Club Car FE290 Maintenance Service Supplement
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Club Car FE290 Maintenance Service Supplement

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2000
MAINTENANCE
S E R V I C E
SUPPLEMENT
FE290 GASOLINE VEHICLES
MANUAL NUMBER 102067508
EDITION CODE 0500A00000

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  • Page 1 2000 MAINTENANCE S E R V I C E SUPPLEMENT FE290 GASOLINE VEHICLES MANUAL NUMBER 102067508 EDITION CODE 0500A00000...
  • Page 3 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.
  • Page 4 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.

  • Page 5: Table Of Contents

    Testing the Low Oil Warning Circuit ....................11-16 Testing the Neutral Lockout Circuit ....................11-17 Testing the Fuel Gauge and Sending Unit Circuit ................. 11-17 Test Procedures ..........................11-18 Index of Test Procedures ....................... 11-18 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page iii...
  • Page 6 Cylinder Head Removal ......................... 13-10 Valve Removal ..........................13-10 Breather Valve (Reed Valve) ......................13-11 Cylinder Head Cleaning and Inspection ..................13-12 Valve Guides ..........................13-12 Valve Seats ............................ 13-13 Page iv 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 7 Slow Speed System ........................14-2 Choke and Fresh Air System ......................14-4 Float System ..........................14-4 Carburetor ............................14-4 Main Jet Elevation/Size Chart ......................14-5 Changing the Main Jet ........................14-5 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page v...
  • Page 8 Fuel Tank Installation ........................14-24 Fuel Lines ............................14-26 Fuel Shut-Off Valve ..........................14-26 SECTION 15 – EXHAUST SYSTEM General Information ........................... 15-1 Muffler ..............................15-2 Muffler Removal ..........................15-2 Muffler Installation .......................... 15-2 Page vi 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 9 Drive Belt Installation ........................17-4 Drive Clutch ............................17-4 Drive Clutch Removal ........................17-5 Drive Clutch Cleaning and Inspection .................... 17-5 Drive Clutch Disassembly ......................17-7 Inspection of Drive Clutch Parts ....................17-8 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page vii...
  • Page 10 Drive Clutch Installation ......................... 17-11 Driven Clutch ............................. 17-13 Driven Clutch Removal ........................17-13 Driven Clutch Disassembly ......................17-13 Driven Clutch Inspection ........................ 17-14 Driven Clutch Assembly ......................... 17-14 Driven Clutch Installation ....................... 17-15 Page viii 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 11: Section 10 - Periodic Maintenance

    • 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...

  • Page 12: General Information

    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.

  • Page 13: Periodic Service Schedule

    See Section 7 in the appropriate maintenance and operation or every 100 service manual. rounds for golf cars). 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...

  • Page 14: Periodic Lubrication Schedule

    100 hours of operation or every 200 rounds for golf Inspect front wheel bearings. Chassis Lube - EP NLGI Grade 2 cars). Repack as necessary. Periodic Lubrication Schedule continued on next page... Page 10-4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 15: Vehicle Capacities

    GASOLINE VEHICLES DS Golf Car 12 - 14 psi (83-96 kPa) Turf 1 and Carryall 1 14 - 16 psi (96-110 kPa) Villager 4 12 - 14 psi (83-96 kPa) 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10-5...

  • Page 16: Engine Oil

    -4°F 14°F 32°F 50°F 68°F Figure 10-5 Oil Viscosity Chart NOTE • USING MULTI-GRADE OILS (5W-20, 10W-30, 10W-40) WILL INCREASE CONSUMPTION. CHECK OIL LEVEL MORE FREQUENTLY WHEN USING MULTI-GRADE OILS. Page 10-6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 17: Fueling Instructions

    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...

  • Page 19: Section 11 - Troubleshooting And Electrical System

    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...

  • Page 20: General Information

    filter Fuel pump malfunction; fuel pressure Section 14 – Fuel System to engine too low Troubleshooting Guide continued on next page. . . Page 11-2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 21 Check intake system for leaks – chamber Section 14 – Fuel System 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...
  • Page 22 Internal gears are damaged or worn Section 16 – Unitized Transaxle Synchronizer rings are worn, damaged Section 16 – Unitized Transaxle or jammed Troubleshooting Guide continued on next page. . . Page 11-4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 23: Electrical System

    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 •...
  • Page 24 See Figure 11-2 for a complete wiring diagram. NEUTRAL LOCKOUT LIMIT SWITCH KILL LIMIT SWITCH 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...

