttle spring bracket 13 Tighten to 50 in Ib 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 the carburetor to 9 in Ib 1 0 N m Figure 13 5 Page 13 9 7 Install the spark plug and thread it in until finger tight then tighten the plug to 20 ft lb 27 N m NOTE e BEFORE INSTALLING THE PLUG CHECK THE CONDITION OF THE THREADS IN THE CYLINDER HEAD SOFTEN DEPOSITS IN CYLINDER HEAD THREADS WITH PENETRATING OIL AND CLEAN THE THREADS WITH A TAP IF NECESSARY 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 21 FE290 ENGINE Crankcase Installation of Remaining Engine Components Continued 8 9 10 11 Install governor cable clevis pin 9 through cable clevis and throttle valve and install cotter pin 10
145. Reverse Limit Switches Figure 12 20 Neutral Lockout Cam 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 Test Procedure 23 Section 11 Page 11 34 Neutral Lockout Cam Removal 1 Disconnect the battery cables as shown Figure 12 1 Page 12 2 2 Remove the external snap ring 14 Figure 12 20 Page 12 18 3 Remove the plastic washer 12 and the spring 13 4 Remove the cam 11 Neutral Lockout Cam Installation 1 Install the cam 11 Figure 12 20 Page 12 18 2 Install the spring 13 and the plastic washer 12 3 Install the external snap ring 14 onto the shaft Be sure the snap ring is installed in the groove on the shaft 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 Battery Protector Spray Club Car Part No 1014305 12 18 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Reverse Warning Buzzer REVERSE WARNING BUZZER Read DANGER and WARNING on page 12 1 Testing the Reverse Warning Buzzer See Test Procedure 20 Section 11 Page 11 33 Reverse Warning Buzzer Removal 1 Disconnect the battery cables as shown Figure 12 1 Page 12 2 2 Remove the center dash panel See Key Switch Removal Page 12 13 3 Disconnect the wires f
146. SE SF or SG Oil or higher FLOORBOARD Figure 10 2 Lubrication Points VEHICLE CAPACITIES LIQUID CAPACITIES GASOLINE VEHICLES Engine Crankcase without filter 32 oz 95 liters Engine Crankcase with filter Unitized Transaxle 38 oz 1 12 liters 27 oz 8 liters Gasoline Tank 7 gallons 26 5 liters TIRE CAPACITIES GASOLINE VEHICLES DS Golf Car 12 14 psi 83 96 kPa Turf 1 and Carryall 1 Villager 4 14 16 psi 96 110 kPa 12 14 psi 83 96 kPa 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10 5 PERIODIC MAINTENANCE Engine Oil ENGINE OIL Read DANGER and WARNING on pages 10 1 and 10 2 Even though the oil warning light on the dash should illuminate if the engine oil level is low the engine oil level should be checked monthly The vehicle should be on a level surface when checking oil A CAUTION DO NOT REMOVE DIPSTICK WHILE ENGINE IS RUNNING Remove a a Reinsert
147. SO WILL DAMAGE THE SPRING STEPS 2 AND 3 Drain carburetor over a catch basin by turning bowl drain screw 11 counterclockwise 2 to 3 turns Mark carburetor and corresponding position of fuel bowl CAUTION DO NOT REMOVE VALVE SPRING FROM FLOAT TO DO SO WILL DAMAGE SPRING If spring looks like this holding float firmly and rotating valve counterclockwise to seat spring in seat of float bowl Check for coil located in groove above both ears Check for spring seated spring to look m like this by QO in recess of float body Figure 14 7 Changing the Main Jet 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 14 7 FUEL SYSTEM Engine Control Linkage Changing the Main Jet Continued NOTE INSPECT THE MAIN JET NOZZLE 7 AND PILOT JET 4 TO ENSURE THEY ARE FREE FROM CONTAMINATION REPLACE ANY PART THAT IS CLOGGED WITH CONTAMINATION REPLACE THE FLOAT IF IT IS DAMAGED OR IF THE FLOAT VALVE IS DAMAGED OR WORN EXAMINE THE FLOAT VALVE SPRING ASSEMBLY TO MAKE SURE THE SPRING IS INSTALLED CORRECTLY FIGURE 14 7 PAGE 14 7 9 Install the fuel bowl Make sure that it is positioned properly by aligning the marks applied in Step 4 See following CAUTION A CAUTION MAKE SURE THE FUEL BOWL IS PROPERLY SEATED AGAINST THE CARBURETOR FUEL BOWL GASKET AND THE GASKET IS NOT PINCHED 10 Install the fuel bowl retaining screw
148. SS DEADLY POISON A WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE 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 SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD REVERSE HANDLE IN THE NEUTRAL POSITION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE 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 TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR ANY OTHER METAL COMPONENT TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT THE BATTERY CABLES NEGATIVE 2 FIRST AS SHOWN FIGURE 12 1 PAGE 12 2 DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING SET THE PARK BRAKE WHEN LIFTING THE FRONT OF THE VEHICLE UNLOAD THE CARGO BED AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LB 454 KG MINIMUM LIFTING CA
149. TING THE VEHICLE VENT SHUT OFF VALVE VENT TUBES Figure 14 20 Fuel Tank 13 Allow the engine to run for a few minutes to ensure that the fuel lines are full of fuel 14 Inspect each fuel line for leaks 14 1 Check all of the fuel line clamps at the carburetor fuel filters fuel pump and fuel tank for leaks 15 Inspect each fuel line to ensure that the lines are not cracked cut or worn 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 14 25 FUEL SYSTEM Fuel Lines FUEL LINES Read DANGER and WARNING on page 14 1 The fuel lines must be properly routed and all hose clamps must be tight The fuel lines should be kept clean See following WARNING A WARNING MAKE SURE FUEL LINES ARE THE RIGHT LENGTH AND ARE PROPERLY ROUTED FAILURE TO HEED THIS WARNING COULD RESULT IN DAMAGE TO FUEL LINES AND FIRE Fuel line No 1 runs directly from the fuel tank to the primary fuel filter The primary fuel filter has an arrow indicating fuel flow direction Figure 14 16 Page 14 19 Fuel line No 2 runs directly from the primary fuel filter to the fuel inlet of the fuel pump Fuel line No 3 runs directly from the fuel outlet of the fuel pump to the secondary fuel filter The secondary fuel filter has an arrow indicating fuel flow direction and is identical to the primary fuel filter Fuel line No 4 runs from the outlet of the secondary fuel filter to the carburetor Small spring steel band cl
150. TS 48 SET INTO SLOTS IN THE SYNCHRONIZER SLEEVE 47 FIGURE 16 42 PAGE 16 18 THESE MAY FALL FREE WHEN THE SYNCHRONIZER CLUTCH HUB 49 IS REMOVED DO NOT LOSE THESE INSERTS 6 Remove the three synchronizer inserts 48 from the synchronizer sleeve Figure 16 42 Page 16 18 7 Press the synchronizer sleeve 47 from the input shaft Figure 16 42 Page 16 18 INTERMEDIATE GEAR DISASSEMBLY 1 Place bearing puller wedge attachment Club Car Part No 1012812 between bearing 38 and shaft gear 56 Figure 16 42 Page 16 18 then press bearing off shaft Figure 16 50 Page 16 22 See following CAUTION A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THIS COULD DAMAGE THE SHAFT Page 16 20 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UNITIZED TRANSAXLE Component Disassembly Use a 1 3 8 in o d arbor and a bearing puller wedge attachment Club Car Part No 1012812 to press bearing from gear case WEDGE Push differential pin through differential gear case Figure 16 46 Differential Pin Figure 16 47 Remove Bearing 2 Place the bearing puller wedge attachment under the bearing 59 and press the bearing from the shaft Figure 16 42 Page 16 18 See following CAUTION 3 Press the gear 58 from the shaft 56 then remove the key 57 Figure 16 42 Page 16 18 IDLER SHAFT DISASSEMBLY 1 Place a bearing pulle
151. TY TO SUPPORT THE VEHICLE AS SEEN FROM PASSENGER SIDE OF VEHICLE FRONT _ OF VEHICLE C Remove N negative 10 cable first BEFORE WORKING ON VEHICLE Figure 12 1 Battery Disconnect STARTER GENERATOR Read DANGER and WARNING on page 12 1 Testing the Starter Generator See Section 11 Test Procedure 8 Page 11 25 and Test Procedure 10 Page 11 27 Starter Generator Removal 1 Disconnect the battery as shown Figure 12 1 Page 12 2 2 Remove the access panel on a DS Golf Car or Villager 4 vehicle lift the cargo bed on a Turf or Carryall vehicle 3 Disconnect the wires from the starter generator 1 Mark wires before disconnecting Loosen the pivot nuts 7 and bolts 5 Figure 12 2 Page 12 3 4 Remove the mounting adjustment nut 12 washer 9 and bolt 11 Lower the starter generator and remove the belt 4 from the pulley 10 Figure 12 2 Page 12 3 5 Support the starter generator so that when the pivot bolts are removed the starter generator will not fall to the ground Remove the pivot nuts 7 and bolts 5 from the mounting bracket 6 Remove the starter generator from the vehicle Page 12 2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Starter Generator FRAME ON CONNECTION Figure 12 2 Starter Generator Removal Disassembly of the Starter Generator to Service the Brushes 1 Remove the two bolts 20 and pull com
152. Test Procedure 10 2 Generator field coil is shorted Section 11 Troubleshooting Test Procedure 10 3 Brushes are worn or Section 12 Electrical Components commutator is dirty Starter Generator Page 12 2 4 Starter generator belt is Section 12 Electrical Components loose or slipping Belt Tension Adjustment Page 12 12 5 Voltage regulator failed Section 11 Troubleshooting Test Procedure 2 6 Battery failed Section 11 Troubleshooting Test Procedure 2 Transmission does not 1 Transmission shifter linkage is binding Section 16 Unitized Transaxle engage or disengage or is out of adjustment smoothly si F aa 2 Insufficient low level of lubricant or Section 16 Unitized Transaxle wrong type of lubricant in transmission 3 Internal gears are damaged or worn Section 16 Unitized Transaxle 4 Synchronizer rings are worn damaged Section 16 Unitized Transaxle or jammed Troubleshooting Guide continued on next page 11 4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Electrical System TROUBLESHOOTING SYMPTOM POSSIBLE CAUSES REFER TO Excessive vehicle 1 Engine mounting nuts or bolts are Section 13 Engine vibration loose 2 Rubber snubber on frame is worn or Section 13 Engine damaged 3 Misaligned muffler mounting clamp Section 15 Exhaust System 4 Damaged drive belt or starter belt Section 1
153. UBE eg IMPULSE FUEL LINE ROUTING LENGTH No DS Turf 1 CA1 Villager 4 Fuel tank to primary fuel filter 6 0 in 15 2 cm Primary fuel filter to fuel pump 6 0 in 21 6 cm Fuel pump to secondary fuel filter 17 0 in 33 0 cm Secondary fuel filter to carburetor 2 5 in 6 4 cm Vent tube Carburetor 22 0 in 55 9 cm Vent tube Gas Tank 17 0 in 43 2 cm Impulse line 17 0 in 43 2 cm 2 0 in 5 1 cm for Carryall 1 and Turf 1 vehicles Front fuel strap present on Carryall and Turf vehicles only Figure 14 16 Fuel and Vent Lines Install the primary fuel filter 17 in the fuel line Use new clamps 16 Figure 14 16 Page 14 19 Install the secondary fuel filter 22 in the fuel line Use new clamps 16 Turn the fuel shut off valve to the ON position Figure 14 22 Page 14 26 Connect the battery cables positive cable first and tighten terminals to 20 ft lb 27 1 N m Boom 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 14 19 FUEL SYSTEM Fuel Pump Fuel Filter Installation Continued 5 Place the Forward Reverse handle in the NEUTRAL position and place the neutral lockout cam in the SERVICE position Start the engine and check for fuel leaks See following WARNING DANGER REPAIR ANY FUEL LEAKS BEFORE OPERATING THE VEHICLE 6 Place the neutral lockout cam in the OPERATE position FUEL PUMP Read DANGER and WARNING on page 14 1 GENERAL INFORMATION
154. VICE ON THIS VEHICLE BEFORE SERVICING VEHICLE READ COMPLETE SECTION S AND ANY REFERENCED INFORMATION RELEVANT TO SERVICE OR REPAIR TO BE PERFORMED NOTE THIS SUPPLEMENT REPRESENTS THE MOST CURRENT INFORMATION AT TIME OF PUBLICATION CLUB CAR INC IS CONTINUALLY WORKING TO FURTHER IMPROVE ITS VEHICLES AND OTHER PRODUCTS THESE IMPROVEMENTS MAY AFFECT SERVICING PROCEDURES ANY MODIFICATION AND OR SIGNIFICANT CHANGE IN SPECIFICATIONS OR PROCEDURES WILL BE FORWARDED TO ALL CLUB CAR AND CARRYALL DISTRIBUTORS DEALERS AND WILL WHEN APPLICABLE APPEAR IN FUTURE EDITIONS OF THIS SUPPLEMENT DAMAGE TO A VEHICLE OR COMPONENT THEREOF NOT RESULTING FROM A DEFECT OR WHICH OCCURS DUE TO UNREASONABLE OR UNINTENDED USE OVERLOADING ABUSE OR NEGLECT INCLUDING FAILURE TO PROVIDE REASONABLE OR NECESSARY MAINTENANCE AS INSTRUCTED IN THE VEHICLE OWNER S MANUAL ACCIDENT OR ALTERATION INCLUDING INCREASING VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS OR MODIFICATIONS WHICH AFFECT THE STABILITY OF THE VEHICLE OR THE OPERATION THEREOF WILL VOID THE WARRANTY CLUB CAR INC RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGNS AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION OR LIABILITY WHATSOEVER THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED IN THIS SUPPLEMENT SEE THE LIMITED WARRANTY FOUND IN THE VEHICLE OWNER S MANUAL OR WRITE TO CLUB CAR INC li 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement
155. Vehicle Maintenance and Service Supplement 12 9 ELECTRICAL COMPONENTS Starter Generator Commutator diameter minimum 1 535 inches 39 mm Concentric with armature shaft within 0 002 inch 0 051 mm Limit depth of cut when machining commutator 0 007 inch 0 2 mm If undercut of segment insulator is less than 0 016 inch 0 406 mm then it should be undercut to 0 031 inch 0 78 mm Dielectric strength 500 VAC for one minute Armature insulation resistance 0 2M Q ohms at 500 VDC Starter field coil resistance 0 006 0 01 Q ohms Generator field coil resistance 4 5 5 5 Q ohms Starter Generator Assembly 1 Place the field coil into the housing The two insulators that look alike fit into the slots next to the F1 and F2 markings on the outside of the housing The insulator that looks different slides into the slot next to the DF marking 2 After the insulators are seated in the slots install the threaded terminals through the wire connectors and then through the insulators Install a flat washer lockwasher and nut onto each threaded terminal on the outside of the housing and tighten to 47 5 in Ib 5 4 N m Figure 12 11 Page 12 8 A CAUTION ROUTE THE FIELD TERMINAL WIRES SO THAT THEY WILL NOT CONTACT THE ARMATURE 3 Install the four pole pieces into the housing Use the four screws to secure pole pieces to the inside of the housing to retain the field wires Tighten screws to 9 f
156. Vehicle Maintenance and Service Supplement Page 16 11 UNITIZED TRANSAXLE Unitized Transaxle Removal Raise rear of vehicle until powertrain can be rolled out With jack stands in place remove floor jack SNUBBER BRACKET Ec Lower snubber to the ground Vehicle body and frame remain stationary on Lift snubber jack stands while out of bracket powertrain is rolled out of the vehicle Roll entire powertrain out from under vehicle body Figure 16 28 Snubber Figure 16 29 Remove Powertrain 21 Remove the six bolts mounting the unitized transaxle to the engine 21 1 Remove four transaxle mounting bolts one at each corner of the transaxle mounting plate as shown Figure 16 34 Page 16 13 21 2 Remove two middle transaxle mounting nuts as shown Figure 16 34 Page 16 13 22 Remove the leaf springs wheels and brake assemblies from the transaxle Page 16 12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Remove bolt and mounting washer from driven clutch Remove two screws holding governor cable bracket TRANSAXLE MOUNTING BOLT AND NUT TYPICAL 4 PLACES WOODEN BLOCKS Figure 16 34 Transaxle Mounting 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Unitized Transaxle Removal Loosen nut Then with governor and accelerator cables still attached remove the governor arm from the shaft Leave cable connected Leave cable
157. YSTEM MAY OCCUR 2 Install the snap on electrical box cover by firmly pressing down on all corners and install the screw tightening to 18 in Ib 2 0 N m 3 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 Battery Protector Spray Club Car Part No 1014305 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12 15 ELECTRICAL COMPONENTS Accelerator Pedal Limit Switch ACCELERATOR PEDAL LIMIT SWITCH Read DANGER and WARNING on page 12 1 Testing the Accelerator Pedal Limit Switch See Test Procedure 5 Section 11 Page 11 23 Accelerator Pedal Limit Switch Removal 1 Disconnect battery wires as shown Figure 12 1 Page 12 2 2 Remove electrical component box cover 1 Figure 12 18 Page 12 17 3 Disconnect the green wire and the orange wire from the accelerator pedal limit switch 11 Figure 12 18 Page 12 17 4 Remove the two nuts 9 and washers 10 that secure the accelerator limit switch in place 5 Remove the accelerator pedal limit switch Accelerator Pedal Limit Switch Installation 1 Install the accelerator pedal limit switch 11 onto the two screws 16 and secure the switch using two washers 10 and nuts 9 Torque to 5 in Ib 0 6 N m Figure 12 18 Page 12 17 A WARNING DO NOT OVER TIGHTEN THE RETAINING NUTS IF THE NUTS ARE OVER TORQUED THE LIMIT SWITCHES COULD BE DAMAGED 2 C
158. ace 14 Figure 17 5 Page 17 6 4 Remove the drive buttons Figure 17 8 Page 17 8 4 1 Remove the screws flat washers drive button take up spring and 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 the weight assemblies with pins from the clutch 5 3 Before removing note the orientations of the wave washer and of the primary and secondary weights to one another Figures 17 12 and 17 13 page 17 10 Remove the plastic washers weights and wave washer from the pin Retain all parts DRIVE CLUTCH HUB PULLER TOOL CLUB CAR PART NO 1014497 Mark the clutch cover and its corresponding position on the moveable casting Figure 17 6 Mark Clutch Cover Figure 17 7 Remove Clutch Cover 6 Remove the retaining ring 3 from the shaft of the fixed face assembly 7 and slide the moveable face 14 off the shaft Figure 17 5 Page 17 6 See following NOTE NOTE IF THE MOVEABLE FACE IS REMOVED FROM THE HUB OF THE FIXED FACE THE SPIRAL BACK UP RINGS 12 FIGURE 17 5 PAGE 17 6 MUST BE REPLACED WITH NEW ONES 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 17 7 TORQUE CONVERTER Drive Clutch Disassembly Continued Remove these C items from ribs S7 10 24 SCREW a FLAT WASHER ad ory DRIVE BUTTON didi DRIVE BUTTON T o
159. ach 2 Gently pry center dash out from under edge of front body brace pull IMPORTANT center ash Bend top right corner of center dash panel inward during removal to provide clearance so the key switch do not touch the frame around the dash d y _ contacts on the back of the Figure 12 17 Center Dash Removal 2 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 Battery Protector Spray Club Car Part No 1014305 SOLENOID Read DANGER and WARNING on page 12 1 Testing the Solenoid See Test Procedure 6 Section 11 Page 11 23 Solenoid Removal 1 Disconnect battery wires as shown Figure 12 1 Page 12 2 2 Remove electrical component box cover Figure 12 27 Page 12 24 3 Disconnect all the wires from the solenoid 4 Remove the two screws that secure the solenoid in place and remove the solenoid 12 14 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Fuse Solenoid Installation 1 Install the solenoid in the electrical component box Use two screws to secure the solenoid to the box and tighten to 14 in Ib 1 6N m 2 Connect the 6 gauge white wire and the 16 gauge red wire from the voltage regulator on a large post on the solenoid See Section 11 Figure 11 2 Page 11 6 3 Connect the 18 gauge white wire from the Fuel Hour Meter to the same
160. age 17 1 Maintaining proper adjustment of the engine and governor as well as the torque converter is essential to the troubleshooting process If these adjustments are within Club Car specifications and when climbing a steep hill the engine begins to lose RPM before the drive belt reaches the top of the driven clutch there is a torque converter problem If the torque converter is not operating properly 1 Check the governor and throttle settings See Section 14 Fuel System 2 Inspect the driven clutch for dirt and dust buildup on its component parts Clean the driven clutch with water to remove any dust or dirt then drive the vehicle and check for proper operation 3 If cleaning the driven clutch does not solve the problem disassemble and thoroughly clean all parts of the drive clutch Be sure to clean the plastic drive buttons 10 Figure 17 5 Page 17 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 wears the engine RPM will increase to compensate for the change in torque converter ratio This will keep the vehicle s maximum ground speed correct See Section 2 Vehicle Specifications in the appropriate maintenance and service manual for appropriate maximum ground speed Grasp belt midway between drive and driven clutches then roll belt off driven clutch
161. 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 replaced before using the vehicle 4 Make sure all connectors in the circuit are clean and tight and examine wires for signs of overheating fraying etc Wires in poor condition and bad connections will affect electrical system operation 5 Measure coil and winding resistance when the part is cold at room temperature 6 All the electrical leads are either single color or two color and with only a few exceptions must be con nected to leads of the same color On any of the two color leads there is a greater amount of one color and a lesser amount of a second color so a two color lead is identified by first the primary color and then the secondary color For example a yellow wire with a thin red stripe is referred to as a yellow red wire LUBRICATION SYSTEM The engine is equipped with a pressurized lubrication system which consists of these components Figure 13 1 Page 13 6 and Figure 13 2 Page 13 6 Inlet filter screen 2 Trochoid pump 3 e Cartridge filter 5 Pressure relief valve 8 13 4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE General Information The pump 3 draws oil from the sump 1 and forces it under pressure into the crankcase passages as shown Figure 13 1
