Club Car FE290 Manuals

Manuals and User Guides for Club Car FE290. We have 2 Club Car FE290 manuals available for free PDF download: Repair And Rebuild Manual, Maintenance Service Supplement

Club Car FE290 Maintenance Service Supplement (236 pages)

Brand: Club Car | Category: Utility Vehicle | Size: 10.85 MB

Table of Contents
5
Section 10 - Periodic Maintenance

11
- General Information
  12
- Daily Pre-Operation Safety Checklist
  12
- Periodic Service Schedule
  13
- Periodic Lubrication Schedule
  14
- Vehicle Capacities
  15
- Engine Oil
  16
  - Oil Viscosity
    16
- Fueling Instructions
  17
- Battery
  17
Section 11 - Troubleshooting and Electrical System

19
- General Information
  20
- Troubleshooting Guide
  20
- Electrical System
  23
- Electrical Circuits
  25
  - Starter Circuit
    25
  - Generator Circuit
    26
  - Engine Ignition Circuit
    26
  - Engine Kill Circuit
    27
  - Reverse Buzzer Circuit
    27
  - Low Oil Warning Circuit
    28
  - Neutral Lockout Circuit
    28
  - Fuel Gauge and Sending Unit Circuit
    29
  - Hour Gauge Circuit
    29
- Circuit Testing
  30
- Test Procedures
  36
  - Index of Test Procedures
    36
  - Page 11-18 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement
    36
Section 12 - Electrical Components

57
- Starter/Generator
  58
- Voltage Regulator
  68
- Key Switch
  69
- Solenoid
  70
- Fuse
  71
- Accelerator Pedal Limit Switch
  72
- Kill Limit Switch
  72
- Neutral Lockout Limit Switch
  73
- Neutral Lockout Cam
  74
- Reverse Warning Buzzer
  75
- Reverse Buzzer Limit Switch
  75
- Oil Warning Light
  76
- Fuel/Hour Gauge
  77
- Fuel Level Sending Unit
  78
- RPM Limiter
  78
- Ignition Coil
  79
- Oil Level Sensor
  82
- Battery
  82
- Ground Straps
  87
Section 13 - Fe290 Engine

89
- General Information
  89
  - Special Engine Service Tools Available from Club Car
    90
  - Before Servicing
    90
  - Mechanical Systems
    90
  - Electrical System
    92
  - Lubrication System
    92
  - Spark Plug
    94
- Engine Mounting Plate
  95
- Cylinder Head
  95
  - General Information
    95
  - Cylinder Shroud Removal
    95
  - Rocker Arm and Push Rod Removal
    97
  - Cylinder Head Removal
    98
  - Valve Removal
    98
  - Breather Valve (Reed Valve)
    99
  - Cylinder Head Cleaning and Inspection
    100
  - Valve Guides
    100
  - Valve Seats
    101
  - Valves
    104
  - Rocker Arm and Rocker Shaft Inspection
    106
  - Push Rod Inspection
    106
  - Cylinder Head Installation
    107
  - Valve Clearance Check and Adjustment
    108
  - Breather Valve (Reed Valve)
    108
  - Installation of Remaining Engine Components
    109
- Crankcase
  110
  - Engine Removal
    110
  - Crankcase Cover Removal
    111
  - Oil Level Sensor
    112
  - Camshaft and Tappets
    113
- Piston and Connecting Rod
  113
- Cylinder Block
  116
- Ignition Coil and Flywheel
  118
- Oil Pump
  119
  - Oil Pressure Relief Valve
    120
- Crankshaft and Counterbalance
  122
  - Counterbalance Weight
    124
  - Oil Screen
    127
  - Ball Bearing
    127
  - Oil Seals
    128
  - Piston and Connecting Rod Installation
    130
- Crankshaft Axial Play Adjustment
  131
  - Crankcase Cover Installation
    133
- Engine Assembly
  134
- Service Specifications
  136
  - Specifications for Resizing Cylinder Bore
    137
  - Torque Specifications
    137
  - Adjustments and Settings
    138
Section 14 - Fuel System