  • Page 25: Electrical Circuits

    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. Figure 11-3 Starter Circuit 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-7...

  • Page 26: Generator Circuit

    RPM limiter, and connecting wires (Figure 11-5, Page 11-8). SPARK PLUG RPM LIMITER 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...

  • Page 27: Engine Kill Circuit

    REVERSE, a cam depresses the reverse limit switch, closing the circuit. The reverse buzzer sounds. (-M) KEY SWITCH Figure 11-7 Reverse Buzzer Circuit Figure 11-8 Low Oil Warning Circuit 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-9...

  • Page 28: Low Oil Warning Circuit

    MOVE SUDDENLY IF THE FORWARD/REVERSE HANDLE IS SHIFTED OR ACCIDENTALLY BUMPED. TO PREVENT THIS, CHOCK THE FRONT AND REAR WHEELS AND FIRMLY SET THE PARK BRAKE BEFORE SERVICING OR LEAVING THE VEHICLE. Page 11-10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 29: Fuel Gauge And Sending Unit Circuit

    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 Page 11-11...

  • Page 30: Circuit Testing

    Figure 11-14 Testing the Starter and Generator Circuits TESTING THE ENGINE IGNITION CIRCUIT Read DANGER and WARNING on page 11-1. Use the following chart (Figure 11-15, Page 11-13) to begin troubleshooting problems with the engine ignition circuit. Page 11-12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 31: Testing The Engine Kill Circuit

    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 Page 11-13...
  • Page 32 WIRES INCORRECTLY WIRES CORRECTLY CONNECTED CONNECTED CONNECT WIRES CORRECTLY CHECK CONTINUITY OF CIRCUIT WIRES (TEST PROCEDURE 9) 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...

  • Page 33: Testing The Reverse Buzzer Circuit

    WIRES INCORRECTLY WIRES CORRECTLY 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 Maintenance and Service Supplement Page 11-15...

  • Page 34: Testing The Low Oil Warning Circuit

    LOW OIL WARNING LIGHT LOW OIL WARNING LIGHT ILLUMINATES DOES NOT ILLUMINATE REPLACE CONTINUITY 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...

  • Page 35: Testing The Neutral Lockout Circuit

    CHECK FUEL GAUGE (TEST PROCEDURE 26) (TEST PROCEDURE 26) VOLTAGE READINGS VOLTAGE READINGS INCORRECT INCORRECT 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 Page 11-17...

  • Page 36: Test Procedures

    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. Page 11-18 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 37 (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.
  • Page 38 If the difference between the cells is 0.020 or 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...
  • Page 39 (–) 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 Page 11-21...
  • Page 40 The reading should be continuity. If the reading is incorrect, check that terminal connections are clean and tight. If the connections are good and the reading is incorrect, repair or replace the wire. Page 11-22 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 41 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 Page 11-23...
  • Page 42 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, and a white wire connected to this limit switch. Page 11-24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 43 If the readings are incorrect, 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. 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-25...
  • Page 44 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...
  • Page 45 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 Page 11-27...
  • Page 46 STOP RUNNING AFTER THE ACCELERATOR PEDAL IS RELEASED. IT WILL BE NECESSARY TO DEPRESS AND HOLD THE CHOKE COVER CLOSED UNTIL THE ENGINE STOPS RUNNING. 5. If the engine fails to run, proceed to Test Procedure 13 – Ignition Spark. Page 11-28 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 47 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 Page 11-29...
  • Page 48 (+) 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 Ω (ohms), replace the coil. Page 11-30 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 49 2. Check for proper wiring and tight connections. LEVER UP KILL LIMIT SWITCH WAVETEK 1000 2000 200k Ω Ω 200mA 1000 --- FUSED 750V Figure 11-41 Test Kill Limit Switch 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-31...
  • Page 50 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...
  • Page 51 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...
  • Page 52 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. Page 11-34 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 53 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...
  • Page 54 6. Set a multimeter to 20 volts DC and place the red (+) probe of the multimeter on the (2) terminal of the fuel gauge with the blue wire. Place the black (–) probe on the (3) terminal of the fuel gauge with the black wire (Figure 11-44, Page 11-36). Page 11-36 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 55 • DO NOT OPERATE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION. THE ENGINE PRODUCES CARBON MONOXIDE, WHICH IS AN ODORLESS, DEADLY POISON. 4. If the reading does not change after six minutes, then replace the fuel/hour gauge. 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-37...

  • Page 57: Section 12 - Electrical Components

    • 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...