162. ame WIRE ASSEMBLY 16 GAUGE RED WIRE ASSEMBLY SOLENOID ELECTRICAL COMPONENT Disconnect the 6 gauge BOX black wire from the battery Place red probe on disconnected end of wire Figure 11 27 Test Battery Ground Strap Figure 11 28 Solenoid Wire Connections 3 Check the engine ground strap 3 1 Place the red probe of the multimeter on the ground strap terminal end located on the oil filler tube bracket on the engine Figure 11 26 Page 11 22 Place the black probe on the vehicle frame The reading should be continuity If the reading is incorrect clean and tighten wire connections If the connections are good and the reading is incorrect repair or replace the wire 4 Check the battery ground cable 4 1 A 6 gauge black wire connects the negative battery post to the frame The frame connection should be clean and tight Visual inspection of the connection on the frame is very difficult The best check for tightness is to pull on the black wire If the wire moves at the connection end disassemble the frame connection and clean the bolt ring terminal and nut Reinstall the frame connection 4 2 Set the multimeter to 200 Q ohms Place the red probe on the unconnected end of the 6 gauge black wire and place the black probe on the vehicle frame Figure 11 27 Page 11 22 The reading should be continuity If the reading is incorrect check that terminal connections are clean and tight If
163. amps are used on all hose connections except at the carburetor A screw band clamp should be used at the carburetor Figure 14 16 Page 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 closed OFF position during vehicle storage towing or trailering Figure 14 21 Page 14 26 Unless the engine will be run as part of a procedure the fuel shut off valve should also be turned OFF before performing maintenance or service procedures Fully Open Position The valve s open position differs from standard valve configurations For the valve to be fully open it must be turned approximately 120 from the closed OFF position until it cannot be turned any further Figure 14 22 Page 14 26 If the valve becomes partially closed the engine will not run properly due to fuel starvation CLOSED OFF POSITION FULL OPEN ON SELECTOR IS ALIGNED POSITION WITH OFF MARKINGS ON THE SIDES OF VALVE VIEWED FROM SELECTOR SIDE OF VALVE VIEWED FROM SELECTOR SIDE OF VALVE Figure 14 21 Closed Fuel Shut off Valve Figure 14 22 Open Fuel Shut off Valve Page 14 26 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM F el Shut Off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 14 23 Incorrect Fuel Shut off Valve 2000 FE290 Gaso
164. and tighten it to 61 in Ib 6 9 N m 11 Write the size of the main jet on the fuel bowl with an indelible ink marker This should be written in a location that will be visible when the carburetor is installed on the engine 12 Install the carburetor on the engine Figure 14 6 Page 14 6 12 1 Attach the throttle return spring 11 to the carburetor and then to the throttle bracket 4 just before positioning the carburetor and securing it to the engine 12 2 Install the intake pipe gasket 16 check for proper orientation and intake pipe 17 12 3 Install the carburetor retaining nuts 19 and tighten them to 50 in Ib 5 7 N m 13 Connect fuel supply line 26 and tighten screw clamp to 9 in Ib 1 0 N m if equipped Figure 14 6 Page 14 6 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 Ib 3 4 N m 17 Install the intake hose 23 and secure with a hose clamp NOTE MAKE SURE THE INTAKE HOSE IS NOT TWISTED DURING INSTALLATION 18 Turn fuel shut off valve on gas tank to the ON position Figure 14 22 Page 14 26 19 Connect the battery cables positive post first and tighten terminals to 20 ft lb 27 1 N m 20 Test drive the vehicle ENGINE CONTROL LINKAGE Read Danger and Warning on page 14 1 GENERAL INFORMATION For proper vehicle operat
165. ands to support the vehicle Figure 16 27 Page 16 12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 9 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal Continued gt BLACK d 7 WIRE or Figure 16 18 Ignition Kill Wire LIFTING POSITION FOR DS AND VILLAGER 4 LIFTING POSITION FOR TURF 1 AND CARRYALL 1 Disconnect shock absorbers from lower mounts Position floor jack under hitch bracket or frame Figure 16 20 Shock Absorbers Figure 16 21 Floor Jack 11 Pull the floor jack from beneath the vehicle and move it away 12 Lift the snubber out of the snubber bracket in the vehicle frame and lower it to the floor Figure 16 28 Page 16 12 The powertrain should be completely disconnected from the vehicle and resting on the floor 13 Grasp the ends of the leaf springs at the rear of the vehicle and roll the drivetrain out from under the vehicle Figure 16 29 Page 16 12 14 Place blocks under the engine pan so they will completely support the engine and keep it level to the floor Figure 16 24 Page 16 11 See following NOTE NOTE PLACE THE BLOCKS SO THEY WILL SUPPORT THE ENGINE WHEN THE TRANSAXLE IS DETACHED AND MOVED AWAY FROM THE ENGINE 15 Remove the drive belt 15 1 Grasp belt midway between drive and driven clutch and pull up on belt to force the driven
166. as instructed on page 17 4 Connect the battery cables positive cable first Connect the spark plug wire to the plug Drive the vehicle and check for proper operation TYPICAL 9 1 gt 3 PLACES Figure 17 16 Driven Clutch Assembly 17 12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH Read DANGER and WARNING on page 17 1 DRIVEN CLUTCH REMOVAL 1 Remove the drive belt as instructed on page 17 3 2 Remove the bolt 11 and mounting washer 12 from the clutch shaft Figure 17 16 Page 17 12 3 Grasp the driven clutch assembly and slide it off the shaft 4 Leave the key 9 in the keyway Figure 17 16 Page 17 12 DRIVEN CLUTCH DISASSEMBLY 1 Using external snap ring pliers remove the retaining ring 4 Figure 17 17 Page 17 13 See follow ing WARNING A WARNING DO NOT PLACE FINGERS UNDER THE CAM WHEN REMOVING THE CAM THE MOVEABLE FACE MAY SPIN WHEN THE CAM BUTTONS RELEASE FROM THE CAM RAMPS RESULTING IN SEVERE PERSONAL INJURY 2 Insert a puller plug 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 1014508 to remove the cam 4 from the fixed face shaft 8 Figure 17 16 Page 17 12 Place puller plug in bore of cam A Then clamp driven clutch cam puller onto three flat surfaces of the cam Using external snap DRIVEN CLUT
167. at is attached to the carburetor and an air duct that provides the engine with air from outside the engine compart ment Clean cool air is drawn through the choke assembly and into the air cleaner intake This feature increases engine horsepower and extends air filter life The choke system aids in starting the engine in cold weather When starting a cold engine the spring loaded choke cover is pushed in by hand This restricts the air flow creating a fuel rich mixture in the carburetor The choke cover is held in until the engine starts and then is released The air flow to the engine is no longer restricted and the engine operates normally The choke assembly is adjusted at the factory and does not require field adjustment However if the choke assembly is subjected to abuse or damaged it may become necessary to replace the assembly CHOKE BUTTON REMOVAL 1 Remove the mounting screws 17 from the back side of the choke Remove the choke assembly from the vehicle body Figure 14 15 Page 14 17 14 14 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM Choke and Air Intake System CHOKE BUTTON INSTALLATION 1 Position the choke assembly 19 on the vehicle body Install the mounting screws 12 from inside the vehicle body and tighten to 18 in lb 2 0 N m Figure 14 15 Page 14 17 2 Check for proper operation If the choke button does not adequately engage the choke positioner 6 loosen the 12
168. ator Circuit Low Oil Warning Circuit Engine Ignition Circuit Neutral Lockout Circuit Engine Kill Circuit 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 11 5 TROUBLESHOOTING Utility vehicles Turf 1 Carryall 1 and Villager 4 have two additional circuits Fuel Gauge and Sending Unit Circuit Hour Gauge Circuit Electrical System Utility vehicles Turf 1 Carryall 1 and Villager 4 have a combination fuel hour gauge Recognizing and understanding the function of each of these circuits will help to quickly isolate the source of an electrical problem Use the troubleshooting flow charts in the Circuit Testing section to find the proper test procedure to correct the electrical problem See Figure 11 2 for a complete wiring diagram FRAME GROUND 2 REVERSE BUZZER PEDAL LIMIT SWITCH amp O KILL LIMIT SWITCH VOLTAGE REGULATOR BATTERY GROUND Dashed lines indicate wiring present on Turf 1 Carryall 1 and Villager 4 vehicles only Figure 11 2 FE290 Gasoline Vehicle Wiring Diagram Page 11 6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ACCELERATOR __ FORWARD REVERSE ASSEMBLY REVERSE BUZZER LIMIT SWITCH 220 NEUTRAL LOCKOUT LIMIT SWITCH STARTER GENERATOR gt YELLOW YELLOW TROUBLESHOOTING Flectrical Circuits ELECTRICAL CIRCUITS STARTER CIRCUIT The starter circuit consists of a 12 v
169. 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 Battery Protector Spray Club Car Part No 1014305 VOLTAGE REGULATOR Read DANGER and WARNING on page 12 1 Testing the Voltage Regulator See Test Procedure 11 Section 11 Page 11 27 Voltage Regulator Removal 1 Disconnect battery cables as shown Figure 12 1 Page 12 2 2 Remove the electrical component box cover and remove the wire tie securing the wires where they exit the component box 3 Disconnect the voltage regulator red wire 1 at the large post on the solenoid and disconnect the yel low wire 2 at the bullet connector Figure 12 16 Page 12 13 4 Disconnect the voltage regulator black ground wire 3 at the battery frame ground and also from the normally open NO terminal of the kill limit switch in the component box Figure 12 16 Page 12 13 5 Remove the voltage regulator mounting screw 4 and remove the regulator 5 Voltage Regulator Installation 1 Position the voltage regulator 5 in the electrical component box and install the mounting screw 4 Figure 12 16 Page 12 13 Tighten screw to 23 in Ib 2 6 N m 12 12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Key Switch 2 Connect voltage regulator red wire 1 to the solenoid and connect the yellow wire 2 bullet connector 3 Connect the black ground wire 3 to the batt
170. ble face assembly 7 onto the fixed face shaft 8 Figure 17 16 Page 17 12 Place the end of the spring 5 into the hole in the moveable face assembly Install the key 3 into the keyway of the fixed face assembly 8 shaft Figure 17 16 Page 17 12 a A WO Im Holding the cam 4 in position for assembly on the shaft install the other end of the spring 5 into the center spring hole of the cam Rotate the cam until the keyway is aligned with the key 3 on the fixed face assembly and then start the cam onto the shaft approximately 1 4 to 3 8 inch 6 3 to 9 5 mm 6 Place the clutch assembly in a press and position the cam press tool Club Car Part No 101809101 on the cam as shown Figure 17 19 Page 17 14 7 Hold the fixed face assembly 3 and rotate the moveable face assembly 1 one third turn clockwise then press the cam 2 onto the fixed face assembly Figure 17 19 Page 17 14 CAM PRESS TOOL MH Hl YJ 0 Figure 17 19 Press Tool 8 Install the retaining ring 2 Figure 17 16 Page 17 12 See following NOTE 17 14 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TORQUE CONVERTER Driven Clutch NOTE THE RETAINING RING CAN BE REUSED IF THE O D DOES NOT EXCEED 1 607 INCHES 40 82 MM OTHERWISE IT MUST BE REPLACED WITH A NEW RING CLUB CAR PART NO 1014080 9 While holding onto the cam tap the end of the fixed face shaft
171. bly serene 14 20 installation edema 14 22 removal ane sees 14 20 fuel shut off valve 14 26 fuel tank disposal nne nOD 14 24 InstallatiOb 2 2 irte ttn dete 14 24 removal aedes 14 23 St ra go 14 24 fuel hour gauge fuel gauge circuit 11 6 11 11 11 36 fuel level sending unit testing n n eee gets 11 35 hour gauge circuit eeen 11 11 testing oe eiu RR 11 37 installation 12 22 removal 2 eke die 12 21 fueling instructions 10 7 fuse installatlOn 12 15 removal nienEIDI END 12 15 testing 11 18 G governor governor system enai 16 2 governor cable installation and adjustment 14 11 removal x nei 14 11 governor gear 16 28 disassembly 5 16 17 ground straps 12 31 oL eee LEN ne ties 11 21 H hour gauge see fuel hour gauge hour gauge circuit 11 6 l idler shaft assembly ne a a iea 16 23 disassembly iea te rrr s 16 21 ignition testing 11 29 2 2000 FE290 Gasoline Vehicle Maintenance and Service Manual
172. carburetor end only Figure 14 6 Page 14 6 1 4 Remove the governor guard 5 1 5 Remove the governor cable cotter pin 25 and clevis pin 24 carburetor end only 1 6 Disconnect the carburetor vent line 14 1 7 Disconnect the fuel supply line 26 at the carburetor 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 NOTE NOTE THE ORIENTATION OF THE GASKET 16 BETWEEN THE CARBURETOR INTAKE 17 PIPE AND THE CARBURETOR BODY 12 SO THAT IT CAN BE REPLACED IN THE SAME ORIENTATION FIGURE 14 6 PAGE 14 6 WHEN REMOVING THE CARBURETOR BODY THE THROTTLE RETURN SPRING 11 MUST BE DISCONNECTED NOTE ITS PROPER ORIENTATION SO THAT IT CAN BE REPLACED IN THE SAME ORIENTATION THE CARBURETOR MUST BE KEPT UPRIGHT DURING REMOVAL 2 Position the carburetor with the drain screw 11 over a catch basin Figure 14 7 Page 14 7 3 Turn the carburetor bowl drain screw counterclockwise two or three turns and drain all the fuel from the bowl into the catch basin Figure 14 7 Page 14 7 Tighten the drain screw to 10 in lb 1 1 Return fuel to the gas tank or dispose of properly 4 Mark the body of the carburetor and the carburetor fuel bowl with an indelible ink marker so that after removal the bowl can be installed again in the same position Figure 14 7 Page 14 7 5 Remove t
173. carburetor through flexible lines Two in line filters are installed between the fuel tank and the carburetor 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 circumstances should the period of time between filter changes 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 14 19 to the closed OFF position Figure 14 21 Page 14 26 3 Remove the primary fuel filter 17 Figure 14 16 Page 14 19 3 1 Remove the clamps 16 and fuel lines 1 and 2 from the filter and plug the fuel lines Figure 14 16 Page 14 19 4 Remove the secondary filter 22 Figure 14 16 Page 14 19 4 1 Remove the clamps 16 and fuel lines 3 and 4 from the filter and plug the fuel lines 3 and 4 Figure 14 16 Page 14 19 FUEL FILTER INSTALLATION A CAUTION e FUEL FILTERS ARE MARKED WITH FLOW DIRECTION ARROWS MAKE SURE THAT FILTERS ARE INSTALLED WITH ARROWS POINTING IN THE DIRECTION OF FUEL FLOW FROM TANK TO CARBURETOR Page 14 18 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM Fuel Filters NO 6 FUEL TANK VENT TUBE NO 2 FUEL LINE NO 1 FUELL 74 SE a INE NO 3 FUEL LINE E NO 5 CARBURETOR AIR VENT T
174. ce and Service Supplement Page 11 15 TROUBLESHOOTING Circuit Testing TESTING THE LOW OIL WARNING CIRCUIT Read DANGER and WARNING on page 11 1 Use the chart below Figure 11 20 to begin troubleshooting the low oil warning circuit LOW OIL LIGHT WILL NOT ILLUMINATE WHEN ENGINE OIL IS LOW CHECK WIRE CONNECTION TO THE OIL LEVEL SENSOR WIRES INCORRECTLY WIRES CORRECTLY CONNECTED CONNECTED RECONNECT WIRES OVERRIDE OIL LEVEL SENSOR r YELLOW WIRE TO GROUND TEST PROCEDURE 21 LOW OIL WARNING LIGHT LOW OIL WARNING LIGHT ILLUMINATES DOES NOT ILLUMINATE REPLACE OIL LEVEL SENSOR CHECK CONTINUITY OF YELLOW WIRE TO LOW OIL WARNING LIGHT CONTINUITY NO CONTINUITY CHECK LOW OIL REPLACE YELLOW WIRE WARNING LIGHT TEST PROCEDURE 22 LOW OIL WARNING LIGHT LOW OIL WARNING LIGHT DOES NOT ILLUMINATE ILLUMINATES CONTINUITY REPLACE OIL LEVEL SENSOR REPLACE LOW OIL WARNING LIGHT Figure 11 20 Testing the Low Oil Warning Circuit Page 11 16 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING TESTING THE NEUTRAL LOCKOUT CIRCUIT Read DANGER and WARNING on page 11 1 Use the chart below Figure 11 21 to begin troubleshooting the neutral lockout circuit ENGINE WILL CRANK WHEN SHIFTER IS IN NEUTRAL POSITION CHECK NEUTRAL LOC
175. chometer Club Car Part No 1016112 to the spark plug lead 5 With the tachometer connected and the engine at normal operating temperature check high speed RPM With the accelerator pedal pressed to the floor the tachometer should read DS Golf Car 2700 30 RPM Carryall Turf 1 2860 30 RPM Villager 4 2700 30 RPM 6 To reduce RPM loosen the accelerator cable retaining nut on the outside of the electrical box wall and tighten the retaining nut on the inside of the wall until the desired rpm is reached Figure 14 9 Page 14 10 or Figure 14 10 Page 14 10 To increase RPM loosen the cable retaining nut inside the electrical box and tighten the nut outside the box until the desired rpm is reached 7 Be sure both retaining nuts are locked against the electrical box and then check the rpm again If the RPM needs to be adjusted repeat step 6 8 If more adjustment is required than the cable housing will allow make sure the spring on the other end of 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 AIR INTAKE SYSTEM Read DANGER and WARNING on page 14 1 GENERAL INFORMATION The choke system is a simple mechanism requiring very little or no maintenance The system consists of a choke assembly that is attached to the driver side of the front body an air filter housing with a hose th
176. clutch sheaves apart Roll the belt counterclockwise while pulling it off driven clutch Figure 16 25 Page 16 11 Page 16 10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UNITIZED TRANSAXLE Unitized Transaxle Removal 16 Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle Figure 16 30 Page 16 13 17 Loosen but do not remove the governor arm retaining bolt Remove the governor arm from the shaft Figure 16 31 Page 16 13 18 Remove screws securing the governor cable bracket to transaxle Figure 16 32 Page 16 13 19 Remove screws securing the accelerator 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 NOTE THE GOVERNOR CABLE AND THE ACCELERATOR CABLE SHOULD REMAIN ATTACHED TO THE GOVERNOR ARM Remove bolts then rotate shackles up and away from spring eae spring retainer bolts Figure 16 22 Rear Shackles Figure 16 23 Spring Retainer Bolts Using wooden blocks B aT Grasp belt midway prop engine pan up so QE SN between drive and that it is level with floor CSL WP driven clutches p lt then roll belt off driven clutch Q Y 3 aes _ CLUTCH gt APPROX 6 IN DRIVE CLUTCH Figure 16 24 Position Powertrain Figure 16 25 Remove Drive Belt 2000 FE290 Gasoline
177. connected Remove two screws holding accelerator cable retaining bracket Figure 16 33 Accelerator Cable Bracket Page 16 13 UNITIZED TRANSAXLE Unitized Transaxle Disassembly REFERENCE FORWARD REVERSE SHIFTER Figure 16 35 Transaxle Gear Casing and Brackets UNITIZED TRANSAXLE DISASSEMBLY Read DANGER and WARNING on page 16 1 NOTE THE FOLLOWING INFORMATION PROVIDES INSTRUCTIONS FOR DISASSEMBLING THE UNITIZED TRANSAXLE HOWEVER THE TRANSAXLE CASE CAN BE SEPARATED AND GEARS ACCESSED WITHOUT REMOVING THE AXLES OR AXLE TUBES FROM THE CASE Page 16 14 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Unitized Transaxle Disassembly 1 Remove the drain plug and gasket Drain and dispose of the oil properly Figure 16 2 Page 16 2 2 Using 90 090 tip internal snap ring pliers remove the internal retaining rings 74 Figure 16 5 Page 16 4 from the axle tubes See also Figure 16 3 Page 16 3 3 Pull the axles 67 and 68 out of the axle tubes Figure 16 5 Page 16 4 4 Remove seven bolts with lock washers 77 mounting each axle tube to the transaxle case Figure 16 5 Page 16 4 Then remove axle tubes from the transaxle case NOTE IT MAY BE NECESSARY TO TAP THE AXLE TUBE WITH A RUBBER OR PLASTIC MALLET TO BREAK IT FREE FROM THE TRANSAXLE CASE 5 Remove the fifteen bolts 27 that hold the transaxle housing together Figure 16 35 Page 16 14
178. crews 12 from the speed nuts 11 12 Lift the fuel tank out of the vehicle FUEL TANK DISPOSAL 1 Remove the cap from the tank and thoroughly rinse it with water The cap may be discarded or kept as a spare 2 In a well ventilated area flush the fuel tank with water to remove any remaining 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 the tank dries completely allow the tank to sit for 24 hours See following CAUTION A CAUTION DISPOSE OF WASTEWATER AND FUEL TANK IN ACCORDANCE WITH FEDERAL STATE AND LOCAL LAWS AND ORDINANCES FUEL TANK STORAGE 1 Remove the cap from the tank and thoroughly rinse it with water 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 the tank dries completely allow the tank to sit for 24 hours 4 Store the tank upside down with the cap installed in a well ventilated area ORANGE CONNECTION Figure 14 19 Fuel Level Sending Unit FUEL TANK INSTALLATION 1 With the retaining straps correctly positioned install the fuel tank in the vehicle 2 Secure the tank with the retaining straps 13 and 18 Figure 14 16 Page 14 19 2 1 Position the straps in the indentions on the tank 2 2 Install the screws 12 into the speed nuts 11 Tighten screws and
179. d TAKE UP SPRING Figure 17 8 Drive Button Mounting Drive Clutch 2 0 1 4 20 SCREW H 5 FLAT WASHER 0 WEIGHT WEIGHT SLOTS IN HUB CASTING Figure 17 9 Weight Position 7 Remove the spacer 16 and spring 4 and retainer 5 The spring retainer can be removed from the spring if necessary Figure 17 5 Page 17 6 8 If necessary remove idler bearing Use a press to remove the bearing Figure 17 10 Page 17 9 See following NOTE NOTE DO NOT REMOVE THE IDLER BEARING UNLESS IT NEEDS TO BE REPLACED IF IDLER BEARING IS REMOVED REPLACE IT WITH A NEW BEARING 9 Use a scribe or small pick to remove the spiral backup rings 12 from each 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 seal damage Figure 17 5 Page 17 6 NOTE IT IS NORMAL FOR A SMALL AMOUNT OF GREASE TO BE PRESENT AT THE EDGE OF SEAL Page 17 8 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TORQUE CONVERTER Drive Clutch 2 Inspect the bore of the moveable face assembly 14 for scarring or wear The moveable face assembly must be replaced if the bore is worn to a diameter of 0 883 inch 22 4 mm or larger Figure 17 5 Page 17 6 3 Inspect the steel shaft 7 on the fixed face assembly There should be
180. driver 2 Part of Club Car Bearing Driver Kit Part No 1016416 drive out the ball bearing 3 as shown Ball Bearing Inspection 1 Clean the ball bearing thoroughly in high flash point solvent and dry it NOTE e NEVER USE COMPRESSED AIR TO DRY BEARING USE OF COMPRESSED AIR WILL RESULT IN PREMATURE BEARING FAILURE 2 Spin the ball bearing by hand and check for A axial play and B radial play Replace the ball bearing if itis noisy does not spin smoothly or if it has any play Figure 13 91 Page 13 41 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 13 39 FE290 ENGINE Crankshatt and Counterbalance Figure 13 91 Check Ball Bearing OIL SEALS Oil seals are used on both ends of the crankshaft Any time the crankshaft is removed from the seals the seals must be replaced with new ones Oil Seal Removal Use an oil seal remover to press or drive the seal out of the casing Oil Seal Installation NOTE NEVER REUSE AN OIL SEAL REPLACE THE OIL SEAL WITH A NEW ONE 1 Puta light coating of clean engine oil on the 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 85 mm seal driver press the oil seal into the flywheel side of the crankcase until it is flush with the hole 4 Using the 1 97 inch 50 mm seal driver press the oil seal