139
- General Information
  139
- How the Carburetor Works
  140
  - Main System
    140
  - Slow Speed System
    140
  - Choke and Fresh Air System
    142
  - Float System
    142
- Carburetor
  142
- Engine Control Linkage
  146
  - General Information
    146
  - Accelerator Rod
    147
  - Governor Cable
    149
  - Accelerator Cable
    151
  - Closed Throttle or Idle Adjustment
    151
  - Engine RPM Adjustment
    152
- Choke and Air Intake System
  152
  - General Information
    152
  - Choke Button Removal
    152
  - Choke Button Installation
    153
  - Air Box Removal
    153
  - Air Box Installation
    153
  - Intake Duct Removal
    153
  - Intake Duct Installation
    153
  - Intake Duct Repair
    154
  - Air Filter
    154
- Fuel Filters
  156
  - General Information
    156
  - Fuel Filter Removal
    156
  - Fuel Filter Installation
    156
- Fuel Pump
  158
  - General Information
    158
  - Fuel Pump Removal
    158
  - Fuel Pump Disassembly
    158
  - Fuel Pump Cleaning and Inspection
    159
  - Fuel Pump Assembly
    159
  - Fuel Pump Installation
    160
- Fuel Tank
  160
  - General Information
    160
  - Preparation for Extended Storage
    160
  - Fuel Tank Removal
    161
  - Fuel Tank Disposal
    162
  - Fuel Tank Storage
    162
  - Fuel Tank Installation
    162
- Fuel Lines
  164
- Fuel Shut-Off Valve
  164
Section 15 - Exhaust System

167
- General Information
  167
- Muffler
  168
  - Muffler Removal
    168
  - Muffler Installation
    168
Section 16 - Unitized Transaxle

171
- General Information
  171
  - Lubrication
    173
- Axle Shaft
  173
  - Axle Shaft and Oil Seal Removal
    175
  - Axle Bearing
    175
  - Axle Shaft Installation
    177
- Unitized Transaxle Removal
  177
- Unitized Transaxle Disassembly
  184
- Component Disassembly
  187
  - Governor Gear Disassembly
    187
  - Differential Gear Case Disassembly
    187
  - Shifter Fork Disassembly
    190
  - Synchronizer Gear Disassembly
    190
  - Intermediate Gear Disassembly
    190
  - Idler Shaft Disassembly
    191
- Unitized Transaxle Component Inspection
  192
- Component Assembly
  193
  - Idler Shaft Assembly
    193
  - Intermediate Gear Assembly
    193
  - Synchronizer Gear Assembly
    193
  - Shifter Fork Assembly
    195
  - Differential Gear Case Assembly
    196
  - Governor Gear Assembly
    198
- Unitized Transaxle Assembly
  198
- Unitized Transaxle Installation
  204
- Forward/Reverse (F&R) Shifter Cable
  209
  - F&R Shifter Cable Removal
    209
  - F&R Shifter Cable Installation
    210
  - F&R Shifter Cable Adjustment
    211
Section 17 - Torque Converter

213
- General Information
  213
- Troubleshooting
  215
- Drive Belt
  215
  - Drive Belt Removal
    215
  - Drive Belt Installation
    216
- Drive Clutch
  216
- Drive Clutch Assembly
  221
- Drive Clutch Installation
  223
- Driven Clutch
  225
  - Driven Clutch Removal
    225
  - Driven Clutch Disassembly
    225
  - Driven Clutch Inspection
    226
  - Driven Clutch Assembly
    226
  - Driven Clutch Installation
    227

Club Car FE290 Repair And Rebuild Manual (264 pages)