181. e to the positive battery post 3 Attach the negative charger cable to the negative battery post 4 The battery may be charged with a slow charge 3 10 amps or a fast charge 20 30 amps Charge until the specific gravity reaches 1 250 See following WARNING 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 12 29 ELECTRICAL COMPONENTS Battery A WARNING IF THE BATTERY CASE FEELS HOT APPROXIMATELY 125 F 51 7 C OR MORE AND OR EMITS GASES AND OR FLUID BOILS FROM VENTS STOP CHARGING AT ONCE FAILURE TO STOP CHARGING BATTERY WHEN THESE CONDITIONS ARE PRESENT COULD RESULT IN AN EXPLOSION PERSONAL INJURY AND OR DAMAGE TO THE BATTERY DO NOT DISCONNECT THE DC LEADS AND BATTERY WHEN THE CHARGER IS ON THE RESULTING ARCING BETWEEN THE DC LEADS AND BATTERY POST COULD CAUSE AN EXPLOSION e IF THE CHARGER MUST BE STOPPED DISCONNECT THE AC SUPPLY CORD FROM THE WALL OUTLET BEFORE DISCONNECTING THE DC LEADS FROM THE BATTERY ALLOW THE BATTERY TO COOL TO ROOM TEMPERATURE AND RESUME CHARGING BATTERY AT A LOWER AMP RATE Battery Installation Read DANGER and WARNING on page 12 1 and DANGER on Page 12 26 1 Place the battery into the vehicle Make sure the battery posts are facing the engine 2 Secure the battery to the vehicle with the clamp Install bolt washer and locknut and tighten to 12 ft lb 16 3 N m 3 Connect battery cables positive cable first and tighten te
182. e 16 30 Then install the washer and using external snap ring pliers 070 tip install retaining ring on the shifter shaft out side of the case Figure 16 72 Page 16 30 Make sure the retaining ring is in the groove of the shaft 7 Install the gear assemblies into the left driver side case 7 1 Stand the left side case on the mounting plate then install the differential gear case assembly as shown Figure 16 73 Page 16 31 Do not seat the assembly in the bore but insert it just far enough that it will not fall out 7 2 Install the idler gear assembly into case as shown Do not seat the assembly in the bore but insert far enough that it will not fall out No gears mesh at this time Figure 16 75 Page 16 31 7 3 Install the oil guide with the baffle toward the case wall as shown Figure 16 75 Page 16 31 Make sure the two tabs on the guide are positioned in the slots in the case 7 4 Position the shifter fork assembly on the synchronizer gear assembly as shown and install them together bearing end first into the bore containing the oil guide Figure 16 76 Page 16 31 Do not seat the assembly but make sure the spur gear 40 is meshed with the governor gear 63 Figure 16 42 Page 16 18 and the shifter lever 14 Figure 16 35 Page 16 14 is positioned in the bracket on the shifter fork See also Figure 16 77 Page 16 32 Page 16 28 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Uniti
183. e Belt Installation sssssssssssssesssesesesnene enne a ssh snnt 17 4 Drive ure EE 17 4 Drive Clutch Removal iiti ia tita i ath avete Lr end eid fad e eU Led uua deb dud 17 5 Drive Clutch Cleaning and Inspection 17 5 Drive Cl tchiDisassembly 32 neta adi T pet oae eem seed 17 7 Inspection of Drive Clutch Parts 17 8 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page vii Drive Clutch Assembly catenin aun eL nuda e ie edit d Tee Uu eae aure eee e Gadel E E Driven Cluteh Removal ald eee a ead Nilesat ae deg ea e Rn e Vnd e vUa Driven Clutch Disassembly Driven Clutch Inspection Driven Cl tch Assembly ii sess acai eink a edet ae Driven Clutch Installation sssssessesssseseeee enne enne en nnns entren nnns Page vili 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement SECTION 10 PERIODIC MAINTENANCE DANGER BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE VEHICLE AND SERVICE AREA VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR A FULL FACE SHIELD AND RUBBER GLOVES
184. e and Service Supplement 17 5 TORQUE CONVERTER Drive Clutch Drive Clutch Cleaning and 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 Figure 17 5 Drive Clutch Assembly 17 6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TORQUE CONVERTER Drive Clutch DRIVE CLUTCH DISASSEMBLY CAUTION THE DRIVE CLUTCH IS BALANCED AS AN ASSEMBLY BEFORE DISASSEMBLY MAKE MATCH MARKS ON THE CLUTCH COVER AND ON THE MOVEABLE FACE ASSEMBLY SO THEY CAN BE REASSEMBLED IN THE SAME POSITIONS FIGURE 17 6 PAGE 17 7 1 Make match marks on the clutch cover and on the moveable face casting Figure 17 6 Page 17 7 2 Remove the clutch cover 1 Figure 17 5 Page 17 6 2 1 Remove the clutch plug 22 Figure 17 5 Page 17 6 2 2 Thread the center bolt of the Drive Clutch Hub Puller Club Car Part No 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 8 Thread the three small bolts of the puller into corresponding holes in the clutch Tighten bolts evenly making sure the face of the puller plate is parallel to the face of clutch Figure 17 7 Page 17 7 2 4 Unscrew the puller center bolt out of the clutch to pull clutch cover off 3 Remove the thrust washer 11 from the moveable f
185. e level and read the scale at the level of electrolyte Figure 11 24 Page 11 20 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 11 19 TROUBLESHOOTING Test Procedures Test Procedure 2 Continued BATTERY CAP HYDROMETER TEST PLATES Hold the hydrometer at eye level Read the ELECTROLYTE scale at the level of LEVEL AT LEAST the electrolyte 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR Figure 11 23 Battery Electrolyte Level Figure 11 24 Reading Hydrometer 7 Record the reading 8 Return the electrolyte to the cell from which it was taken Replace vent cap 9 Repeat steps 2 8 on all cells Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 F 27 C The readings obtained as described above must be corrected for temperature For each 10 F 5 6 C above 80 F 27 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 approximate state of charge can be determined from the following table SPECIFIC GRAVITY AT 80 F 27 C STATE OF CHARGE 1 250 1 280 1 220 1 240 1 190 1 210 1 160 1 180 If the difference between the cells is 0 020 o
186. e piston rings oil seals or gaskets The breather valve is a reed type valve which limits the direction of air flow caused by the piston moving up and down Air can flow out of the crankcase but the one way reed valve blocks return flow It thus maintains a vacuum in the crankcase Breather Valve Inspection 1 2 3 Inspect the reed valve 1 for sticking or binding Replace if necessary Figure 13 41 Page 13 22 Inspect the reed valve for hairline cracks distortion or breakage Replace if necessary Inspect the reed valve 1 seating surface It must not have any nicks or burrs Page 13 20 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Cylinder Head Breather Valve Installation 1 Installation is the reverse of removal See Breather Valve Reed Valve Removal Page 13 12 NOTE e PLACE THE REED VALVE ON THE SEAT SO THERE IS A SLIGHT GAP 2 0 008 INCH MAXIMUM 0 203 MM BETWEEN THE VALVE AND THE SEAT FIGURE 13 41 PAGE 13 22 MOUNTING SCREW Figure 13 41 Reed Valve INSTALLATION OF REMAINING ENGINE COMPONENTS Read DANGER and WARNING on page 13 1 1 Install rocker cover 2 Install lower upper and head shrouds 1 along with two ended bolt 2 Figure 13 42 Page 13 23 NOTE THE SHORTER END OF THE TWO ENDED BOLT 2 GOES THROUGH WASHER AND UPPER SHROUD TO PREVENT LEAKS APPLY A LIGHT COAT OF CLEAN ENGINE OIL TO THE O RING SEAL 7 BEFORE INSTALLATION CA
187. e pressing the accelerator pedal the following events should occur in exactly the order shown EVENT APPROXIMATE PEDAL TRAVEL Park Brake Release 0 4 Solenoid Activation 4 8 Carburetor Throttle Actuation 8 12 9 While holding the accelerator ball joint with pliers tighten the jam nuts against the ball joints accelera tor ball joint first at each end of the accelerator rod RETAINING NUTS E UN Figure 14 10 Turf 1 Carryall 1 and Villager 4 Cam Position Figure 14 9 DS Golf Car Cam Position 14 10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM Engine Control Linkage W Pull spring release to install accelerator rod BOTTOM VIEW Figure 14 11 Accelerator Rod 10 Again check rod adjustment for proper switch activation 11 After the pedal group and accelerator rod are properly adjusted adjust the engine RPM setting See Engine RPM Adjustment Page 14 14 12 Install the electrical box cover and tighten retaining screw GOVERNOR CABLE Governor Cable Removal 1 Remove seat or lift bed to access engine compartment 2 Remove the governor guard 5 Figure 14 6 Page 14 6 3 Remove the cotter pin 25 and clevis pin 24 at the carbure
188. e the red probe of the multimeter on the 1 terminal of the fuel gauge Voltage should read between 10 0 volts and 10 5 volts If the reading is incorrect replace fuel gauge Figure 11 45 Page 11 36 TEST PROCEDURE 27 HOUR GAUGE Read DANGER and WARNING on page 11 1 NOTE KEEP THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 27 1 Place the Forward Reverse handle in the NEUTRAL position place the neutral lockout cam in the SERVICE position and chock the wheels 2 Turn the key switch to ON and record the current hour gauge reading 3 Depress and hold the accelerator pedal to run the engine for at least six minutes the meter records in six minute increments See following DANGER A DANGER DO NOT OPERATE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON 4 fthe reading does not change after six minutes then replace the fuel hour gauge 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 11 37 SECTION 12 ELECTRICAL COMPONENTS DANGER BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE VEHICLE AND SERVICE AREA VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR A FULL FACE SHIELD AND RUBBER GLOVES WHEN WORKING ON OR NEAR BATTERIES BATTERY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTID
189. ed 12 27 periodic lubrication schedule 10 4 periodic service schedule 10 3 muffler see also exhaust system installation neiise 15 2 removal pce hae ial Pas le M E ua 15 2 N neutral lockout 11 17 11 24 11 34 16 2 cam installation ceteri 12 18 FEMOVAL 12 18 limit switch installation 12 17 ida Bea 12 17 neutral lockout circuit 11 5 oil level sensor installation ee 12 26 13 24 removal 12 26 13 24 TESNO ce er I RH ise 11 33 oil light see low oil warning light oil pressure relief valve INSPECTION RE diede 13 33 installation ctr a 13 33 mE 13 32 oil pump cover removal rrain asni a 13 31 INSPECTION TT ATE 13 32 installatiOri 5 ao te 13 33 oil screen 1 6 etre zer nciht rex exe 13 39 FEMOVAl 13 39 oll englne 22 terme 10 6 P periodic lubrication schedule 10 4 periodic service schedule 10 3 Page i 3 INDEX piston boring the engine 13 29 13 49 inspection and repair 13 26 installation tice er coe 13 42 removal sled 13 25 separation from connecting
190. ee eee d d de ue dee 14 20 Fuel Pump Disassembly ras iirin e eee de Pe d eae 14 20 Fuel Pump Cleaning and Inspection enne nnne ennt 14 21 Fuel PUMP ASSEMBLY 3 ecce eise t tet Cete inta o Cet da REY e TUR 14 21 Fuel Pump lnstallatiori 2 ete ee ee meds tite edat tte pdt 14 22 USM nm EI ET 14 22 General Informations cidcm Re lotus ett t etiem ite eee 14 22 Preparation for Extended Storage ssssssssssssssssesese 14 22 Fuel Tank Removal uc e ment ent ettet et e eis 14 23 Fuel Tank DISPOSI nce re core e te RA P ERE e a 14 24 Fuel Tank Storage eite eene e eb e fi Re de Dee rode 14 24 Fuel Tank Installation seissen nennen nennen nennen 14 24 14 26 Fuel Shut Off de e n 14 26 SECTION 15 EXHAUST SYSTEM General INFOPMALION 15 1 II ELEM 15 2 M ffl r Removal terere ede eA 15 2 M ffler Installatior et het ei eere t e tette o tvi edad 15 2 Page vi 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement SECTION 16 UNITIZED TRANSAXLE General Informatobiz oct d eh eise be E ds 16 1 Eris eu avd een ented eae el std Dee tite
191. ehicle and disassembled by a qualified technician See Starter Generator Removal Section 12 Electrical Components Page 12 2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11 25 TROUBLESHOOTING Test Procedures Test Procedure 8 Continued An incorrect reading from A1 or A2 terminal indicates three possible problems 1 a grounded A1 or A2 terminal 2 a grounded wire in the brush area or 3 a grounded armature commutator f the F1 or F2 reading is incorrect it indicates a possible grounded F1 or F2 terminal or a grounded field coil If the DF reading is incorrect it indicates a possible grounded DF terminal or a grounded field coil 4 Disconnect the ground wire from the A2 terminal and the green wire from the A1 terminal on the starter generator YELLOW YELLOW WIRE as STARTER Q Figure 11 33 Check Terminal Continuity Figure 11 34 Jumper Wire Ground DF to A2 5 Using a multimeter set to 200 Q ohms place the red probe on the A1 terminal and the black probe on the A2 terminal The reading should be continuity If the reading is incorrect a possible open or poor contact in a brush assembly and or open armature windings may be the cause The starter generator will need to be removed from the vehicle and disassembled by a qualified technician See Starter Generator Removal Section 12 Electrical Components Page 12 2 6 With the
192. elescoping gauge and micrometer measure the inside diameter of the bearing bore If the inside diameter is greater than 1 0283 inches 26 119 mm or the bore show signs of wear or damage replace counterbalance weight Figure 13 82 Page 13 38 Page 13 36 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Crankshaft and Counterbalance Measure each position in 2 places 90 apart Measure in two places 90 apart Figure 13 82 Measure I D of Counterbalance Figure 13 83 Measure O D of Counterbalance Weight Bore Guide Shaft Counterbalance Guide Shaft Inspection 1 Clean the shaft surface and inspect it for wear or damage 2 With an outside micrometer measure the outside diameter of the guide shaft surface Figure 13 83 Page 13 38 3 If the outside diameter is smaller than 1 0199 inches 25 907 mm or the shaft show signs of wear or damage replace the guide shaft 4 Check the O Ring seal to make sure the O Ring is not damaged Replace if necessary Measure each position in 2 places 90 apart Measure each position in 2 places 90 apart Figure 13 84 Measure Main Journals Figure 13 85 Measure Connecting Rod Journal Crankshaft Inspection 1 Clean and inspect the journals for scoring Inspect the crankshaft gear for cracks scoring or broken teeth Replace parts if necessary 2 Using a micrometer measure both main journals PTO side and flywheel side at several points along their lengt
193. emove the three screws 7 that hold the sensor to the bracket 5 Cil Level Sensor Installation 1 If the oil level sensor was removed from the bracket install sensor 6 into bracket 5 and secure with three screws 7 Figure 13 47 Page 13 24 Tighten to 16 8 in Ib 1 9 N m Position sending unit and bracket on inside of crankcase and install two mounting screws Connect sensor wire 2 to cord connector 1 Figure 13 47 Page 13 24 Install screw 3 through wire clamp and into crankcase cover Tighten to 30 in Ib 3 4 N m TYPICAL 4 N TYPICAL 4 PLACES 5 DOS 2 PLACES TYPICAL 2 PLACES Figure 13 48 Engine Mounting Plate 13 24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Piston and Connecting Rod CAMSHAFT AND TAPPETS Measure in 2 places 90 apart Y Figure 13 49 Measure Camshaft Journals Figure 13 50 Measure Camshaft Lobes Camshaft Removal 1 Turn the engine upside down to keep tappets 1 from catching the cam lobes Figure 13 45 Page 13 23 2 Take the camshaft out of the engine block Pull both tappets out NOTE DUE TO INDIVIDUALIZED WEAR PATTERNS EACH TAPPET SHOULD BE REINSTALLED IN THE SAME POSITION FROM WHICH IT WAS REMOVED Camshaft Inspection 1 Inspect the camshaft for wear or broken gear teeth 2 Inspect the camshaft gear to ensure it is securely fastened to the shaft If the cam gear is loose replace the camshaft
194. en properly wired replace the buzzer See Reverse Warning Buzzer Removal Section 12 Electrical Components Page 12 19 TEST PROCEDURE 21 OIL LEVEL SENSOR Read DANGER and WARNING on page 11 1 NOTE KEEP THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 21 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse handle in the NEUTRAL position turn the key switch to the OFF position disconnect the spark plug wire and chock the wheels 2 Ensure that the low oil warning light and all connecting wires are functioning correctly See Test Procedure 22 Page 11 34 3 Drain the engine oil into an approved container and properly dispose of used oil 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11 33 TROUBLESHOOTING Test Procedures Test Procedure 21 Continued 4 Turn the key switch ON closing the circuit The oil light should illuminate If the low oil warning light does not illuminate the oil level sensor needs to be replaced See Oil Level Sensor Removal Section 13 FE290 Engine Page 13 24 5 Fill the engine with new oil and install a new oil filter before returning the vehicle to service See Engine Oil Section 10 Periodic Maintenance Page 10 6 TEST PROCEDURE 22 OIL WARNING LIGHT Read DANGER and WARNING on page 11 1 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse shifter handle in the NEUTRAL position chock the
195. enance and Service Supplement UMTIZED TRANSAXLE Forward Reverse F amp H Shifter Cable Connect impulse line and squeeze clamp to position it Connect air intake hose and install clamp IMPULSE LINE Figure 16 102 Air Intake Hose Connect tube to carburetor Squeeze clamp to position it Figure 16 103 Carburetor Tube FORWARD REVERSE F amp R SHIFTER CABLE Read DANGER and WARNING on page 16 1 If the F amp R shifter cable is damaged in any way it must be replaced F amp R SHIFTER CABLE REMOVAL NOTE e BEFORE REMOVING CABLE NOTE CABLE ROUTING AND POSITIONS OF WIRE TIES OR OTHER DEVICES SECURING THE CABLE TO THE VEHICLE WHEN REINSTALLED CABLE MUST BE ROUTED AND SECURED AS IT WAS ORIGINALLY 1 Remove the ball joint socket 2 from the F amp R shifter assembly ball stud 3 Figure 16 106 Page 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 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 39 UNITIZED TRANSAXLE Forward Reverse F amp R Shifter Cable F amp R Shifter Cable Removal Continued 3 4 Loosen the retaining nuts 5 on both ends of the cable and remove the wire tie Figure 16 106 Page 16 41 Remove cable from the vehicle SHIFTER ARM SHIFTER LEVER Figure 16 104 F amp R Cable Routing Figure 16 105 F amp R Positions F amp R SHIFTER
196. ene dee ena NEEE dee RE rn dogs MEET M telecom ELE Neutral Lockout Limit Switch ssssssssssssssseseeese senes nen nene nnnr nennen Neutral Lock t t ere ee arenes atl expe ee ra Ru dcbet e PER kai ete Reverse Warning Buzzer a aa ru aree n AERE EEN E A EER E EER AEAEE Reverse Buzzer Limit Switch a Oil Wearing slight 4 du de De E u el Elour GAUGE nai tt Fuel Level Sending Unit recente edt og de eo dnte Y n age aca PRM EMCO Em ce niece cere PEE SIRE EI dE tuom estu tutus c soc ud it ec at I b at n SECTION 13 FE290 ENGINE General Information ats oti etre dette a RE ete nes Special Engine Service Tools Available from Club Car sene Betore Servicing el e Gad UD adc a d ge Mechanical SYSTEMS o eate ih E Ee ete Reiten ds Electrical Syst m ose n dde A e tea ced led aue L brication SySteM s e den a see Rv Spark Pl gi 25 o cai tette t ae e ope od catenas Engine Mounting Plate crier eese eet ceste Gylinder Head IEEE Generali Information ia eA an Ad
197. er Head Coat guide with light film of engine oil before driving into head Figure 13 19 Valve Guide Removal Figure 13 20 Valve Guide Installation 4 With the rocker arm side of the head facing up drive the new valve guide into the head with the valve guide arbor 3 until the snap ring 2 just seats on the head Figure 13 20 Page 13 14 5 Ream the guide with a stanisol or kerosene lubricant and a valve guide reamer Club Car Part No 101641201 The valve guide inside diameter should be 0 2756 0 2762 inch 7 000 7 015 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 replace the cylinder head 2 Using Prussian Blue coat the valve seat 3 Push the valve into the guide 4 Rotate the valve against the seat with a lapping tool 1 Figure 13 22 Page 13 14 Coat valve seat with prussian blue before rotating valve against valve seat s Figure 13 21 Ream Valve Guide Figure 13 22 Rotate Valve against Valve Seat 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 13 13 FE290 ENGINE Cylinder Head Valve Seat Inspection Continued 5 Pull the valve out and check the mark on the valve head It must be 0 0197 0 0433 inch 50 1 10 mm in width and even all the way around the seat and valve Figure 13 23 Page
198. er compression test should be performed using a standard compression tester Low compression would normally indicate a problem in the cylinder assembly such as defective rings gaskets etc At a cranking speed of 550 600 rpm the compres sion should be 156 185 psi CYLINDER SHROUD REMOVAL A CAUTION e BEFORE REMOVAL AND DISASSEMBLY CLEAN THE ENGINE Access the engine compartment Remove spark plug wire from spark plug Loosen air intake hose clamp 7 from the intake pipe 5 and remove hose 6 Figure 13 6 Page 13 9 Disconnect the fuel line 9 and vent tube10 from the carburetor 4 Figure 13 5 Page 13 9 mop mc 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 7 FE290 ENGINE Cylinder Head Cylinder Shroud Removal Continued A WARNING PLUG FUEL LINE TO PREVENT GAS FROM DRAINING FROM LINE Figure 13 5 Carburetor Figure 13 6 Carburetor Removal 5 Remove governor guard 1 Figure 13 6 Page 13 9 6 Remove cotter pin 3 and clevis pin 2 from throttle lever Figure 13 6 Page 13 9 7 Remove nuts at carburetor intake pipe 5 and remove intake pipe Figure 13 6 Page 13 9 See fol lowing CAUTION A CAUTION DISCONNECT THE GOVERNOR LINKAGE FROM THE CARBURETOR BEFORE ATTEMPTING TO REMOVE THE CARBURETOR FAILURE TO DO SO COULD DAMAGE THE LINKAGE 8 Remove carburetor 4 along with throttle spring 8 and throttle spring bracket 23 Figure 13 6
199. ery voltage reading with the table below Make sure you have the correct ambient temperature If Temperature is Minimum Voltage Required is 70 F 20 C and above 60 F 16 50 F 10 C 40 F 4 C 30 F 1 20 F 7 10 F 12 0 F 18 4 f 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 3 GROUND STRAPS Read DANGER 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 disconnect battery negative cable first 2 Check the starter generator ground strap 2 1 Set the multimeter to 200 ohms Place the red probe on the A2 terminal of the starter generator and place the black probe on the vehicle frame Figure 11 25 Page 11 22 The reading should be continuity If the reading is incorrect clean and tighten wire connections If the connections are good repair or replace the wire 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 11 21 TROUBLESHOOTING Test Procedures Test Procedure 3 Continued The engine ground is attached to the oil filler bracket and E A2 TERMINAL TNN La Figure 11 26 Test Engine Ground Strap Place black probe on 6 GAUGE WHITE fr
200. ery frame connection bolt ring terminal and also to the normally open NO terminal slip on of the kill limit switch Figure 12 16 Page 12 13 Install a new wire tie 4 nstall snap on electrical component box cover Be sure to firmly press down all corners Install screw 5 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 Battery Protector Spray Club Car Part No 1014305 6 Place Forward Reverse handle in NEUTRAL and place the neutral lockout cam in the SERVICE posi tion Start the engine and check regulator for proper functioning as described under voltage regulator testing See Test Procedure 11 Section 11 Page 11 27 TO BATTERY bo FRAME GROUND 2 NES Go TO BULLET D CONNECTOR TO SOLENOID Figure 12 16 Voltage Regulator Installation 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 Switch Removal 1 Disconnect battery cables as shown Figure 12 1 Page 12 2 2 Remove the center dash panel 2 1 Remove the plastic cap covering the screw on each side of the center dash 2 2 Loosen but do not remove the screw on each side of the center dash panel 2 3 Insert screwdriver at the top center of the dash between dash and cowl brace Gently pry center dash out slightly from under edge of cowl brace 2 4 Pull center
201. flat washers 3 from the muffler bracket 2 Remove the muffler and bracket assembly from the vehicle NOOR WL Remove the muffler clamp 6 from the muffler bracket 2 MUFFLER INSTALLATION NOTE ANY TIME THE MUFFLER IS REMOVED FROM THE VEHICLE INSTALL NEW MUFFLER CLAMP 6 CLUB CAR PART NO 1017689 AND MUFFLER GASKET FIGURE 15 2 PAGE 15 3 1 Use the muffler clamp 6 to attach the muffler bracket 2 to the muffler as shown Figure 15 2 Page 15 3 Leave the muffler clamp loose enough to allow the muffler to move as the mounting hardware is tightened If installing a new muffler use the old one as a positioning guide for the clamp and bracket 2 Place a new gasket 12 on the exhaust manifold mounting flange as shown e Position the muffler and bracket assembly and the governor cable bracket 13 and install the bolts 5 lock washers 4 and flat washers 3 Thread the bolts in only enough to support the muffler and bracket assembly Do not tighten them Install the hex nuts 10 and lock washers 11 Tighten the nuts fingertight Install the flat washer 9 lock washer 8 and hex head cap screw 7 Tighten the cap screw fingertight Tighten the hex nuts 10 to 11 ft lb 14 9 N m Tighten the hex cap screw 7 to 14 ft lb 18 9 N m Figure 15 2 Page 15 3 Tighten the muffler clamp 6 to 40 in Ib 4 5 N m Tighten the muffler bracket mounting bolts 5 to 75 in Ib 8 5 N m
202. following chart Figure 11 15 Page 11 13 to begin troubleshooting problems with the engine ignition circuit Page 11 12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Circuit Testing ENGINE CRANKS CAR WILL NOT RUN IGNITION GAP TEST TEST PROCEDURE 13 IGNITION GAP TEST IGNITION GAP TEST GOOD NOT GOOD REPLACE SPARK PLUG DISCONNECT ENGINE KILL WIRE ENGINE RUNS ENGINE DOES NOT RUN GOOD SPARK NO SPARK CHECK FUEL SYSTEM CHECK FOR CHECK RPM LIMITER SEE SECTION 14 GROUNDED WIRE TEST PROCEDURE 14 TEST PROCEDURE 18 CHECK COMPRESSION CHECK PLUG GAP SEE CYLINDER HEAD IN CHECK KEY SWITCH SEE SETTING THE SPARK SECTION 13 TEST PROCEDURE 17 PLUG GAP IN SECTION 13 REPAIR OR REPLACE CHECK COIL TEST PROCEDURE 15 Figure 11 15 Testing the Engine Ignition Circuit TESTING THE ENGINE KILL CIRCUIT Read DANGER and WARNING on page 11 1 Use the following charts Figure 11 16 Page 11 13 through Figure 11 18 Page 11 14 to begin troubleshooting problems with the engine kill circuit ENGINE WILL NOT STOP RUNNING WHEN FOOT IS OFF ACCELERATOR PEDAL CHECK KILL LIMIT SWITCH TEST PROCEDURE 16 INCORRECT CORRECT CONTINUITY READING CONTINUITY READING REPLACE LIMIT SWITCH CHECK WIRE CONNECTION OF CIR
203. ft at three different locations in the bore The first measurement location is 0 4 inch 10 mm from the top of the cylinder The second location is in the center or 2 4 inches 60 mm from the top and the third location is 0 3 8 mm from the bottom of the cylinder or bottom of ring travel See locations 1 2 and 3 in Figure 13 59 Page 13 30 Page 13 28 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Cylinder Block The standard bore diameter is 3 0700 3 0708 inches 77 980 78 000 mm The maximum cylinder bore diameter wear limit is 3 0735 inches 78 067 mm The maximum acceptable out of round cylinder bore is 0 0022 inch 0 056 mm 3 If the cylinder bore is not within these measurements the cylinder bore will need to be resized Measure each level in bore at 2 places 90 apart HONING TOOL XX NAA jn V Figure 13 59 Measure Cylinder Bore To Resize Bore to Next Oversize Always resize the bore to exactly 0 010 inch 0 25 mm or to exactly 0 020 inch 0 50 mm over standard size 1 When the bore is resized to 0 010 inch over standard size the new bore dimension is 3 0791 3 0799 inches 78 210 78 230 mm When the bore is resized to 0 020 inch over standard size the new bore dimension is 3 0890 3 0898 inches 78 460 78 480 mm See Specifications for Resizing Cylinder Bore Table Page 13 50 NOTE
204. gure 16 95 Oil Level Sensor Jumper wire Connect yellow wire Figure 16 94 Ignition Kill Wire Connect ground wire at A2 terminal Connect white wire le o Figure 16 96 Starter Generator 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 37 UNITIZED TRANSAXLE Unitized Transaxle Installation Unitized Transaxle Installation Continued 31 Check that all wiring is secured properly See following WARNING A WARNING e IF WIRES ARE REMOVED OR REPLACED MAKE SURE WIRING AND WIRING HARNESS 15 PROPERLY ROUTED AND SECURED TO VEHICLE FRAME FAILURE TO PROPERLY ROUTE AND SECURE WIRING COULD RESULT IN VEHICLE MALFUNCTION PROPERTY DAMAGE OR PERSONAL INJURY 32 Connect the spark plug wire 33 Connect the battery cables positive cable first and tighten to 20 ft lb 27 1 N m 34 Adjust the engine RPM setting See Engine RPM Adjustment Section 14 Fuel System Page 14 14 TOP VIEW _ 1 T Connect engine ground wire Rec IN and tighten retaining nut Pull spring release back to connect shifter Tighten nuts cable to lever Figure 16 97 Connect Shifter Cable Connect fuel line cam and tighten retaining nuts and tighten clamp Connect accelerator cable to Figure 16 99 Connect Cable to Cam Figure 16 100 Connect Fuel Line Page 16 38 2000 FE290 Gasoline Vehicle Maint
205. h to driven clutch is 92 to 1 On steep grades or when the vehicle is heavily loaded higher torques are achieved through the use of a torque sensing ramp device on the driven clutch This device overcomes the force of the centrifugal weights to close the driven clutch and open the drive clutch thus increasing axle torque with little or no change in engine RPM The engine and torque converter rotate clockwise as viewed from the clutch side of the engine To provide optimum performance for the OHV engine and powertrain the vehicle uses a pair of tuned clutches To properly assemble and disassemble the torque converter the following tools should be used Torque Converter Tool Kit Club Car Part No 1014510 Figure 17 1 Page 17 2 Scribe or small pick not included in torque converter tool kit TORQUE CONVERTER TOOL KIT CLUB CAR PART NO 1014510 Cm C CT DRIVEN CLUTCH CAM PRESS TOOL CLUB CAR PART NO 101809101 DRIVE CLUTCH HUB PULLER M M CLUB CAR M J Ce PART NO 1014497 2 DRIVEN CLUTCH CAM PULLER En CLUB CAR CLUB CAR PART NO 1014508 PART NO 1014507 ca _ WARNING Uu DRIVE DRIVE CLUTCH HOLDER TOOL CLUTCH PULLER CLUB CAR PART NO 1015524 CLUB CAR PART NO 1014496 Figure 17 1 Torque Converter Tool Kit 17 2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TORQUE CONVERTER Troubleshooting TROUBLESHOOTING Read DANGER and WARNING on p
206. he carburetor fuel bowl retaining screw and washer 12 then remove the fuel bowl 10 and clean it with a nonflammable solvent Figure 14 7 Page 14 7 See following NOTE 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14 5 FUEL SYSTEM Carburetor Changing the Main Jet Continued NOTE e MAKE SURE THE FUEL BOWL GASKET 9 REMAINS PROPERLY 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 OUT OF THE CARBURETOR BODY AFTER THE FUEL BOWL IS REMOVED TYPICAL 2 PLACES Page 14 6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Figure 14 6 Carburetor Installation FUEL SYSTEM Carburetor 6 Remove the main jet 8 from the carburetor body and discard it Figure 14 7 Page 14 7 NOTE e MAKE SURE THE FUEL NOZZLE 7 DOES NOT FALL OUT OF THE CARBURETOR BODY AFTER REMOVAL OF THE MAIN JET THIS IS BEST ACCOMPLISHED BY POSITIONING THE CARBURETOR UPSIDE DOWN DURING MAIN JET REMOVAL FIGURE 14 7 PAGE 14 7 7 Select the proper size main jet See chart on Page 14 5 Check the size designation on the jet to make sure it is the correct part 8 Install the new main jet and tighten it to 12 in Ib 1 4 N m See following CAUTION and NOTE CAUTION DO NOT REMOVE THE VALVE SPRING ASSEMBLY FROM THE FLOAT ASSEMBLY DOING
207. he six bolts in the sequence shown Figure 13 38 Page 13 20 Increase the torque in four increments of 50 in Ib 6 N m and then tighten to final torque of 220 in Ib 25 N m See following CAUTION CAUTION DO NOT TURN ANY ONE BOLT DOWN COMPLETELY BEFORE TIGHTENING THE OTHERS DOING SO MAY CAUSE THE CYLINDER HEAD TO WARP 7 Adjust valve clearances 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 13 19 FE290 ENGINE Cylinder Head VALVE CLEARANCE CHECK AND ADJUSTMENT 1 2 3 Check and adjust clearance when the engine is cold Turn the crankshaft until the piston is at the top of the compression stroke Using a feeler gauge 1 measure the clearance 2 between the adjuster screw 3 and the top of the valve stem 4 Figures 13 39 and 13 40 If necessary loosen the locknut 3 and turn the adjuster 6 up or down to adjust the clearance to 0 005 inch 0 127 mm for both intake and exhaust Figure 13 39 Page 13 21 While keeping the adjuster from turning with the screw holder 5 Club Car Part No 1016413 tighten the locknut 3 to 90 in Ib 10 N m Figure 13 39 Page 13 21 Recheck the clearance on both valves Figure 13 39 Valve Clearance Figure 13 40 Cutaway View of Valve Clearance BREATHER VALVE REED VALVE General Information The function of the breather valve is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through th
208. he steering joint assembly Figure 14 14 Page 14 16 Drill out the two pop rivets 26 securing the intake duct to the floorboard Figure 14 15 Page 14 17 Remove three screws 23 and flat washers 22 from the bottom of the air box assembly Lift air box assembly off the intake duct Be careful that the intake seal on the bottom of the air box assembly is not dislodged in the process 7 Pull the intake duct forward and out of the vehicle INTAKE DUCT INSTALLATION The intake duct assembly is installed from the front of the vehicle 1 Slide the intake duct between 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 Secure the front of the duct to the underside of the floorboard with two pop rivets 25 and flat washers 26 Figure 14 15 Page 14 17 3 Install air box See Air Box Installation Page 14 15 4 Install steering joint See following NOTE 9 idco 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 14 15 FUEL SYSTEM Choke and Air Intake System Intake Duct Installation Continued NOTE MAKE SURE STEERING WHEEL AND FRONT WHEELS ARE PROPERLY ALIGNED BEFORE INSTALLING STEERING JOINT 4 1 Position steering joint assembly 1 on vehicle as shown Install three lock washers and three screws and tighten to 15 ft Ib 20 3 N m Figure 14 15
209. head seating area is eroded or nicked it may be possible to repair the valve on a valve refacing machine Follow the refacing machine manufacturers instructions The valve seating surface angle for the FE290 engine is 45 Figure 13 28 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 valve head as shown Figure 13 28 Page 13 17 2 If the valve head thickness A Figure 13 28 Page 13 17 is less than 0 024 inch 0 610 mm replace the valve Valve Stem Bend 1 Support the valve in V blocks at each end of the stem Figure 13 29 Page 13 18 2 Position a dial gauge perpendicular to the stem 3 Turn the valve and read the variation on the dial gauge 4 If stem bend is greater than the service limit of 0 0012 inch 0 0305 mm replace the valve Valve Stem Diameter 1 Using a micrometer measure the diameter of the stem at several points along its length Figure 13 30 Page 13 18 2 If the outside diameter is less than the service limit of 0 2728 inch 6 930 mm intake 0 2722 inch 6 915 mm exhaust replace the valve Page 13 16 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Cylinder Head Measure each position in 2 places 90 apart Figure 13 29 Measure Valve Stem Bend Figure 13 30 Measure Valve Stem Diameter Measure each position
210. hicle 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 springs in the front spring mounts and install the bolts and locknuts Tighten to 15 ft lb 20 3 N m Figure 16 91 Page 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 the shock mounts and install cushions mounting washers and nuts Figure 16 93 Page 16 37 Tighten nuts until cushions expand to be the same diameter as the mounting washers 18 Connect brake cables See Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual STUDS Install two TRANSAXLE x accelerator cable MOUNTING KS retaining bracket 2 mounting screws BLOCKS pce MOUNTING NU NN TYPICAL 2 PLACES Figure 16 86 Accelerator Cable Bracket 1 Install the governor arm on the governor shaft 4 Tighten the retaining nut 2 Turn shaft counterclockwise Install two governor cable bracket mounting screws Figure 16 87 Governor Cable Bracket Figure 16 88 Governor Arm 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 35 UNITIZED TRANSAXLE Unitized Transaxle Installation Unitized Transaxle Installation Continued Install key onto input shaft Roll powertrain under
211. hs Figure 13 84 Page 13 38 2 1 If either journal diameter is less than 1 1783 inches 29 929 mm replace the crankshaft 3 Using a micrometer measure connecting rod journal at several points along its length Figure 13 85 Page 13 38 3 1 If the journal diameter is less than 1 3954 inches 35 443 mm replace the crankshaft 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 13 37 FE290 ENGINE Crankshatt and Counterbalance Crankshaft Inspection Continued 4 Using a micrometer measure the crankshaft link rod journals at several points Figure 13 86 Page 13 39 4 1 If the diameter of either journal is less than 1 8474 inches 46 924 mm replace the crankshaft 5 Check the crankshaft alignment 5 1 Place the crankshaft in an alignment jig 5 2 Turn the crankshaft 1 slowly and measure total indicated run out at the location shown 2 Figure 13 87 Page 13 39 5 3 If total run out exceeds 0 002 inch 0 051 mm replace the crankshaft Measure each position in 2 places 90 apart Figure 13 86 Measure Crankshaft Link Rod Journal Figure 13 87 Measure Total Indicated Run Out Undersized Connecting Rod The connecting rod journal can accept 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 crankshaft journal A Figure
212. icle Maintenance and Service Supplement 13 33 FE290 ENGINE Crankshaft and Counterbalance CRANKSHAFT AND COUNTERBALANCE Read DANGER and WARNING on page 13 1 Crankshaft and Counterbalance Removal 1 Remove the four nuts 1 and pull out the counterbalance guide shaft 2 and the O Ring 3 Figure 13 73 Page 13 34 2 Pull out the crankshaft and the counterbalance together as an assembly Figure 13 76 Page 13 36 HELICAL GEAR GEAR YOKE PRESS RAM GEAR YOKE BLOCKS 2 PRESS TABLE SEE FOLLOWING WARNING Figure 13 74 Place Assembly In Press Figure 13 75 Remove Helical and Spur Gears Crankshaft and Counterbalance Disassembly 1 Slide the spacer 2 and the link rod 3 off the flywheel end of the crankshaft Remove the counterbal ance from the remaining link rod Figure 13 76 Page 13 36 Go to Link Rod Inspection Page 13 36 2 f 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 Position the gear yoke with the side blocks positioned as close to the crankshaft as possible Figure 13 74 Page 13 35 4 Using a press push on the end of the crankshaft to pull the spur gear and the helical gear off the crank shaft Figure 13 75 Page 13 35 See following WARNING and CAUTION A WARNING e SUPPORT THE CRANKSHAFT WHILE PRESSING THIS WILL PREVENT THE
213. ighten and replace connections as necessary Hydrometer Test A hydrometer measures the specific gravity The higher the specific gravity the higher the state of charge of the battery A fully charged battery should read between 1 250 and 1 280 at 80 F 27 C Never add acid to the battery to obtain a higher specific gravity Performing the Hydrometer Test CAUTION DO NOT ALLOW BATTERY ACID FROM BATTERY CAPS OR HYDROMETER TO DRIP ONTO THE BODY BATTERY ACID WILL CAUSE PERMANENT DAMAGE WASH OFF IMMEDIATELY 1 Be sure that the battery has sufficient water to cover the plates by approximately 1 2 inch 12 7 mm and is fully charged prior to beginning the test If water must be added recharge the battery before performing the hydrometer test Figure 11 23 Page 11 20 2 Remove the vent cap 3 Using a battery thermometer Club Car Part No 1011767 record the electrolyte temperature of a center cell 4 Squeeze the rubber bulb of the hydrometer and insert into the cell Slowly release 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 strike the bottom of the rubber bulb Remove the hydrometer from the cell and release the pressure from the bulb 6 Hold the hydrometer vertically ensuring that the float is not contacting the sides of the glass tube Hold the hydrometer at ey
214. igure 16 52 Remove Idler Shaft Clean all of the component parts of the transaxle in a high flash point solvent and then dry them Inspect all components for excessive wear or damage Inspect all bearings by spinning them by hand Check the bearings for excessive axial A and radial B play Figure 16 53 Page 16 22 Replace bearings if they do not spin smoothly if they are noisy or if they have excessive play Replace bearings if they are rusted worn cracked pitted or discolored Gears should be inspected for tooth surface damage or fractures Synchronizer ring teeth should be inspected for severe wear fractures or other damage Using a feeler gauge measure the distance X at several points around the assembly The synchro ring should be replaced when X is 0 02 inch 0 5 mm or less Figure 16 54 Page 16 23 PRESS RAM Press idler shaft from bearing using a 3 4 in o d or less arbor anda wedge attachment Club Car Part No 1012812 Figure 16 51 Remove Bearing Figure 16 53 Inspect Bearings 16 22 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UNITIZED TRANSAXLE Component Assembly COMPONENT ASSEMBLY Read DANGER and WARNING on page 16 1 IDLER SHAFT ASSEMBLY 1 Press a new bearing 66 Figure 16 42 Page 16 18 onto each end of the idler shaft Figure 16 55 Page 16 23 See fo
215. il onto the cast mounting bosses on the engine crankcase insert two mounting bolts and finger tighten 10 Rotate the flywheel until the magnet is positioned directly under the coil Use a 012 inch 0 304 mm bronze feeler gauge to set the air gap between the coil and the flywheel magnet Tighten the mounting bolts to 30 in Ib 3 4 N m Figure 12 29 Page 12 25 11 Connect the 18 gauge black wire to the spade terminal on the coil o 0 012 Inch 0 304 mm Figure 12 29 Set Air Gap 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12 25 ELECTRICAL COMPONENTS Ol Level Sensor Ignition Coil Installation Continued 12 Position the fan housing close to the engine crankcase and install the plug wire grommet into the notch on the housing 13 While installing fan housing make sure the top front corner of the housing is above the upper cylinder shroud The front edge of the fan housing should be behind the lower cylinder shroud Align the slots in the housing with the flanged head bolts loosened earlier 14 Install the four remaining flange bolts that secure the fan housing to the engine crankcase Tighten all seven mounting bolts to 90 in lb 10 1 N m Figure 12 27 Page 12 24 15 Install the stiffener with four hex head bolts and locknuts Tighten the hardware to 23 ft lb 31 2 N m Figure 12 26 Page 12 24 16 Tie wrap the wire harness to the stiffener Insert tie wrap through the
216. in 2 places 90 apart Figure 13 31 Measure Free Length of Spring Figure 13 32 Measure 1 0 of Rocker Arm Bearing Valve Spring Inspection 1 Inspect the valve springs 1 for pitting cracks corrosion and burrs Replace the springs if necessary Figure 13 31 2 Measure the free length of the spring If the measurement is less than the service limit of 1 29 inch 32 77 mm replace the spring Figure 13 31 Page 13 18 Valve Installation 1 Valve installation is the reverse of removal See Page 13 11 and following NOTE NOTE VALVE SPRING COILS ARE CLOSER TOGETHER HAVE A NARROWER PITCH AT ONE END OF THE SPRING THAN AT THE OTHER SEE FIGURE 13 35 PAGE 13 19 INSTALL SPRINGS WITH THE NARROW PITCH ENDS ON THE SPRING SEATS 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 13 17 FE290 ENGINE Cylinder Head Measure each position in 2 places 90 apart Figure 13 33 Measure O D of Rocker Shaft Figure 13 34 Measure Push Rod Bend ROCKER ARM AND ROCKER SHAFT INSPECTION 1 Using a telescoping gauge measure the inside diameter of each rocker arm bearing at several points along its length If the inside diameter is more than the service limit of 0 4754 inch 12 075 mm replace the rocker arm Figure 13 32 Page 13 18 2 Using a micrometer measure the outside diameter of the rocker shaft at several points along its length Figure 13 33 Page 13 19 If the outside diameter is less than the