Engines and Drivetrain Components

Brand: Club Car | Category: Engine | Size: 45.52 MB

Table of Contents
5
Section 1 - Safety
13
General Warning
13
Section 2 - Fe290 Engine
17
General Information
17
Special Engine Service Tools Available from Club Car
17
Recommended Replacement Parts for Engine Teardown
18
Before Servicing
18
Mechanical Systems
18
Cylinder Components
20
Cylinder Head
20
General Information
20
Cylinder Shroud Removal
20
Rocker Arm and Push Rod Removal
23
Cylinder Head Removal
23
Valve Removal
24
Breather Valve (Reed Valve)
24
Cylinder Head Cleaning and Inspection
25
Valve Guides
25
Valve Seats
27
Valves
29
Rocker Arm and Rocker Shaft Inspection
31
Push Rod Inspection
32
Cylinder Head Installation
32
Valve Clearance Check and Adjustment
34
Breather Valve (Reed Valve)
34
Installation of Remaining Engine Components
35
Crankcase Components
36
Crankcase Cover Removal
36
Camshaft and Tappets
38
Piston and Connecting Rod
38
Cylinder Block
41
Ignition Coil and Flywheel
43
Oil Pump
45
Oil Pressure Relief Valve
46
Crankshaft and Counterbalance
47
Counterbalance Weight
50
Oil Screen
52
Ball Bearing
53
Oil Seals
53
Piston and Connecting Rod Installation
55
Crankshaft Axial Play Adjustment
56
Crankcase Cover Installation
58
Engine Assembly
59
Engine Installation
60
Service Specifications
61
Specifications for Resizing Cylinder Bore
62
Torque Specifications
62
Adjustments and Settings
63
Section 3 - Fe350 Engine
65
General Information
65
Special Engine Service Tools Available from Club Car
65
Recommended Replacement Parts for Engine Teardown
66
Before Servicing
66
Mechanical Systems
66
Cylinder Components
68
Cylinder Head
68
General Information
68
Cylinder Shroud Removal
68
Rocker Arm and Push Rod Removal
71
Cylinder Head Removal
71
Valve Removal
72
Breather Valve (Reed Valve)
72
Cylinder Head Cleaning and Inspection
73
Valve Guides
74
Valve Seats
75
Valves
77
Rocker Arm and Rocker Shaft Inspection
79
Push Rod Inspection
80
Cylinder Head Installation
80
Valve Clearance Check and Adjustment
81
Breather Valve (Reed Valve)
81
Installation of Remaining Engine Components
82
Crankcase Components
84
Crankcase Cover Removal
84
Camshaft and Hydraulic Lifters
85
Piston and Connecting Rod
87
Cylinder Block
90
Ignition Coil and Flywheel
92
Oil Pump
93
Oil Pressure Relief Valve
95
Crankshaft and Counterbalance
96
Counterbalance Weight
99
Oil Screen
102
Ball Bearing
102
Oil Seals
103
Piston and Connecting Rod Installation
105
Crankshaft Axial Play Adjustment
106
Camshaft Axial Play Adjustment
107
Crankcase Cover Installation
108
Engine Assembly
109
Engine Installation
110
Service Specifications
111
Specifications for Resizing Cylinder Bore
112
Torque Specifications
112
Adjustment and Settings
113
Section 4 - Fe400 Engine
115
General Information
115
Special Engine Service Tools Available from Club Car
115
Recommended Replacement Parts for Engine Teardown
116
Before Servicing
116
Cylinder Head
116
General Information
116
Muffler Removal and Installation
117
Cylinder Block
117
Engine Installation
120
Service Specifications
120
Specifications for Resizing Cylinder Bore
120
Torque Specifications
120
Adjustment and Settings
120
Section 5 - Mc008C-Es00 and Mc008C-Fs00 Unitized Transaxles
121
General Information
121
Transaxle Models and Identification
121
Axle Shaft
122
Unitized Transaxle Removal
122
Unitized Transaxle Disassembly
122
Component Disassembly
126
Governor Gear Disassembly
126
Differential Gear Case Disassembly
129
Shifter Fork Disassembly
131
Synchronizer Gear Disassembly
131
Intermediate Gear Disassembly
132
Idler Shaft Disassembly
133
Unitized Transaxle Component Inspection
134
Component Assembly
134
Idler Shaft Assembly
134
Intermediate Gear Assembly
134
Synchronizer Gear Assembly
135
Shifter Fork Assembly
138
Differential Gear Case Assembly
139
Governor Gear Assembly
141
Unitized Transaxle Assembly
141
Axle Tubes
146
Unitized Transaxle Installation
146
Lubrication
146
Section 6 - Mc010C-Bs00 Unitized Transaxle with Differential Lock
147
General Information
147
Transaxle Models and Identification
147
Axle Shaft
148
Unitized Transaxle Removal
148
Unitized Transaxle Disassembly
148
Component Disassembly
153
Differential Gear Lock Housing Disassembly
153
Governor Gear Disassembly
153
Differential Gear Case Disassembly
154
Shifter Fork Disassembly
156
Synchronizer Gear Disassembly
156
Intermediate Gear Disassembly
158
Idler Shaft Disassembly
158

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Club Car FE290 Manuals

Club Car FE290 Maintenance Service Supplement (236 pages)

Table of Contents

Section 10 - Periodic Maintenance

Section 11 - Troubleshooting and Electrical System

Section 12 - Electrical Components

Section 13 - Fe290 Engine

Section 14 - Fuel System

Section 15 - Exhaust System

Section 16 - Unitized Transaxle

Section 17 - Torque Converter

Club Car FE290 Repair And Rebuild Manual (264 pages)

Table of Contents

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