217. includes the symptom probable cause s and suggested checks The procedures used in making these checks can be found in the referenced sections of the maintenance and service manual SYMPTOM POSSIBLE CAUSES REFER TO Engine does not start 1 Spark plug is partially fouled or in Section 13 Engine easily poor condition 2 Spark plug wire is damaged or loose Section 13 Engine 3 Loose wire connection at Section 11 Troubleshooting ignition coil or RPM limiter Test Procedures 13 14 and 15 4 Intermittent ignition coil failure Section 11 Troubleshooting Test Procedures 13 14 and 15 5 Low cylinder compression Section 13 Engine 6 Water or dirt in the fuel system and or Section 14 Fuel System carburetor dirty or clogged fuel filter 7 Carburetor improperly adjusted Section 14 Fuel System 8 Starter generator belt is slipping Section 12 Electrical Components Belt Tension Adjustment page 12 12 Engine starts but does not 1 Spark plug is fouled or in Section 13 Engine run smoothly poor condition 2 Spark plug wire is damaged or loose Section 13 Engine 3 Intermittent ignition coil failure Section 11 Troubleshooting Test Procedures 13 14 and 15 4 Water or dirt in the fuel Section 14 Fuel System System and or carburetor dirty or clogged fuel filter 5 Fuel pump malfunction fuel pressure Section 14 Fuel System to engine too low Troubleshooting G
218. into the crankcase cover until it is 0 157 inch 4 mm below the outside surface Figure 13 92 Inspect Bearing Surfaces Figure 13 93 Inspect Camshaft Surface in in Crankcase Crankcase Cover Page 13 40 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Crankshaft and Counterbalance Plain Bearing Surface Inspection Plain bearing surfaces are used for both ends of the camshaft and the flywheel end of the crankshaft 1 Inspect the camshaft surfaces one in the crankcase 3 Figure 13 92 Page 13 41 and the other in the crankcase cover 1 Figure 13 93 Page 13 41 Using an inside micrometer or telescoping gauge measure the inside diameter of each bearing surface If the inside diameter is greater than 0 9080 inch 23 063 mm replace the crankcase and or the crankcase cover 2 Inspect the crankshaft bearing surface 2 in the crankcase Using an inside micrometer or telescoping gauge measure the inside diameter of the bearing surface If the 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 CHAMFERED INSIDE DIAMETER CHAMFERED INSIDE DIAMETER Figure 13 94 Crankshaft Assembly A CAUTION BEFORE ASSEMBLY MAKE SURE ALL PARTS ARE CLEAN NOTE WHEN REASSEMBLING THE CRANKSHAFT AND THE COUNTERBALANCE WEIGHT APPLY A LIGHT FILM OF ENGI
219. ion it is important the accelerator pedal governor linkage and throttle adjustments are done correctly and in the proper sequence See following CAUTION Page 14 8 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM Engine Control Linkage CAUTION IMPROPER ADJUSTMENT CAN RESULT IN POOR VEHICLE PERFORMANCE AND OR DAMAGE TO THE ENGINE COMPONENTS ACCELERATOR ROD DANGER e TO ENSURE THE VEHICLE DOES NOT RUN OVER YOU WHILE YOU DISCONNECT OR ADJUST THE ACCELERATOR PUSH ROD DO THE FOLLOWING TURN KEY SWITCH OFF PLACE FORWARD REVERSE HANDLE IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG Accelerator Rod Removal 1 Raise the front of the vehicle Place chocks at the rear wheels and lift the front of the vehicle with a chain hoist or floor jack Place jack stands under the round frame cross tube to support the vehicle See DANGER above See also WARNING on Page 14 1 2 Remove the accelerator rod by disconnecting the ball joint 1 from the ball stud 2 on the accelerator pedal Figure 14 8 Page 14 9 and from the bell crank at the electrical box Figure 14 11 Page 14 11 Figure 14 8 Accelerator Rod Accelerator Rod Installation and Adjustment 1 Before installing the accelerator rod adjust accelerator pedal position See Section 5 Accele
220. ity testing essen 11 27 wiring diagram 55 555 11 6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page i 5 CLUB CAR Golf Cars and Utility Vehicles kin GM UE R a NERA Club Car Inc INGERSOLL RAND P O Box 204658 Augusta GA 30917 4658
221. k and is controlled by the reverse buzzer limit switch that is activated by a cam located on the back of the Forward Reverse shifter When the Forward Reverse handle is placed in REVERSE a cam depresses the reverse limit switch closing the circuit The reverse buzzer sounds FORWARD REVERSE ASSEMBLY REVERSE BUZZER LIMIT SWITCH 1 ge ee SE e c FRAME M KEY GROUND SWITCH SX FUSE by BLOCK REVERSE BUZZER Figure 11 7 Reverse Buzzer Circuit 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement lt A KEY B SWITCH SS GROUND OIL SENDING Figure 11 8 Low Oil Warning Circuit Page 11 9 TROUBLESHOOTING Electrical Circuits LOW OIL WARNING CIRCUIT The low oil warning circuit consists of an oil level sensor in the engine a dash mounted low oil warning light key switch and connecting wires Figure 11 8 Page 11 9 The light receives power through the key switch when the key switch is turned to the ON position When the oil level in the crankcase is low the oil level sensor closes the circuit to the ground and illuminates the low oil warning light NEUTRAL LOCKOUT CIRCUIT The neutral lockout circuit prevents the operator from starting the vehicle in NEUTRAL Also if the vehicle is started in FORWARD or REVERSE and then shifted to NEUTRAL the engine will stop running The neutral lockout circuit consists of the connecting wires a limit switch that is located on
222. kshaft Installation Figure 13 96 Press On Spur Gear and Helical Gear PISTON AND CONNECTING ROD INSTALLATION 1 Reassemble the piston and the connecting rod into a unit if disassembled 1 1 Align the arrow mark 1 on the piston head toward the words MADE IN JAPAN 2 on the con necting rod Insert the piston pin through the piston holes and the connecting rod Install the two retaining rings to hold the pin in place The gap in the 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 13 42 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Crankshaft Axial Play Adjustment 2 Apply a light film of engine oil to the connecting rod bearing surfaces and the two connecting rod bolts 3 Put the piston and connecting rod into the cylinder bore with the lettering MADE IN JAPAN on the connecting rod oriented toward the PTO side of the engine Position piston ring gaps so that they are oriented toward the corresponding letters in A Top Ring Gap B Second Ring Gap C Upper Side Rail Gap installed in the lowest ring groove D Lower Side Rail Gap installed in the lowest ring groove 4 Compress the rings on the piston and finish sliding piston into the cylinder Figure 13 98 Page 13 44 NOTE e THE LETTER R MARKED ON THE TOP TWO PISTON RINGS SHOULD BE FACING UP WHEN
223. l Section 12 Electrical Components Page 12 23 Retest with a multimeter set on 200 Q ohms Place the black probe of the meter on the core 2 and place the red probe into the end of the spark plug wire 3 Figure 11 40 Page 11 31 If the resistance is still not between 6 0 11 0 k O ohms replace the coil 11 30 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Test Procedures PRIMARY COIL SECONDARY COIL Figure 11 39 Test Primary Coil Figure 11 40 Test Secondary Coil 4 These tests will find most of the bad coils Some coils may bench test okay but fail under a load due to heat while operating Another method of testing is to replace the coil and then run the engine If the engine runs properly keep the new coil in the circuit TEST PROCEDURE 16 KILL LIMIT SWITCH Read DANGER and WARNING on page 11 1 The kill limit switch is located inside the electrical component box The kill limit switch is the lower of the two limit switches and has a white black wire 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 cable first 2 Check for proper wiring and tight connections LEVER UP Nr NO ij t KILL LIMIT C SWITCH Figure 11 41 Test Kill Limit Switch
224. l Figure 13 14 Spring Seat Removal BREATHER VALVE REED VALVE General Information The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings oil seals or gaskets The breather has a reed valve which limits the direction of air flow caused by the piston moving up and down Air can flow out of the crankcase but the one way reed valve blocks return flow 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 rocker chamber most oil separates from the air and drains back to the crankcase The air passes through a tube and vents to the intake manifold Breather Valve Reed Valve Removal 1 Unscrew the mounting screw 1 and remove the back plate 2 and reed valve 3 Figure 13 15 Page 13 12 See Page 13 21 for Installation Figure 13 15 Reed Valve Figure 13 16 Combustion Chamber 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 11 FE290 ENGINE Cylinder Head CYLINDER HEAD CLEANING AND INSPECTION 1 Clean the head with a non flammable solvent and dry thoroughly 2 Bead blast or scrape carbon deposits from head When scraping carbon deposits be careful to avoid scratching or nicking the cylinder head 3 Inspect the spark plug port threads for damage If threads are damaged replace the head 4 Place the cylinder head
225. large post 4 Connect the 6 gauge red wire and the 10 gauge red wire from the fuse block on the other large post on the solenoid See Section 11 Figure 11 2 Page 11 6 5 Connect the 18 gauge blue wire from the key switch to a small post on the solenoid 6 Connect the 18 gauge orange wire from the accelerator pedal limit switch to the other small post on the solenoid See Section 11 Figure 11 2 Page 11 6 7 Tighten the hex nuts on the large solenoid posts to 60 in Ib 6 7 N m Tighten the nuts on the small solenoid posts 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 Ib 2 0 N m 9 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 Battery Protector Spray Club Car Part No 1014305 FUSE Read DANGER and WARNING on page 12 1 Testing the Fuse See Test Procedure 1 Section 11 Page 11 18 Fuse Removal 1 Disconnect battery cables as shown Figure 12 1 Page 12 2 2 Remove electrical component box cover 3 Remove the fuse from the fuse block Fuse Installation 1 Install the fuse Use a 10 amp fuse only A WARNING IF THE FUSE IS BLOWN DETERMINE THE CAUSE OF THE FAILURE AND MAKE NECESSARY REPAIRS BEFORE INSTALLING A NEW FUSE USE 10 AMP FUSES ONLY IF A FUSE WITH A HIGHER AMP RATING IS USED DAMAGE TO THE VEHICLE ELECTRICAL S
226. lf Full 120 20 Q ohms Half Full Upper Position Tank Full 60 20 ohms Full 5 If the readings are within the specifications listed above the fuel level sending unit is working properly If the readings are incorrect the fuel level sending unit has failed and the fuel tank must be replaced See Fuel Tank Removal in Section 14 page 14 23 6 If the readings are correct and the fuel gauge does not function correctly check the continuity of the orange wire from the fuel level sending unit to the fuel hour gauge Leave the battery disconnected while checking continuity Also check the continuity of the blue wire from the fuel hour gauge to the key switch and the black ground wires at the fuel level sending unit and at the fuel hour gauge See Fuel Hour Gauge Removal in Section 12 page 12 21 7 If the readings are correct according to the position of the float but give an incorrect reading on the fuel hour gauge test the fuel hour gauge See Test Procedure 26 Fuel Gauge on page 11 36 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11 35 TROUBLESHOOTING Test Procedures 18 GAUGE BLUE WIRE TO NO 1 ON 18 GAUGE BLACK KEY SWITCH REAR VIEW OF WIRE TO GROUND FUEL HOUR GAUGE Remove 18 gauge orange wire e 18 GAUGE ORANGE WIRE REAR VIEW OF FUEL HOUR GAUGE Figure 11 44 Test Fuel Gauge Figure 11 45 Test Fuel Gauge Voltage
227. life and efficient combustion of fuel The spark gap is 0 027 0 031 inch 0 69 0 79 mm Spark Plug Removal Read DANGER and WARNING on page 13 1 A CAUTION e BEFORE REMOVAL AND DISASSEMBLY CLEAN THE ENGINE Remove all dirt from plug base in the cylinder head before removing plug Use a 13 16 deep well socket wrench or 13 16 plug wrench to loosen the plug Figure 13 4 Spark Plug Spark Plug Cleaning Inspection and Repair Examine the plug Figure 13 4 Page 13 7 The deposits on the plug base and electrode are an indication of the correct heat range and efficiency as well as a guide to the general condition of 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 The electrode should not be eroded Black color excessive carbon and or a wet plug indicate a too rich condition White burned or melted elec trodes indicate a too lean condition or pre ignition Oily deposits on the plug electrode are an indication of worn rings valve guides cylinder wall etc Also examine the spark plug wire Remove rubber boot and inspect internal spring for damage Inspect spark plug wire for damage and be sure spring coil is securely attached to spark plug See following WARNING A WARNING e REMOVE SPARK PLUG WIRE TO AVOID ACCIDENTAL START UP OF THE ENGINE WHEN SERVICING VEHICLE TO AVOID
228. line Vehicle Maintenance and Service Supplement 14 27 SECTION 15 EXHAUST SYSTEM DANGER e GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM VEHICLE AND SERVICE AREA SERVICE ONLY IN A WELL VENTILATED AREA DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON A WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE 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 SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD REVERSE 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 CHAINS ETC BEFORE SERVICING VEHICLE HOT DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST SYSTEM FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS 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 TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNE
229. llowing CAUTION A CAUTION e APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRESSURE ANYWHERE ELSE WILL DAMAGE THE BEARING INTERMEDIATE GEAR ASSEMBLY 1 If the gear 58 was removed from the shaft install the key 57 into the slot and then position the gear on the shaft with keyway properly aligned with key Press gear into place on the key Figure 16 42 Page 16 18 2 Press the bearing 59 onto the end of the shaft next to the large gear that was installed in step one Figure 16 42 Page 16 18 See preceding CAUTION 3 Press a new bearing 38 onto the other end of the shaft Figure 16 42 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 the short end of the shaft the machined circular face surrounding the ends of the internal splines in the sleeve must be flush with the machined lip of the shaft at the ends of the shaft splines Figure 16 56 Page 16 24 2 Install the synchronizer springs 46 Figure 16 42 Page 16 18 in the sleeve as shown Figure 16 57 Page 16 24 NOTE MAKE SURE THE ENDS OF THE SPRINGS ARE POSITIONED BETWEEN THE SYNCHRONIZER INSERT SLOTS FIGURE 16 57 PAGE 16 24 Press bearing onto idler shaft Synchro ring must be replaced when x MY Ni AES G distance is less than
230. mutator end cover 23 free of starter generator housing 24 Figure 12 3 Page 12 4 See following NOTE NOTE e IF THE BRUSHES ARE NOT REMOVED CONTACT BETWEEN THE BRUSHES AND COMMUTATOR AS THE COMMUTATOR END COVER IS BEING REMOVED OR INSTALLED COULD DAMAGE THE BRUSHES LIFT THE BRUSH SPRINGS OUT OF THE NOTCHES IN THE BRUSHES AND PULL THE BRUSHES BACK FROM THE CENTER OF THE COMMUTATOR END COVER THE SPRINGS WILL REST ON THE SIDES OF THE BRUSHES AND HELP PREVENT THEM FROM SLIDING TOWARDS THE CENTER OF THE COVER FIGURE 12 7 PAGE 12 5 2 Remove brush covers 29 and 30 screws 25 and lockwashers 26 brush springs 28 and brushes 27 Figure 12 4 Page 12 4 NOTE TO CLEAN AND INSPECT THE ARMATURE COMMUTATOR AND BEARINGS SEE DISASSEMBLY OF THE STARTER GENERATOR TO SERVICE THE ARMATURE COMMUTATOR PAGE 12 5 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 12 3 ELECTRICAL COMPONENTS TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 12 3 Commutator End Cover STARTER GENERATOR V WEAR LINE dr 9 BRUSH Ke BRUSH DX HOLDER Figure 12 5 Inspect Brushes Brush Inspection and Replacement Starter Generator TYPICAL 4 PLACES Figure 12 4 Brush Installation 1 Visually inspect brushes Replace brushes that are cracked or severely chipped 2 Check the wear line on the side of the brush If the end of the brush is within 1 16 of an inch 1 6 mm of the
231. n the engine until fuel remaining in the carburetor fuel pump and fuel lines is 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 drain screw 11 Figure 14 7 Page 14 7 and drain fuel remaining in the carburetor bowl into an approved container Retighten carburetor drain screw 8 Using a siphon with a suction device siphon all fuel out of the tank and into an approved container See following DANGER and WARNING DANGER GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE VEHICLE AND SERVICE AREA A WARNING e NEVER ATTEMPT TO SIPHON FUEL USING A HOSE THAT DOES NOT HAVE A BUILT IN SUCTION DEVICE NEVER ATTEMPT TO SIPHON FUEL USING YOUR MOUTH 9 If vehicle is equipped with a fuel gauge detach the black wire and orange wire from the fuel level sending unit on the tank Figure 14 19 Page 14 24 Do NOT remove the lower nut on the center stud of the sending unit A WARNING MAKE SURE THE KEY SWITCH IS OFF BEFORE DETACHING WIRING 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 14 23 FUEL SYSTEM F el Tank Fuel Tank Removal Continued 10 Remove vent tube 6 and fuel line 1 form the fuel tank Figure 14 16 Page 14 19 11 Loosen the straps 13 and 18 by removing the s
232. n the ring grooves are open 4 Visually inspect the piston rings and ring grooves for uneven wear or damage Replace the piston and or piston rings if uneven wear or damage is present or if they exceed the wear limits 5 Using a new piston ring and a feeler gauge measure the clearance between the grooves and ring at several points around the grooves 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 f the second groove has a clearance greater than 0 0055 inch 0 14 mm replace the piston 8 The oil ring is made of three pieces upper and lower rails and expander It is difficult to measure the ring groove clearance and thickness Inspect visually for wear or damage Figure 13 51 Connecting Rod Cap Bolts Figure 13 52 Measure Piston Ring and Groove Clearance Piston Ring Inspection 1 Insert the ring squarely into the cylinder bore to a point approximately 1 inch 25 mm down from the top the cylinder See following NOTE NOTE e USE THE TOP OF THE PISTON TO PUSH THE RING INTO THE BORE TO BE SURE IT IS SQUARE 2 Using a feeler gauge measure the ring end gap Figure 13 53 Page 13 28 Page 13 26 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Piston and Connecting Rod Figure 13 53 Measure Ring End Gap Figure 13 54 Measure Piston Ring Thickness 3 If the end gap of any ring is greater than 0 0472 inch 1 199 mm
233. ndicating the actual fuel level The hour gauge displays the number of hours of use in increments of 1 hour but does not record additional time unless the engine is running When the hour gauge is recording the hourglass icon at the left of the field blinks slowly Fuel Hour Gauge Removal 1 Disconnect the battery wires as shown Figure 12 1 Page 12 2 2 Remove the center dash panel See Key Switch Removal Page 12 13 3 Disconnect the wires from the fuel hour gauge Figure 12 23 Page 12 21 Do not allow wires to touch 4 Remove the hex nuts and lockwashers from the studs on the back side of the gauge Figure 12 23 Page 12 21 Remove the mounting bracket from the back side of the gauge and remove the gauge from the center dash HEX NUT CENTER DASH MOUNTING BRACKET FUEL HOUR GAUGE Figure 12 23 Fuel Hour Gauge Installation 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12 21 ELECTRICAL COMPONENTS Fuel Level Sending Unit Fuel Hour Gauge Installation 1 Install a new gauge into hole in dash Be sure flange seats tightly against dash Figure 12 23 Page 12 21 Slide the mounting bracket onto the threaded studs on back of the fuel hour gauge Secure mounting bracket to the gauge with two lockwashers and hex nuts Tighten hardware to 2 5 in Ib 28 N m Place one drop of Loctite on each hex nut Do not allow Loctite to come into contact with the fuel hour gauge casing
234. ng end of the cable conduit Figure 14 12 Page 14 12 Before tightening the cable housing retaining nuts make sure the engine RPM adjustment is correct See Engine RPM Adjustment Page14 14 7 Install the electrical box cover and tighten retaining screw CLOSED THROTTLE OR IDLE ADJUSTMENT When the accelerator pedal is released the engine will stop Therefore it is not possible to measure or set idling speed under normal vehicle operating conditions Set throttle valve as follows 9 Gr dm i9 1 Loosen the carburetor idle screw so that it is not touching the throttle lever Figure 14 13 Page 14 13 2 Slowly tighten the idle screw until it lightly touches the throttle lever then tighten it an additional 3 4 turn Figure 14 13 Idle Screw 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 14 13 FUEL SYSTEM Choke and A r Intake System ENGINE RPM ADJUSTMENT DANGER THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS AND DEADLY POISON DO NOT OPERATE THE ENGINE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION 1 If the governor is adjusted proceed to step 2 otherwise adjust the governor See Governor Cable Installation and Adjustment Page 14 11 2 Connect the battery cables positive cable first Tighten terminals to 20 ft lb 27 1 N m 3 Place the Forward Reverse handle in the NEUTRAL position and place the neutral lockout cam in the SERVICE position 4 Connect a ta
235. ning and inspection 13 12 installation nere 13 19 r moVval ecd cdd aus 13 10 cylinder shroud retmoVal cuneo ers 13 7 D diagram schematic 11 6 differential see unitized transaxle Page 7 INDEX differential gear case assembly eisini utet 16 26 disassembly 2 22 ative nhs rtg 16 17 drive belt 17 3 installation 17 4 1 17 3 drive clutch assembly ieu e hibet 17 9 cleaning and inspection 17 5 17 8 disassembly sse 17 7 installation ANA eae 17 11 removal iit tele eee 17 5 drive unit see unitized transaxle driven clutch assembly seas 17 14 disassembly etie cre 17 13 inspection ca teet etn gr 17 14 installation sess 17 15 removal TE 17 13 E electrical system 11 5 13 4 electrical testing senes 11 12 engine ignition circuit 11 5 11 8 11 12 see also ignition coil and ignition testing engine kill circuit 11 5 11 9 fuel gauge sending unit circuit 11 6 11 11 11 17 generator circuit 11 5 11 8 hour gauge circuit 11 6 11 11 low oil warning circuit
236. no measurable wear anywhere on the shaft Replace the shaft if it is worn scratched or damaged Figure 17 5 Page 17 6 4 Inspect the thrust washer 11 for wear If it is worn more than 0 030 inch 0 76 mm turn it over or replace it with a new one Figure 17 5 Page 17 6 5 Inspect the primary weights 2 and the hub casting for wear If the primary weights show signs they are touching the casting the tips of the weights have worn beyond specification and they must be replaced Figure 17 5 Page 17 6 6 Inspect the pins on the primary weights 2 There should be no measurable wear Replace them if they are worn scratched or damaged Figure 17 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 PRESS RAM Use a scribe to remove v e spiral back up rings from both sides of fixed face assembly IDLER BEARING BEARING PULLER FIXED FACE ASSEMBLY Figure 17 10 Remove Idler Bearing Figure 17 11 Spiral Back up Rings DRIVE CLUTCH ASSEMBLY 1 Press idler bearing 6 onto the shaft of the fixed face assembly 7 Press on the inner race of the bearing only Make sure that the cup side of bearing is facing away from the fixed face Figure 17 5 Page 17 6 Using needle nose pliers install the spring retainer 5 onto the spring 4 Figure 17 5 Page 17 6 Install the spring
237. nt it is attached to 3 Set the multimeter to 200 ohms and place the red probe on the terminal at one end of the wire Place the black probe on the other terminal end of the wire The reading should be continuity If the reading is incorrect repair or replace the wire TEST PROCEDURE 10 STARTER GENERATOR GENERATOR FUNCTION Read DANGER and WARNING on page 11 1 NOTE KEEP THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 10 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Check to ensure that the wires are connected correctly and are tight If they are not rewire or tighten as necessary 3 Disconnect the yellow wire from the DF terminal on the starter generator Cover the connector on the yellow wire to make sure the yellow wire will not short to ground Then using a jumper wire ground the DF terminal to the A2 terminal Figure 11 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 and place the black probe on the negative post Turn the key switch to the ON position and depress the accelerator pedal to start the engine Run the engine at full governed speed The reading should show the voltage rising on the meter If the voltage rises see Test Procedure 11 Voltage Regulator Page 11 27 If the voltage does no
238. o drive clutch then tighten puller to remove hub DRIVE CLUTCH PULLER CLUB CAR PART NO 1014496 IN GRAY Figure 17 3 Loosen Retaining Bolt Figure 17 4 Drive Clutch Removal DRIVE CLUTCH Read DANGER and WARNING on page 17 1 A CAUTION 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 REPLACE IT 17 4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TORQUE CONVERTER Drive Clutch DRIVE CLUTCH REMOVAL 1 Remove the drive belt as instructed on page 17 3 2 Loosen the starter generator mounting and adjusting hardware and then remove the starter belt See WARNING on page 17 1 3 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jackstands under the axle tubes to support the vehicle This will allow the weight of the centerline of the drive clutch to drop below the frame I beam for access to the bolt securing the drive clutch See follow ing WARNING A WARNING e LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES UNLOAD THE CARGO BED AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LB 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED
239. o keep the flywheel and fan assembly 1 from turning while tightening the flywheel nut to 63 ft lb 85 4 N m Figure 13 105 13 47 See following CAUTION A CAUTION THE FLYWHEEL NUT HAS RIGHT HAND THREADS TURN IT CLOCKWISE TO TIGHTEN OR COUNTERCLOCKWISE TO LOOSEN e BE CAREFUL NOT TO DAMAGE THE FAN BLADES USE A STRAP WRENCH TO HOLD FLYWHEEL DO NOT PLACE SCREWDRIVER OR PRY BAR BETWEEN FAN BLADES Page 13 46 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Engine Assembly 4 5 10 11 12 13 14 15 16 17 18 19 20 Install ignition coil See Ignition Coil Installation Page 13 32 Install cylinder head shrouds Installation is the reverse of removal See Cylinder Shroud Removal Steps 12 and 13 Page 13 10 Install carburetor See Section 14 Fuel System Place engine onto engine mounting plate and tighten hardware to 21 ft lb 28 4 N m Figure 13 48 Page 13 25 Install drive clutch See Section 17 Torque Converter Install drive belt See Section 17 Torque Converter Install muffler See Section 15 Exhaust System Install starter generator and belt See Section 12 Electrical Components Install the powertrain by performing steps 13 through 31 pages 16 35 through 16 38 in Section 16 Unitized Transaxle Install oil drain plug in the crankcase and tighten to 20 ft lb 27 1 N m Apply a light film of oil on the seal
240. olt battery fuse key switch accelerator pedal limit switch neutral lockout limit switch solenoid starter generator and connecting wires Figure 11 3 Page 11 7 The battery is the source of power for the system The fuse provides protection to the solenoid activating circuit See following NOTE NOTE THE STARTER CIRCUIT IS COMPLETELY INDEPENDENT OF THE IGNITION CIRCUIT THE BATTERY DOES NOT SUPPLY POWER FOR IGNITION THE BATTERY SUPPLIES POWER TO THE STARTER GENERATOR WHICH IN TURN STARTS THE ENGINE COMPONENTS ROTATING ONCE THE ENGINE IS RUNNING THE IGNITION CIRCUIT SUPPLIES POWER TO THE SPARK PLUG SEE ENGINE IGNITION CIRCUIT Page 11 8 The starter circuit is activated when the key switch is turned to the ON position the accelerator pedal is depressed and the Forward Reverse handle is placed in either the FORWARD or REVERSE position thus actuating the neutral lockout limit switch See Neutral Lockout Circuit Page 11 10 Electrical current is then supplied to 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 pulleys NOTE ENGINE ROTATION CLOCKWISE IS AS VIEWED FROM THE CLUTCH ASIDE OF THE ENGINE FRAME ASSEMBL GROUND x NEUTRAL LOCKOUT LIMIT SWITCH ACCELERATOR PEDAL LIMIT SWITCH Q FORWARD REVERSE STARTER 5 GENERATOR BATTERY
241. on 11 Page 11 34 Oil Warning Light Removal 1 Disconnect the battery wires as shown Figure 12 1 Page 12 2 2 Remove the center dash panel See Key Switch Removal Page 12 13 3 Disconnect the wires from the oil warning light 11 Figure 12 22 Page 12 20 Do not allow wires to touch 4 Depress the two retaining tabs and remove the light from the center dash Figure 12 22 Oil Warning Light Page 12 20 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Fuel Hour Gauge Oil Warning Light Installation 1 Push a new unit into hole in dash until plastic tabs engage dash Figure 12 22 Page 12 20 2 Connect yellow wire from the key switch and yellow wire from the oil level sensor to the oil light 3 Reinstall the center dash in reverse order of removal Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place 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 Battery Protector Spray Club Car Part No 1014305 FUEL HOUR GAUGE Read DANGER and WARNING on page 12 1 Testing the Fuel Hour Gauge See Test Procedures 26 and 27 Section 11 Page 11 36 With the 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 i
242. on 14 Fuel System Loss of engine power 1 Exhaust valve is restricted with carbon Section 13 Engine deposit 2 Muffler or exhaust pipe restricted with Section 15 Exhaust System carbon or other substance 3 Ignition coil failed Section 11 Troubleshooting Test Procedures 13 14 and 15 4 Air filter is dirty or clogged Section 14 Fuel System 5 Governor is improperly adjusted Section 14 Fuel System 6 Throttle linkage out of adjustment Section 14 Fuel System 7 Low cylinder compression Section 13 Engine 8 Spark plug failed Section 13 Engine 9 Restricted fuel flow Section 14 Fuel System 10 Torque converter is not backshifting Section 17 Torque Converter properly Spark plug fouls repeatedly 1 Incorrect plug Section 13 Engine 2 Spark plug wire is damaged or loose Section 13 Engine 3 Unsuitable fuel or Section 14 Fuel System incorrect rich fuel mixture 4 Ignition coil failed Section 11 Troubleshooting Test Procedures 13 14 and 15 5 Dirt entering combustion Check intake system for leaks chamber Section 14 Fuel System 6 Rings worn out low cylinder pressure Section 13 Engine Troubleshooting Guide continued on next page 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11 3 TROUBLESHOOTING Troubleshooting Guide SYMPTOM POSSIBLE CAUSES REFERTO Carburetor floods
243. on a surface plate Figure 13 17 Page 13 13 5 Measure the space between the surface plate and the head with a feeler gauge 1 to check the flat ness of the head surface Figure 13 17 Page 13 13 6 If the head is warped more than 0 002 inch 0 05 mm replace the head See following CAUTION A CAUTION SMOOTH OUT ANY DAMAGED SPOTS IN THE COMBUSTION CHAMBER 1 USING A SMALL GRINDER SHARP EDGES IN THE COMBUSTION CHAMBER MAY CAUSE PRE IGNITION DO NOT REMOVE ANY MORE MATERIAL THAN IS NECESSARY OR CHANGE THE SHAPE OF THE COMBUSTION CHAMBER FIGURE 13 16 PAGE 13 12 DO NOT GRIND THE VALVE SEATS OR THE GASKET SURFACE eS Measure each position in 2 places 90 apart Figure 13 17 Check Flatness of Head Surface Figure 13 18 Measure I D of Valve Guides VALVE GUIDES Valve Guide Inspection 1 Measure the inside diameter of each guide with a telescoping gauge Figure 13 18 Page 13 13 2 f the inside diameter exceeds 0 2781 inch 7 065 mm replace the guide Valve Guide Replacement 1 With the combustion chamber side of the head facing up drive the guide out of the head with a valve guide arbor 1 Club Car Part No 101641202 Figure 13 19 Page 13 14 2 Install the snap ring 2 on the new valve guide Figure 13 20 Page 13 14 3 Coat the guide with a light film of clean engine oil Page 13 12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Oylind
244. onnect the green wire to common COM terminal and the orange wire to the normally closed NC terminal of the accelerator pedal limit switch Figure 12 18 Page 12 17 3 Depress the accelerator pedal to make 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 Battery Protector Spray Club Car Part No 1014305 KILL LIMIT SWITCH Read DANGER and WARNING on page 12 1 Testing the Kill Limit Switch See Test Procedure 16 Section 11 Page 11 31 Kill Limit Switch Removal 1 Disconnect battery cables as shown Figure 12 1 Page 12 2 2 Remove electrical component box cover 1 Figure 12 18 Page 12 17 3 Remove the nuts 9 and washers 10 that secure the accelerator pedal limit switch 11 Do not dis connect the wires attached to this switch Figure 12 18 Page 12 17 4 Disconnect the two white black wires and the black wire from the kill limit switch 12 5 Remove the kill limit switch 12 Kill Limit Switch Installation 1 Install the kill limit switch 12 onto the screws 16 Figure 12 18 Page 12 17 2 Connect the two white black wires to the common COM terminal and the black wire to the normally open NO terminal of the kill limit switch 12 3 Install the accelerator pedal limit switch 11 onto the screws 16 Secure the switch with washers 10 and nut
245. or Continued 2 Remove the two bolts 20 and pull commutator end cover 23 free of the starter generator housing 24 Figure 12 3 Page 12 4 3 To separate armature 33 from output end cover 36 remove nut 41 lockwasher 40 pulley 39 shaft key 34 spacer 37 and bearing retainer screws 43 Figure 12 8 Page 12 6 TYPICAL 3 PLACES Figure 12 8 Armature and Output End Cover Assembly Bearing Cleaning and Inspection 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 if it is noisy does not spin smoothly or has excessive play Check the bearings and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing Bearings should be replaced if there is extensive wear or pitting on the balls or on the rolling surfaces Do not remove the bearings unless they are to be replaced Figure 12 9 Bearing Play Inspection Page 12 6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Starter Generator Bearing Removal 1 Place the wedge attachment tool Club Car Part No 1012812 between the bearing and the armature Make sure the wedge attachment tool is supporting the inner race of the bearing If a press is not avail able secure a bearing puller Club Car Part No 1012
246. proper reconnection Figure 16 16 Generator Wires Figure 16 17 Oil Level Sensor Jumper Wire 3 11 Cut away the wire ties securing the engine kill switch 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 motor mount beneath the muffler 4 Disconnect the brake cables 4 1 Remove cotter pins 1 brake cable clevis pins 2 and E clips 3 Figure 16 19 Page 16 10 4 2 Remove the cable from the cable support bracket Figure 16 19 Page 16 10 5 Remove only the ower shock mounting hardware from both rear shocks Figure 16 20 Page 16 10 6 Position a floor jack under the vehicle frame crossmember or trailer hitch mount as shown Figure 16 21 Page 16 10 7 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 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 hitch is higher than the top of the unitized transmission enough to allow transaxle and engine to be rolled under and out of vehicle Figure 16 26 Page 16 12 10 Position jack stands adjusted to support the vehicle at this height under the frame cross member between the leaf spring mounts and side stringers just forward of each rear wheel Lower the floor jack to allow the jack st
247. prybar under seal then pull seal out of its axle tube seat Figure 16 6 Seal Lip 7 Inspect the axle shaft assembly to be sure the bearing 71 and collar 73 have not slipped and are still seated against the shoulder on the axle shaft Figure 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 external retaining ring pliers 047 tip to remove the retaining ring 74 Figure 16 5 Page 16 4 then place a bearing puller wedge attachment Club Car Part No 1012812 on the axle shaft between the wheel mounting flange and the bearing See following CAUTION A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE AXLE SHAFT THIS COULD DAMAGE THE AXLE SHAFT WHEN PRESSING THE BEARING AND COLLAR OFF 2 Press the bearing 71 and collar 73 off together Leave retaining ring 70 on the axle shaft Figure 16 5 Page 16 4 See also Figure 16 7 Page 16 6 See following NOTE NOTE IT MAY BE NECESSARY TO HEAT THE COLLAR TO REMOVE IT 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 5 UNITIZED TRANSAXLE Axle Shaft Axle Bearing Installation 1 Install axle bearing 71 on axle 67 or 68 Push bearing onto axle until bearing is flush against axle shoulder Figure 16 5 Page 16 4 2 Apply two drops of Loctite 2719 to inside of the collar See following CAUTION A CAUTION e APPLY LO
248. r Element See page 14 16 Fuel Filters See page 14 18 Choke and Air Intake System for restriction of air flow See page 14 14 Fuel Pump See page 14 18 Fuel Lines from fuel tank to filter to pump to filter to carburetor See page 14 26 Exhaust System for restrictions See Section 15 Exhaust System 14 4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FUEL SYSTEM Carburetor If the carburetor floods or leaks fuel at the float bowl gasket or carburetor vent tube the fuel inlet valve could be worn or dirty Another cause of this condition may be a damaged float that has filled with fuel and sinks For elevations above 3000 feet main jets other than standard operate more effectively The following chart lists the elevation ratings for various jet sizes No adjustment is required for the pilot jet If the vehicle idles roughly turn the pilot air screw Figure 14 3 Page 14 3 out until the vehicle idles smoothly MAIN JET ELEVATION SIZE CHART ALTITUDE FE290 ENGINE FEET ABOVE SEA LEVEL MAIN JET SIZE 0 3000 82 3000 5000 80 5000 8000 78 8000 10 000 75 10 000 AND OVER 72 CHANGING THE MAIN JET 1 Remove the carburetor 1 1 Remove the seat or raise the bed to gain access to the engine 1 2 Turn fuel shut off valve on gas tank to the closed OFF position Figure 14 21 Page 14 26 1 3 Loosen the air intake hose clamp 22 and disconnect the air intake hose 23 at the
249. r and governor gear mesh Large idler gear and synchronizer MO SHIFTER gear mesh FORK Shifter arm and the shifter fork slotted arm also mesh Figure 16 77 Gear Alignment Several gears mesh as you insert the intermediate gear assembly The small gear on the intermediate gear assembly meshes with the differential ring gear INTERMEDIATE GEAR These three gears mesh DIFFERENTIAL RING GEAR SMALL IDLER GEAR Figure 16 78 Gear Alignment 16 32 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Unitized Transaxle Assembly 11 6 Install the left driver side axle shaft 67 in the left axle tube 75 Figure 16 5 Page 16 4 Using 90 angle 090 tip snap ring pliers install the retaining ring as shown Figure 16 84 Page 16 34 See WARNING on page 16 32 The edges of the input Clean mating surfaces of any oil drive gear and large dirt grease or residue of any kind intermediate gear should be flush After cleaning mating surfaces apply a continuous bead of Three Bond No The outside edges of the idler intermediate 1215 completely around the mating and differential bearings are on the same plane surface of the right side casing and The synchronizer bearing protrudes slightly around all bolt holes Figure 16 79 Gear Alignment Figure 16 80 Prepare Mating Surfaces In the sequence shown torque to 17 ft lb 23 1 N m the fifteen bolts
250. r more the low cell should be suspected It may require a catch up charge or it may be a weak cell When the variations between cells reach 0 050 or more the battery should be replaced Page 11 20 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Test Procedures Voltage Test 1 Place the red probe of a multimeter set at volts DC 20 volt range on the positive post and place the black probe on the negative post of the battery and take a voltage reading If it shows less than 12 4 volts or if the lowest specific gravity reading from the hydrometer test is less than 1 225 recharge the battery If battery voltage is greater than 12 4 volts and specific gravity is greater than 1 225 the problem is not with the battery If the battery does not reach 12 4 volts or if the specific gravity of a cell is still less than 1 225 after charging replace the battery See following NOTE NOTE e A FULLY CHARGED BATTERY THAT IS IN GOOD CONDITION SHOULD HAVE A SPECIFIC GRAVITY OF AT LEAST 1 225 IN ALL CELLS AND THE DIFFERENCE IN THE SPECIFIC GRAVITY OF ANY TWO CELLS SHOULD BE LESS THAN 50 POINTS OPEN CIRCUIT VOLTAGE SHOULD BE AT LEAST 12 4 VOLTS Load Test 1 Using a 160 ampere load tester connect the load tester to the battery posts 2 Turn the switch on the load tester to the ON position 3 Read the battery voltage after the load tester has been turned on for 15 seconds Compare the batt
251. r wedge attachment Club Car Part No 1012812 between the bearing 66 and the small gear on the idler shaft 65 Figure 16 42 Page 16 18 then press the bearing off the shaft as shown Figure 16 51 Page 16 22 See following CAUTION A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THE SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF 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 the bearing off the shaft as shown Figure 16 52 Page 16 22 BEARING PULLER WEDGE ATTACHMENT WEDGE Figure 16 48 Remove Bearing Figure 16 49 Remove Bearing 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 21 UNITIZED TRANSAXLE Unitized Transaxle Component Inspection UNITIZED TRANSAXLE COMPONENT INSPECTION Read DANGER and WARNING on page 16 1 1 Use a 7 8 inch o d or smaller arbor and a bearing puller wedge attachment Club Car Part No 1012812 to press bearing from shaft WEDGE a ATTACHMENT PRESS RAM Press idler shaft from bearing using a 3 4 in or less o d arbor anda wedge attachment Club Car Part No 1012812 ATTACHMENT F
252. rator and Brake Pedal Group in the appropriate maintenance and service manual 2 Install the ball joint on the ball stud at the accelerator pedal Figure 14 8 Page 14 9 Remove seat or lift bed to access engine compartment 4 Remove the electrical box cover Figure 14 9 Page 14 10 e 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14 9 FUEL SYSTEM Engine Control Linkage Accelerator Rod Installation and Adjustment Continued 5 Adjust length of accelerator rod For the DS vehicle with the ball joint jam nuts 3 Figure 14 8 Page 14 9 loose adjust the length of the accelerator rod to obtain a throttle cable cam position of 15 17 as shown Figure 14 9 Page 14 10 For Turf 1 Carryall 1 and Villager 4 vehicles with the ball joint jam nuts 3 loose Figure 14 8 Page 14 9 adjust the length of the accelerator rod to obtain a throttle cable cam position of 0 as shown Figure 14 10 Page 14 10 A CAUTION e BE SURE THAT APPROXIMATELY AN EQUAL NUMBER OF THREADS IS EXPOSED AT EACH END OF THE ACCELERATOR ROD 6 Install the accelerator rod on the bell crank ball joint on the electrical box Figure 14 11 Page 14 11 A CAUTION INSPECT THE LIMIT SWITCH INSIDE THE ELECTRICAL BOX IF THE LIMIT SWITCH LEVER IS BENT REPLACE THE SWITCH 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 Whil
253. re the battery should be checked more often When storing the battery keep in a cool place See Battery Storage Page 12 30 Water Level The water level should be checked semi annually to be sure water is at its proper level Figure 12 30 Page 12 28 Never allow the water level to fall below the tops of the plates because this will cause the exposed part of the plate to become permanently inactive Check the water level more frequently in hot weather or when the battery becomes old BATTERY CAP PLATES WATER LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR Figure 12 30 Battery Water Level Vibration Damage The battery clamp should always be tight enough to keep the battery from bouncing Battery life may be severely shortened if the clamp is too loose Excessive vibration shortens the life of the battery It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts The acid which is lost reduces the capacity of the battery 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 be sure mineral contents are below the levels listed in the following table See following
254. rminals to 20 ft lb 27 1 N m Figure 12 1 Page 12 2 Coat terminals with Battery Protector Spray Club Car Part No 1014305 Battery Storage Read DANGER and WARNING on page 12 1 and DANGER on Page 12 26 1 Keep the battery clean and free of corrosion as outlined in Preventive Maintenance Page 12 27 2 The battery cables should be disconnected from the vehicle so it can be connected to the charger The battery can be left in the vehicle 3 Fully charge the battery prior to storage 4 Store in a cool area The colder the area in which the battery is stored the less the battery will self dis charge A battery stored at 0 F 17 8 C will discharge very little over a four month period A battery stored at 80 F 27 C will have to be recharged every few weeks 5 Check the state of 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 A WARNING e IF THE BATTERY IS FROZEN OR THE CONTAINER IS BULGED DISCARD BATTERY FROZEN BATTERY CAN EXPLODE 6 The frequency of recharging required depends on the temperature of the storage area but it is recom mended that the battery be monitored for state of charge every month Also if the storage area is unheated in a cold climate and recharging is required it is recommended that the area be heated to at least 60 F 15 6 C prior to charging The ba
255. rod 13 26 piston pin INSPOCHION visti oann 13 27 piston ring INSPOCHION E 13 26 push rod INSPECHION Aare eis ee ae 13 18 temoVval p onouieexe nude 13 9 R reed valve see breather valve reverse buzzer 11 5 11 9 11 15 11 33 installation race 12 19 limit switch installation re 12 20 removal 12 20 remowval uiia ter Rb 12 19 testing oerte dts tec etur ds 11 33 ring piston see piston ring rocker arm In SDectiori eee R 13 18 temoval isi dir CRISIS 13 9 rocker shaft SPECON t EL 13 18 RPM adjustment 14 14 RPM limiter Installation ic ee 12 22 removal iini 12 22 I II 11 29 S safety daily pre operation safety checklist 10 2 schematic diagram 11 6 service schedule see periodic service schedule see also periodic lubrication schedule service tools enigllg chien moe ub einen 13 2 torque converter 17 2 unitized transaxle eene 16 3 shifter fork unitized transaxle assembly 5 tte remus 16 25 disassembly erento 16 20 solenoid instalation ziii e Erie fee 12 15 temowval certet tetas coe 12 14 testing aeter ti eret ties 11 23 spark plug n 13 6 14 4 cleaning inspection and repair 1
256. roken wires or thrown solder it is obvious without testing that it should be replaced Faults seen during the visual inspection can aid in diagnosing the original cause of the failure Items to look for are listed below Burned charred or cracked insulation Improperly cured varnish Thrown solder Flared armature windings Worn burned or glazed commutator Loose or raised commutator bars Bruised or damaged armature core laminations Worn armature bearing or shaft Dirty or oily commutator 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12 7 ELECTRICAL COMPONENTS Starter Generator P POLE PIECE SCREW RETAINING NUT Y 9 SET Z C lt HOUSING FIELD COIL TERMINAL FIELD COIL Figure 12 11 Field Coil Assembly Commutator Cleaning Inspection and Replacement 1 Clean the carbon dust dirt and 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 commuta tor can be polished away with 400 grit or finer sandpaper See following CAUTION A CAUTION e NEVER USE EMERY CLOTH ON THE COMMUTATOR PARTICLES OF EMERY ARE CONDUCTIVE AND MAY SHORT CIRCUIT THE COMMUTATOR BARS NEVER USE OIL OR LUBRICANTS ON THE COMMUTATOR OR BRUSHES 2 Using a micrometer measure the outside diameter at two points along the commutator If the commutator outside diame
257. rom the reverse warning buzzer 3 Do not allow wires to touch Figure 12 21 Page 12 19 4 Remove reverse warning buzzer mounting screws 2 Figure 12 21 Page 12 19 Reverse Warning Buzzer Installation 1 Install the screws through the buzzer bracket tabs and tighten to 4 in Ib 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 harness to the positive terminal on the buzzer Figure 12 21 Page 12 19 4 Reverse removal procedures to reinstall the center dash in the vehicle Be sure that the key switch ter minals cannot touch the frame and that the panel is properly seated and snapped in place 5 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 Battery Protector Spray Club Car Part No 1014305 REVERSE _ BUZZER Ps VIEWED WITH FRONT BODY 22 REMOVED Figure 12 21 Reverse Buzzer REVERSE BUZZER LIMIT SWITCH Read DANGER and WARNING on page 12 1 Testing the Reverse Buzzer Limit Switch See Test Procedure 19 Section 11 Page 11 33 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 12 19 ELECTRICAL COMPONENTS Oil Warning Light Reverse Buzzer Limit Switch Removal 1 Disconnect the battery wires as shown Figure 12 1 Page 12 2 2 Disconnect the orange and red white
258. rt No 1014305 IGNITION COIL Read DANGER and WARNING on 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 negative first as shown Figure 12 1 Page 12 2 Disconnect the spark plug wire Remove the governor guard 1 Figure 12 25 Page 12 24 Remove the muffler See Section 15 Exhaust System c RON Cut the tie wrap that holds the wire harness to the flywheel stiffener and remove the four hex head bolts securing the stiffener to the mounting plate Figure 12 26 Page 12 24 D Remove the screws securing the fan shroud to the fan housing Figure 12 27 Page 12 24 7 Loosen but do not remove three screws attaching the fan housing as shown Figure 12 27 Page 12 24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12 23 ELECTRICAL COMPONENTS Ignition Coil Ignition Coil Removal Continued 8 Remove the remaining four screws attaching the fan housing as shown Figure 12 27 Page 12 24 then while opening the housing detach the spark plug wire 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 12 24 TRANSAXLE MOUNTING PLATE STIFFENER FAN HOUSING Loosen Remove
259. s 9 Tighten to 5 in Ib 0 6 N m 12 16 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Neutral Lockout Limit Switch A WARNING DO NOT OVER TIGHTEN THE RETAINING NUTS IF THE NUTS ARE OVER TORQUED LIMIT SWITCHES COULD BE DAMAGED TYPICAL 2 PLACES TYPICAL 2 PLACES BLACK WIRE FROM VOLTAGE c REGULATOR pu oe Figure 12 18 Accelerator Pedal and Kill Limit Switches 4 Depress and release the accelerator pedal to make sure that both switches are being actuated when the pedal is released 5 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 Battery Protector Spray Club Car Part No 1014305 NEUTRAL LOCKOUT LIMIT SWITCH Read DANGER and WARNING on page 12 1 Testing the Neutral Lockout Limit Switch See Test Procedure 7 Section 11 Page 11 24 Neutral Lockout Limit Switch Removal 1 Disconnect the battery cables as shown Figure 12 1 Page 12 2 2 Disconnect the green white and black wires from the neutral 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 neutral lock out limit switch off of the screws Figure 12 19 Page 12 18 Neutral Lockout Limit Switch Installation 1 Install the neutral lockout limit switch 5
260. seated against the housing or on the shaft 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 3 FE290 ENGINE General Information Circlip Retaining Ring Replace circlips and retaining rings that were removed with new circlips and retaining rings as removal weakens and deforms them During installation take care to compress or expand them only enough for installation High Flash point Solvent To reduce fire danger a high flash point solvent is recommended A commercial solvent commonly available in North America is Stoddard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent Molybdenum Disulfide MoS5 Grease NOTE THIS MANUAL MAKES REFERENCE TO MOLYBDENUM DISULFIDE GREASE IN THE ASSEMBLY OF CERTAIN ENGINE AND CHASSIS PARTS ALWAYS CHECK MANUFACTURER RECOMMENDATIONS BEFORE USING SUCH SPECIAL LUBRICANTS Engine Rotation When turning the crankshaft by hand always turn it clockwise as viewed from the clutch side of the engine This will ensure proper adjustments ELECTRICAL SYSTEM See also Section 11 Troubleshooting and Electrical System and Section 12 Electrical Components 1 Always minimize shock hazards when working on electrical equipment Work in a clean dry environ ment with dry hands 2 Electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock can damage an electric
261. small bore at several points along its length Figure 13 57 Page 13 29 3 If the inside diameter exceeds 0 7500 inch 19 050 mm replace the connecting rod 4 Remount the connecting rod cap to the connecting rod at the large bore end aligning the pilot groove on the rod Screw in the connecting rod bolts and tighten them to 16 5 ft lb 23 N m 5 Using a telescoping gauge or an inside micrometer measure the inside diameter of the large bore at several points along its length Figure 13 58 Page 13 29 6 If the inside diameter exceeds 1 4003 inches 35 568 mm replace the connecting rod NOTE THE CONNECTING ROD AND CAP MUST STAY TOGETHER AS A SET DO NOT MIX WITH PARTS FROM ANY OTHER ENGINE IF THE CONNECTING ROD IS BENT OR TWISTED IT MUST BE REPLACED Measure Measure each side in 2 places of oil groove 90 apart in 2 places 90 apart Figure 13 57 Measure 1 0 of Small Bore Figure 13 58 Measure I D of Large Bore Piston and Connecting 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 wall scoring Repair or replace as necessary 1 Usean inside micrometer or telescoping gauge together with a micrometer to measure the cylinder bore 2 Make the first measurement parallel with the crankshaft and the second at right angles to the crank sha
262. small chisel or similar pointed instrument to pry the pivot arm oil seal 22 Figure 16 35 Page 16 14 out of the case Figure 16 41 Page 16 17 15 4 Remove the governor gear assembly 63 and 64 and flat washer 62 Figure 16 42 Page 16 18 by lightly tapping the gear shaft through the case wall from the outside with a hammer and drift See also Figure 16 43 Page 16 19 Remove synchronizer gear assembly and shifter fork together as a unit Pry input shaft oil seal from INTERMEDIATE GEAR ASSEMBLY IDLER SHAFT ASSEMBLY Figure 16 38 Remove Intermediate Gear Figure 16 39 Input Shaft Oil Seal Page 16 16 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Component Disassembly SHIFTER SHAFT Use a small chisel or similar tool to pry out the pivot arm oil seal i IL FLOW GUIDE Figure 16 40 Oil Flow Guide Figure 16 41 Pivot Arm Oil Seal COMPONENT DISASSEMBLY Read DANGER and WARNING on page 16 1 GOVERNOR GEAR DISASSEMBLY NOTE IT WILL BE NECESSARY TO DISASSEMBLE THE GOVERNOR GEAR ASSEMBLY IN ORDER TO REINSTALL IT INTO THE TRANSAXLE CASE 1 Secure the governor gear assembly in a vise as shown Wrap shaft in a cloth to prevent damage Figure 16 44 Page 16 19 2 Use two small screwdrivers to pry the gear and flyweight off the shaft as shown Figure 16 44 Page 16 19 DIFFERENTIAL GEAR CASE DISASSEMBLY A CAUTION MARK PARTS FOR IDENTIFICATION
263. ssible the spark plug has failed internally Check the spark plug gap The gap should be set at 027 to 031 of an inch 69 to 79 mm If the gap is correct replace the spark plug with a new part and test the engine for proper operation TEST PROCEDURE 14 RPM LIMITER Read DANGER and WARNING on page 11 1 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 first 2 Disconnect both of the bullet terminals Figure 11 38 Page 11 30 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 11 29 TROUBLESHOOTING Test Procedures Test Procedure 14 Continued 3 Using a multimeter set on 200 Q ohms place the red probe on the brown ground wire and place the black probe on one of the black wire female bullet connectors The reading should be no continuity If the reading is not correct replace the RPM Limiter This test will find most bad RPM Limiters Some of them may bench test okay but fail under a load due to heat while operating Another method of testing is to replace the RPM Limiter and then run the engine If the engine runs properly keep the new RPM Limiter in the circuit BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE BLACK FEMALE BULLET KILL CIRCUIT WIRE TERMINAL Figure 11 38 RPM Limiter BLACK WIRE TEST PROCEDURE 15
264. sssssssseeeeeeene enne enhn 14 13 E gine nennen ntes eene nenne nennen nnns 14 14 Choke and Air Intake System a eaaa aea aaar aaee 14 14 General Information 14 14 Choke Button Removal c cccsccccececeececseeseesseaeceseececeseneseesseaaeaeceeeeeecesesesseasesaeaeceseceseeseseseesesaeeas 14 14 Choke Button Installation cccccccccccccececseesseesseceecececescesseeseaaaeaeceeeeescescuessesseaaeaeceseeeseeeeseneeseeaees 14 15 Air B x Removal e e uS ind ee edt excede ex esed 14 15 Air Box Installation eet e e 14 15 Intake Duct Removal reet tst eo t Gets Fe baee 14 15 Intake D ctl stallationks z reete reed ec aenea ette da secet aura eda 14 15 Intake DUCE RE Pall A 14 16 e a EDD INIM ULL mE 14 16 I UeliFilters 5 n i tdt a d e tet e dte dedi ees 14 18 General Informationi 3 2 a rc ttc t t dtt 14 18 F el Filter Removal ens teet cet n s 14 18 Fuel Filter InstallatiQri nk edet 14 18 F el PUlp isssie a ente e imet 14 20 General Information 14 20 Fuel Pump Removal cc aie eec ee e
265. ssssssssssssssesseeeee nennen nennen en tens nnns en 13 50 SECTION 14 FUEL SYSTEM General Information Ra e eene tee de ae ede e e ee PR 14 1 How The Carburetor Works esses eene nnne nnne nen nennen 14 2 Main System o eo et e E m iR Mec f 14 2 Slow Speed System 14 2 Choke and Fresh Air System 14 4 Float Systemin ea aenea a uee e ree ete do 14 4 ate 14 4 Main Jet Elevation Size Chart esses enne en nnns nennen nnns 14 5 Changing the Main Jet 14 5 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Engine Control Linkages ccs eicere recreo lese et a Deva E e Eran ene eee de neas 14 8 General Informaltiob sii it rtt bereitet tertie botte be aita O ptt ied iym ERE 14 8 Accelerator 2 50 t o ete edit dt ipt eee te diia meet 14 9 Governor able dim mee e E Ie UR etaed dae 14 11 Accelerator Gables Ditta ier bete e Mast tue estote e 14 13 Closed Throttle or Idle Adjustment sssssss
266. t nennen Aa e ns sin 11 9 Low Oil Warning 11 10 Neutral Lockout d ei dcr re eda tot vat e e e Ea 11 10 Fuel Gauge and Sending Unit Circuit ssssssssssssseseee eee nnne 11 11 Hour Gauge Circuit RR 11 11 Circuit Festing T renee EE 11 12 Testing the Starter Circuit and Generator Circuit 0 ccccceeeeeeeeeeeeceeeeeeeaeeeeeeeeeseaeeeeeaeeesnaeeeeeeeeees 11 12 Testing the Engine Ignition Circuit nennen 11 12 Testing the Engine Kill Circuit nnne nn 11 13 Testing the Reverse Buzzer Circuit 11 15 Testing the Low Oil Warning Circuit nnne 11 16 Testing the Neutral Lockout Circuit ssssessssssseeseseeeee ener rennen 11 17 Testing the Fuel Gauge and Sending Unit Circuit 11 17 Test Procedures dE Rea Hee dE EE Eee Ree done Be ua N deed 11 18 Index of Test aiaiai aiaiai 11 18 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page ilii SECTION 12 ELECTRICAL COMPONENTS Starter Generaltor e AE Eee NEM e A REL REM REDEEM aee lane ante Neenah Voltage Regulator a dicere dide iare an ao R
267. t Ib 12 N m Figure 12 11 Page 12 8 4 Slide the bearing retainer onto the output end of the armature shaft 33 so that it will hold the outside of the bearing 35 only 5 Press a new ball bearing 35 onto the output end of the armature Figure 12 8 Page 12 6 Press a new ball bearing onto the commutator end of the armature shaft See following CAUTION A CAUTION e TO PREVENT DAMAGE TO THE RETAINER USE CARE WHILE PRESSING NEW BEARING ONTO THE OUTPUT END OF THE SHAFT e PRESS AGAINST THE INNER RACE OF THE NEW BEARING UNTIL IT IS FULLY SEATED 6 Install the output end cover 36 onto the armature Secure the bearing retainer 32 to the cover using three M5 x 8 x 18mm screws 43 and tighten to 39 in Ib 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 align housing with the cover NOTE THE TERMINAL INSULATORS SHOULD BE ON THE COMMUTATOR END OF THE HOUSING 8 To prevent contact between the brushes and commutator as the commutator cover is installed and pos sible damage to the brushes lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 12 7 Page 12 5 Page 12 10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COM
268. t 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 lapping compound Measure seats in several places Figure 13 25 Measure Seat Width Figure 13 26 Lap Valve to Seat 4 2 Use the vacuum cup lapping tool 1 to grip the top of the valve Rotate the valve in a circular motion to lap the valve to the seat Figure 13 26 Page 13 16 4 3 Lift the valve slightly from the seat every 8 to 10 strokes continuing the lapping operation until a uniform ring appears around the entire surface of the valve face 5 When lapping is completed wash all parts in solvent to remove lapping compound Dry the parts thoroughly 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13 15 FE290 ENGINE Cylinder Head Valve Seat Repair Continued 6 Note the position of the lapping mark on the valve face The lapping mark should appear on or near the center of the face 7 When the engine is assembled be sure to adjust the valve clearance See Valve Clearance Adjust ment Page 13 21 45 Figure 13 27 Valve Head Seating Area Figure 13 28 Valve Seating Surface Area VALVES Visual Inspection 1 Inspect the valve head seating area 1 for erosion nicks and warping etc Figure 13 27 Page 13 17 2 f the valve head seating area is worn replace the valve 3 If the valve
269. t rise see Disassembly of the Starter Generator Section 12 Electrical Components Page 12 3 5 Reconnect the yellow wire to the DF terminal on the starter generator TEST PROCEDURE 11 VOLTAGE REGULATOR Read DANGER and WARNING on page 11 1 NOTE KEEP THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 11 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Check that wires are connected correctly and are tight If they are not rewire or tighten as necessary 3 Check the engine RPM setting to ensure that it is correctly adjusted See Engine RPM Adjustment Section 14 Fuel System Page 14 14 4 With the battery in good condition and fully charged run the engine for several minutes to bring the voltage regulator to operating temperature 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement 11 27 TROUBLESHOOTING Test Procedures Test Procedure 11 Continued 5 Turn the key switch to OFF killing the engine Using a multimeter set to volts DC DC V place the red probe on the large post of the solenoid with the red wire from the voltage regulator attached Place the black probe on the negative post of battery Turn the key switch to the ON position Depress the accelerator to start the engine and run it at full governed speed If the reading is between 14 7 and 15 3 volts the reg
270. ter is less than 1 535 inches 39 mm replace the armature and bearings Figure 12 12 Page 12 8 Measure each position in two places 90 apart Figure 12 12 Inspect Commutator Page 12 8 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Starter Generator Armature Ground Test A CAUTION DO NOT SUBMERGE ARMATURE IN SOLVENT NOTE e BEFORE TESTING WIPE THE ARMATURE WITH A CLEAN CLOTH AND REMOVE CARBON DUST AND METAL PARTICLES FROM BETWEEN COMMUTATOR BARS 1 Using a multimeter set on 200 Q ohms place the positive probe on the commutator bars and the neg ative probe on the armature core The reading should be NO continuity If the reading is incorrect replace the armature and the two bearings Figure 12 13 Page 12 9 ARMATURE V COMMUTATOR ARMATURE SHAFT Figure 12 13 Armature Ground Test Visual Inspection of Field Coils If the insulation on the field coils appears blackened or charred the serviceability of the coils 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 housing Starter Generator Rework Any rework must be performed by a qualified technician Starter Generator service specifications are listed in the following table 2000 FE290 Gasoline
271. that secure the casing together qom Clean the mating surface of the right axle tube then apply a continuous bead of Three Bond No 1215 to mating surface Figure 16 81 Casing Torque Sequence Figure 16 82 Axle Tube Surface 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16 33 UNITIZED TRANSAXLE Unitized Transaxle Installation Unitized Transaxle Assembly Continued Clean mating surface on casing before installing axle tube In the sequence shown above torque bolts with lock washers to 36 ft lb 48 9 N m Figure 16 83 Install Axle Tubes Figure 16 84 Retaining Ring UNITIZED TRANSAXLE INSTALLATION Read DANGER and WARNING on page 16 1 1 Install the wheels See Section 8 Wheels and Tires in the appropriate maintenance and service manual Install the leaf springs See Section 9 Rear Suspension in the appropriate maintenance and ser vice Manual Position the transaxle mounting plate on the two mounting studs at the rear of the engine and then install the two mounting nuts Figure 16 85 Page 16 35 Install the remaining four mounting bolts and four nuts one bolt and nut at each corner of the mounting plate 5 Tighten the four corner nuts with bolts to 30 ft Ib 40 7 N m Tighten the two center nuts on the 10 11 12 studs to 17 ft lb 23 1 N m Install the accelerator cable bracket on transaxle case Tighten the mounting screws to 134 in Ib 15
272. the 6 gauge black wire from the negative post of the battery before reconnecting the wires to the solenoid SOLENOID SOLENOID ELECTRICAL COMPONENT BOX ELECTRICAL ri EN Figure 11 30 Test Solenoid Continuity Figure 11 31 Test Solenoid Ground TEST PROCEDURE 7 NEUTRAL LOCKOUT LIMIT SWITCH Read DANGER and WARNING on page 11 1 This switch is located on the Forward Reverse shifter assembly There is a black wire a green wire anda white wire connected to this limit switch Page 11 24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Test Procedures 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 first 2 Check for proper wiring and tight connections 3 Set a multimeter to 200 Q ohms Place the red probe of the multimeter on the common COM terminal of the limit switch Place the black probe on the normally open NO terminal of the limit switch Without the lever depressed the reading should be NO continuity With the lever depressed the reading should be continuity If either reading is incorrect replace the limit switch Figure 11 32 Page 11 25 LEVER UP LEVER DEPRESSED NEGATIVE NEGATIVE A POSITIVE Tester light is on Meter reads approximately zero ohms
273. the fan 7 with a strap wrench 5 and using a 22 mm socket remove the flywheel nut and flat washer by turning it counterclockwise Figure 13 63 Page 13 32 A CAUTION THE FLYWHEEL NUT HAS RIGHT HAND THREADS TURN IT CLOCKWISE TO TIGHTEN OR COUNTERCLOCKWISE TO LOOSEN DO NOT DAMAGE THE FAN BLADES WITH THE STRAP WRENCH DO NOT PLACE SCREWDRIVER OR PRY BAR IN THE FAN BLADES 4 Remove the flywheel with a puller Club Car Part No 1016627 5 Remove the flywheel key from its groove Loosen Figure 13 61 Flywheel Housing Figure 13 62 Ignition Coil Flywheel Installation See Engine Assembly on Page 13 47 Ignition Coil Inspection and Repair See Test Procedure 15 Section 11 Page 11 30 Page 13 30 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Oil Pump Ignition Coil Installation 1 Installation is the reverse of removal 2 While tightening the two bolts 3 use a bronze feeler gauge to adjust the ignition coil air gap to 0 012 inch 0 304 mm Figure 13 64 Page 13 32 3 Tighten the two ignition coil bolts to 30 in Ib 3 4 N m BOLT TIGHTENING SEQUENCE TYPICAL 6 PLACES Figure 13 65 Oil Pump 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 Page 13 32 2 Peel off the oil pump cover gasket 3 3 Remove the pump gear cover plate 4 Figure 13 65 Page
274. tized Transaxle Assembly Continued Unitized Transaxle Assembly 11 2 Apply a continuous bead of Three Bond No 1215 Club Car Part No 101928701 around the opening on the mating surface of the right passenger side axle tube as shown Figure 16 82 Page 16 33 Then position the axle tube on the right side of the transaxle case as shown and install seven mounting bolts 77 with lock washers 78 Figure 16 5 Page 16 4 finger tight In the sequence shown tighten the bolts to 36 ft Ib 48 8 N m Figure 16 83 Page 16 34 11 3 Duplicate step 11 2 for the left driver side axle tube 11 4 If removed prior to disassembly install left and right brake cluster assemblies to the axle tubes See Section 6 Wheel Brake Assemblies in the maintenance and service manual 11 5 Install the right 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 A WARNING BE SURE THE RETAINING RING IS PROPERLY SEATED IN ITS GROOVE IF THE RING IS NOT PROPERLY INSTALLED THE AXLE ASSEMBLY WILL SEPARATE FROM THE TRANSAXLE AND DAMAGE THE AXLE ASSEMBLY AND OTHER COMPONENTS LOSS OF VEHICLE CONTROL COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH As you insert the synchronizer gear assembly complete with shifter fork into the casing several gears must mesh together Spur gea
275. tor throttle bracket Figure 14 6 Page 14 6 4 Remove the E ring 7 at the governor cable engine bracket 11 and governor cable support bracket 10 Figure 14 12 Page 14 12 5 Remove the cotter pin 9 and clevis pin 8 from the governor lever arm 15 Figure 14 12 Page 14 12 6 Remove the cable 2 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 12 Page 14 12 2 Push the cable dust shields onto the ends of the cable conduit 3 Install the clevis pin 8 and cotter pin 9 through the clevis and carburetor throttle at the carburetor Figure 14 12 Page 14 12 4 Install the clevis pin 8 and cotter pin 9 through the rear clevis and governor lever arm 5 With the governor lever arm loose on the governor shaft use a 1 8 inch punch or scratch awl to turn the governor arm shaft counterclockwise until it stops Then pull the governor lever arm rearward until the carburetor throttle is in the wide open throttle WOT position 6 While holding the arm and shaft in the fully counterclockwise position tighten the governor arm lever nut to 36 in Ib 4 0 N m 7 Check the engine RPM adjustment See Engine RPM Adjustment Page 14 14 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14 11 FUEL SYSTEM Engine Control Linkage cg PED c9
276. ts are good and the voltage reading is zero there may be a broken or damaged 6 gauge white wire from the solenoid to the starter generator See Test Procedure 8 Starter Generator Starter Function Page 11 25 TEST PROCEDURE 25 FUEL LEVEL SENDING UNIT Read DANGER and WARNING on page 11 1 A WARNING TO AVOID THE POSSIBILITY OF FIRE OR EXPLOSION MAKE SURE THE FUEL TANK CAP IS SECURELY IN PLACE WHILE PERFORMING THIS TEST PROCEDURE 1 Turn the key switch to the OFF position put the Forward Reverse handle in the NEUTRAL position disconnect the battery negative cable first and chock the wheels 2 Disconnect the orange wire from the center post of the fuel level sending unit 3 With a multimeter set to 2 KQ ohms place the red probe of the multimeter on the center post of the sending unit Place the black probe on the ground connection of the sending unit Figure 11 43 Page 11 36 4 The following resistance readings in ohms should be obtained depending on the position of the float inside the fuel tank The resistance reading will vary according to the exact position of the float The chart below may be used as a guideline to determine if the fuel level sending unit is operating correctly Make sure the float is at the surface of the fuel in the tank FLOAT POSITION RESISTANCE READING FUEL GAUGE READINGS Lower Position Tank Empty 240 20 Q ohms Empty Center Position Tank Ha
277. tte e tede e ee E P ne eR Re red exa aee ge gatos 13 25 Piston and Connecting ROG tir tee e aaa beb dae Mun 13 25 Gylinder BIOGK irt tete E re tre n a tae setate 13 28 Ignition Coil and Flywheel sss nrns rennen nennen nnns nnn nenas 13 30 BU ER 13 31 Oil Pressure Relief Valve 13 32 Crankshaft and Counterbalance 13 34 Gounterbalance Weight 5 3 ete ir 13 36 OIL SCIGOn iet o d AL mH tec ett ets 13 39 Ball Bearing s eni eO Mee egueet Rea ed Sanaa eR 13 39 SICH O 13 40 Piston and Connecting Rod Installation ssssssssssseeseeeeenneen nennen nens 13 42 Crankshaft Axial Play Adjustment sess enne eene nnne rnnt nen renis 13 43 Grankcase Gover Installatlon iter eri ete e i acp e rp rede e Lean ER ed ep A bed 13 45 etsare t 13 46 Service Specifications 13 48 Specifications for Resizing Cylinder Bore 13 49 Torque Specifications 13 49 Adjustments and Settings
278. ttery will not charge effectively in cold temperatures for the same reasons that it does not discharge as rapidly in cold temperatures Page 12 30 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement ELECTRICAL COMPONENTS Ground Straps Charging a Dead Battery Read DANGER and WARNING on page 12 1 and DANGER on Page 12 26 The vehicle is equipped with a starter generator The generator is not designed to charge a dead battery If the vehicle battery has become discharged it must be charged using a properly rated automotive type charger A WARNING DO NOT JUMP START A DEAD BATTERY USING ANOTHER BATTERY AND JUMPER CABLES GROUND STRAPS Read DANGER and WARNING on page 12 1 Testing the Ground Straps See Test Procedure 3 Section 11 Page 11 21 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12 31 SECTION 13 FE290 ENGINE DANGER GASOLINE VAPORS FLAMMABLE DO NOT SMOKE KEEP SPARKS FLAMES CIGARETTES AWAY FROM VEHICLE AND SERVICE AREA TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACROSS A BATTERY INSULATED TOOLS SHOULD BE USED EXTREME CARE SHOULD BE TAKEN WHEN DISCONNECTING OR RECONNECTING THE BATTERY WHEN WIRES ARE DISCONNECTED BE SURE TO KEEP THEM AWAY FROM BATTERY TERMINALS AND OTHER WIRES SERVICE ONLY IN WELL VENTILATED AREAS DO NOT OPERATE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLE
279. ugh material to produce a smooth and concentric seat Figure 13 24 Page 13 15 See fol lowing CAUTION 13 14 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Cylinder Head CAUTION e USE CARE NOT TO DULL THE CUTTER DO NOT TURN THE CUTTER COUNTERCLOCKWISE OR ALLOW IT TO HIT A METAL OBJECT 2 5 Use a 30 x 35mm seat cutter 1 Club Car Part No 1016554 to narrow the seat width to the standard width Figure 13 24 Page 13 15 See following CAUTION and NOTE 2 6 Turn the seat cutter 1 clockwise one turn at a time while pressing down very lightly Recheck the width after each cutter revolution Figure 13 24 Page 13 15 See following CAUTION and NOTE A CAUTION THE 30 X 35MM SEAT CUTTER REMOVES MATERIAL VERY QUICKLY CHECK THE SEAT OUTSIDE DIAMETER FREQUENTLY TO PREVENT OVER CUTTING NOTE KEEP THE SEAT WIDTH AS CLOSE AS POSSIBLE TO 0 031 INCH 0 8 MM 2 7 Make a light pass with the 45 cutter 1 32mm Exhaust Valve Seat Cutter Club Car Part No 1016553 and 35mm Intake Valve Seat Cutter Club Car Part No 1016554 to remove any possi ble burrs at the edge of the seat 3 After applying a coat of Prussian Blue to the valve face insert the valve and snap it closed against the seat several times The valve surface should show good contact all the way around Be sure the valve seat is centered on the valve face The position of the valve in the sea
280. ugh the adjusting bracket 4 and then through the starter generator Install a lockwasher 9 and 5 16 nut 12 onto the end of the adjustment bolt 11 Tighten to finger tight Figure 12 14 Page 12 11 4 Install the belt 3 then tighten the mounting screws See Belt Adjustments 5 Connect the yellow wire from the voltage regulator to the DF terminal on the starter generator Figure 12 2 Page 12 3 Install a flat washer lockwasher and nut onto the terminal Tighten the nut to 31 in Ib 3 5 N m 6 Connect the white wire from the solenoid to the F2 terminal on the starter generator and connect the ground wire from the frame to the A2 terminal on the starter generator Figure 12 2 Page 12 3 Install a flat washer lockwasher and nut onto each terminal and tighten the nut to 48 in Ib 5 4 N m 7 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 Battery Protector Spray Club Car Part No 1014305 TYPICAL 2 PLACES Figure 12 14 Starter Generator Installation Figure 12 15 Belt Tension Gauge 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12 11 ELECTRICAL COMPONENTS Voltage Regulator Belt Tension Adjustment Belt tension should be checked periodically If the belt slips when starter generator motor operates adjust belt to correct tension 1 Place the neutral lockout cam in the SERVI
281. uide continued on next page Page 11 2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Troubleshooting Guide TROUBLESHOOTING SYMPTOM POSSIBLE CAUSES REFER TO Engine turns but fails 1 Fuel tank is empty Section 14 Fuel System 2 Fuel line or filters clogged Section 14 Fuel System 3 Fouled spark plug Section 13 Engine 4 Spark plug wire damaged or loose Section 13 Engine 5 Loose wire connection Section 11 Troubleshooting at ignition coil or RPM limiter Test Procedures 13 14 and 15 6 Ignition coil failed Section 11 Troubleshooting Test Procedures 13 14 and 15 7 Engine flooded with fuel as result of Section 3 General Information excess choking Choke in the appropriate maintenance and service manual 8 Kill circuit grounded Section 11 Troubleshooting Test Procedures 16 17 and 18 9 Fuel pump malfunction or failure Section 14 Fuel System Engine overheats 1 Fan screen is partially blocked or plugged Section 13 Engine 2 Governor is improperly adjusted Section 14 Fuel System 3 Carburetor is too lean check main Section 14 Fuel System jet size Engine pre ignites 1 Excessive carbon deposits on piston Section 13 Engine head or in combustion chamber 2 Spark plug heat range is Section 13 Engine incorrect for the engine 3 Unsuitable or contaminated fuel Secti
282. ulator is good If the reading is lower than 14 7 volts but rising steadily check battery condition See Hydrometer Test Page 11 19 If the reading is lower than 14 7 volts and not rising and the starter generator is good or if the reading is over 15 3 volts and continues to rise replace voltage regulator Figure 11 36 Page 11 29 ud 22 di LIMITER Figure 11 35 Disconnect White Black Engine Kill Wire TEST PROCEDURE 12 DISCONNECTED KILL WIRE Read DANGER and WARNING on page 11 1 NOTE KEEP THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 12 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 engine kill white black wire at the bullet connector located by the RPM limiter Figure 11 35 Page 11 28 3 With the neutral lockout cam in the SERVICE position turn the key switch to the ON position In a well ventilated area depress the accelerator to start the engine 4 f the engine begins to run test the engine kill circuit for a shorted wire or other failed components in the engine kill circuit See Test Engine Kill Circuit Page 11 13 See following WARNING A WARNING WHEN THE WHITE BLACK ENGINE KILL WIRE IS DISCONNECTED THE ENGINE WILL NOT STOP RUNNING AFTER THE ACCELERATOR PEDAL IS RELEASED IT WILL BE NECESSARY TO DEPRESS AND HOLD THE CHOKE COVER CLOSED UNTIL THE ENGIN
283. utton over the rib and take up spring as shown Figure 17 8 Page 17 8 15 Install remaining two buttons 16 Install a No 10 24 button retaining screw with flat washer through each button and into the rib Tighten the screws to 34 in lb 3 8 N m Figure 17 9 Page 17 8 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 disassembling the clutch Press the hub assembly on by hand Figure 17 5 Page 17 6 DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED Figure 17 15 Correct Orientation of Drive Button Take up Spring DRIVE CLUTCH INSTALLATION 1 Place the drive clutch assembly on the crankshaft taper Position the mounting washer with the green side facing out on the bolt 17 and start the bolt into the crankshaft See following NOTE NOTE THE DRIVE CLUTCH MOUNTING BOLT HAS LEFT HAND THREADS 2 Tighten the drive clutch retaining bolt 17 to 25 ft lb 33 9 N m Figure 17 5 Page 17 6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 17 11 TORQUE CONVERTER Drive Clutch 3 nb Oro k Install the starter generator belt and adjust belt tension as instructed in Section 12 Electrical 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 Install the drive belt
284. val Page 13 32 2 Remove the valve seat 1 ball 2 and spring 3 Figure 13 71 Page 13 34 Page 13 32 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement FE290 ENGINE Oil Pump Oil Pressure Relief Valve Inspection 1 Note the condition of the ball 2 and the valve seat 1 They must not have any nicks or burrs Figure 13 71 Page 13 34 2 Inspect the relief valve spring 3 for pitting cracks rusting and burrs Replace it if necessary 3 Measure free length of the spring 3 with a vernier caliper Figure 13 72 Page 13 34 If the free length of the relief valve spring is less than 0 748 inch 19 00 mm replace the spring Cil Pressure Relief Valve Installation 1 Installation is the 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 CAUTION DO NOT ALLOW ANY DUST OR OTHER FOREIGN MATTER INTO THE OIL PUMP 1 Installation is the reverse of removal 2 Install the inner rotor with its tang in the slot in the end of the camshaft Figure 13 70 Page 13 34 3 Install six bolts 1 and finger tighten Then tighten to 7 ft lb 9 5 N m in the sequence shown Figure 13 65 Page 13 32 After tightening bolts check torque of first bolt Figure 13 72 Measure Free Length of Spring Figure 13 73 Counterbalance Guide Shaft and O Ring 2000 FE290 Gasoline Veh
285. vice Supplement Page 16 25 UNITIZED TRANSAXLE Component Assembly DIFFERENTIAL GEAR CASE ASSEMBLY 1 If the bearings 79 were removed press new ones onto the differential gear carrier case 84 and car rier case cover 87 Figure 16 5 Page 16 4 See following CAUTION A CAUTION e APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRESSURE ANYWHERE ELSE WILL DAMAGE THE BEARING 2 Install differential gear 91 into carrier case 84 Figure 16 5 Page 16 4 as shown Figure 16 61 Page 16 26 3 Start the differential pin 88 into the carrier case by lightly tapping it in with a plastic or rubber hammer Before the pin enters the inside of the carrier case position the thrust plate 85 and idler gear 89 Figure 16 5 Page 16 4 in the case and then continue tapping the pin through the thrust plate and idler gear as shown Figure 16 62 Page 16 26 4 Position the other thrust plate 85 and idler gear 89 Figure 16 5 Page 16 4 in the carrier case Then continue to drive the pin through them and the wall of the carrier case until the ends of the pin are flush with the sides of the carrier case Figure 16 63 Page 16 27 5 Install the thrust 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 the carrier case cover on the carrier case Figure
286. ward Reverse shifter red white and orange wires are connected to it Figure 11 7 Page 11 9 1 Place the neutral lockout cam in the SERVICE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Move the Forward Reverse handle to REVERSE and listen for an audible click from the limit switch If there is no click check the switch for proper alignment and switch arm movement 3 If the switch is being activated but the buzzer does not function place the red probe of the multimeter on one terminal and the black probe on the other terminal of the limit switch Without the lever depressed the reading should be NO continuity Depress the lever and the reading should be continuity If either 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 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 first 2 Remove the center dash assembly See Key Switch Removal Section 12 Electrical Components Page 12 13 3 Check for proper wiring and tight connections Using a multimeter individually check for continuity through each wire that connects to the reverse buzzer Figure 11 7 Page 11 9 If the buzzer will not function wh
287. wheels and disconnect battery negative cable first 2 Remove the center dash assembly See Key Switch Removal Section 12 Electrical Components Page 12 13 3 Check that the wires are connected correctly and are tight If they are not rewire or tighten as necessary Figure 11 8 Page 11 9 4 Disconnect the yellow wire to the oil level sensor from the terminal on the oil light Using an alligator clip jumper wire connect the oil light terminal to the frame of the vehicle Connect the red battery cable to the positive post of the battery then attach the black cable to the negative post of the battery 5 Turn the key switch ON The oil light should illuminate If it does not check continuity of the yellow wire from the key 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 test okay then replace the oil light TEST PROCEDURE 23 NEUTRAL LOCKOUT CAM Read DANGER and WARNING on page 11 1 1 Check to be sure the lobes on the cam are depressing the neutral lockout limit switch lever as the Forward Reverse handle is being shifted The limit switch should make an audible click as it is depressed 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 actuate the limit switch replace the
288. wires still disconnected using a multimeter set on 200 Q ohms place the red probe on the F1 terminal and the black probe on the F2 terminal The reading should be between approximately 1 and 3 O ohms If the reading is incorrect a possible open field coil or bad connections at terminals may be the cause The starter generator will need to be removed from the vehicle and disassembled by a qualified technician See Starter Generator Removal Section 12 Electrical Components Page 12 2 7 With the wires still disconnected using a multimeter set on 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 incorrect a possible grounded DF terminal and or grounded field coil may be the cause The starter generator will need to be removed from the vehicle and disassembled by a qualified technician See Starter Generator Removal Section 12 Electrical Components Page 12 2 Page 11 26 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement TROUBLESHOOTING Test Procedures TEST PROCEDURE 9 WIRE CONTINUITY Read DANGER and WARNING on page 11 1 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 first 2 To test a wire for continuity disconnect either end from the electrical compone
289. with 4 When Used with Nuts ADJUSTMENTS AND SETTINGS 130 in Ib 15 N m 50 in lb 5 9 N m 30 in Ib 3 4 N m 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 Filter bypass valve opening pressure 11 4 to 17 0 psi 78 to 118 kPa Compression Pressure MIN 156 psi 1076 kPa Crankcase Vacuum MIN at governed speed 1 18 inches 30 mmHg Cylinder Head Gasket Surface Flatness MAX 0 002 inch 0 05 mm Valve Clearance IN and EX when engine is cold 0 006 inch 0 15 mm Engine RPM 2700 RPM 30 DS Golf Car Villager 4 2860 RPM x 30 Turf 1 Carryall 1 Page 13 50 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement SECTION 14 FUEL SYSTEM DANGER e GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM VEHICLE AND SERVICE AREA SERVICE ONLY IN A WELL VENTILATED AREA DO NOT OPERATE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON A WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL
290. y durable and should require very little service under normal operating con ditions The only service required on the unitized transaxle is to maintain proper lubricant level See Periodic Lubrication Schedule Section 10 Under normal operating conditions adjustment to the system should not be required Lubricant should be level with bottom of level indicator hole SHIFTER ARM SHIFTER LEVER Figure 16 1 Shifter Positions Figure 16 2 Lubricant Level 16 2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement UMTIZED TRANSAXLE Tools Required For This Section Hydraulic floor jack or Chain Hoist jack stands 2 One Ton Capacity Hydraulic Press Bench Vise Standard Slip Joint Pliers External Snap Ring Pliers 070 inch Tip External Snap Ring Pliers 047 inch Tip 90 Internal Snap Ring Pliers 090 inch Tip Feeler Gauge 16 inch Rolling Head Prybar Small Punch or Scratch Awl 1 4 inch Diameter Drift or Metal Rod Bearing Puller Wedge Attachment Club Car Part No 1012812 12 to 18 inch Straight Edge Small Ball Peen Hammer 10 oz Plastic or Rubber Mallet Ratchet Wrench 3 8 inch Drive Torque Wrench 3 8 inch Drive 3 8 inch Socket 3 8 inch Drive 7 16 inch Socket 3 8 inch Drive 10 mm Combination Wrench 1 2 inch Socket 3 8 inch Drive 9 16 inch Socket 3 8 inch Drive 5 8 inch Socket 3 8 inch Drive 12 mm Socket 3 8 inch Drive Axle Seal Tool Club Car Part No 101
291. zed Transaxle Assembly 7 5 Install the intermediate gear assembly into the case as shown Figure 16 78 Page 16 32 Do not seat the assembly into the bore but make sure the output ring gear meshes with the input drive gear 52 Figure 16 42 Page 16 18 on the synchronizer gear assembly and with the small gear on the idler shaft 65 Figure 16 42 Page 16 18 7 6 As a group and while keeping the gears meshed work all of the gear assemblies into the bores until they are seated When all of the assemblies are correctly seated the outside edges of the input drive gear 52 and the intermediate gear 58 Figure 16 42 Page 16 18 should be flush in the same plane as shown Figure 16 79 Page 16 33 Also the outside surfaces of the idler gear bearing the intermediate gear bearing and the differential gear bearing should be flush Figure 16 79 Page 16 33 See following CAUTION A CAUTION e IF THE EDGES OF THE INPUT DRIVE GEAR AND INTERMEDIATE GEAR ARE NOT FLUSH THEN THE OIL GUIDE 37 FIGURE 16 42 PAGE 16 18 MAY NOT BE PROPERLY POSITIONED IN THE BORE 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 they are not scratched or damaged in any way 9 Apply a continuous bead of Three Bond No 1215 Club Car Part No 101928701 sealant to the mating surface around the complete profile of the right passenger side case Figure 16 80 Page

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