  • Page 58: Starter/Generator

    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...
  • Page 59 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 STARTER/GENERATOR SERVICE ARMATURE/ COMMUTATOR, PAGE 12-5. 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-3...
  • Page 60 • 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. Page 12-4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 61 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 Page 12-5...
  • Page 62 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...
  • Page 63 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. 1012811) 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).
  • Page 64 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...
  • Page 65 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 Vehicle Maintenance and Service Supplement Page 12-9...
  • Page 66 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...
  • Page 67 flat washer, lockwasher, and nut onto each terminal and tighten the nut to 48 in-lb (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...

  • Page 68: Voltage Regulator

    • REMOVE PRY BAR BEFORE STARTING ENGINE. 8. 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). VOLTAGE REGULATOR Read DANGER and WARNING on page 12-1.

  • Page 69: Key Switch

    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.

  • Page 70: Solenoid

    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.

  • Page 71: Fuse

    18 in-lb (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.

  • Page 72: Accelerator Pedal Limit Switch

    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.

  • Page 73: Neutral Lockout Limit Switch

    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.

  • Page 74: Neutral Lockout Cam

    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.

  • Page 75: Reverse Warning Buzzer

    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...

  • Page 76: Oil Warning Light

    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.

  • Page 77: Fuel/Hour Gauge

    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.

  • Page 78: Fuel Level Sending Unit

    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). FUEL LEVEL SENDING UNIT Read DANGER and WARNING on page 12-1.

  • Page 79: Ignition Coil

    50 in-lb (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 Part No. 1014305). IGNITION COIL Read DANGER and WARNING on page 12-1.
  • Page 80 MOUNTING PLATE STIFFENER Figure 12-25 Governor Guard Removal Figure 12-26 Stiffener Removal HOUSING Loosen. Remove. Remove. Remove. Remove. FAN SHROUD Figure 12-27 Fan Housing and Shroud Installation Figure 12-28 Coil Installation Page 12-24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 81 30 in-lb (3.4 N·m) (Figure 12-29, Page 12-25). 11. Connect the 18 gauge black wire to the spade terminal on the coil. 0.012 Inch (0.304 mm) Figure 12-29 Set Air Gap 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-25...

  • Page 82: Oil Level Sensor

    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.
  • Page 83 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).
  • Page 84 See following NOTE. NOTE • CONTACT YOUR LOCAL WATER DEPARTMENT FOR MINERAL CONTENT ANALYSIS. Page 12-28 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 85 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 Page 12-29...
  • Page 86 (16.3 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). Battery Storage Read DANGER and WARNING on page 12-1 and DANGER on Page 12-26.

  • Page 87: Ground Straps

    • 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...

  • Page 89: Section 13 - Fe290 Engine

    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.

  • Page 90: Special Engine Service Tools Available From Club Car

    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 Valve Seat Cutter 30° and 45° x 35 mm Diameter 1016554 Valve Seat Cutter Guide...
  • Page 91 Press the ball bearing until it is seated against the housing or on the shaft. 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-3...

  • Page 92: Electrical 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) • Cartridge filter (5) • Pressure relief valve (8) Page 13-4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 93 (9) Tappet 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...

  • Page 94: 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 life and efficient combustion of fuel. The spark gap is 0.027 - 0.031 inch (0.69 - 0.79 mm).

  • Page 95: Engine Mounting Plate

    3. Loosen air intake hose clamp (7) from the intake pipe (5) and remove hose (6) (Figure 13-6, Page 13-9). 4. Disconnect the fuel line (9) and vent tube10) from the carburetor (4) (Figure 13-5, Page 13-9). 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-7...
  • Page 96 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...

  • Page 97: Rocker Arm And Push Rod Removal

    Page 13-10). See following NOTE. NOTE • 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...

  • Page 98: Cylinder Head Removal

    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).

  • Page 99: Breather Valve (Reed Valve)

    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...

  • Page 100: Cylinder Head Cleaning And Inspection

    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).

  • Page 101: Valve Seats

    (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).
  • Page 102 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 enough material to produce a smooth and concentric seat (Figure 13-24, Page 13-15).
  • Page 103 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.

  • Page 104: Valves

    3. If the valve head seating area is eroded or nicked, it may be possible to repair the valve on a valve refacing machine. Follow the refacing machine manufacturer’s 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.
  • Page 105 • 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 Page 13-17...

  • Page 106: Rocker Arm And Rocker Shaft Inspection

    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...

  • Page 107: Cylinder Head Installation

    (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 Page 13-19...

  • Page 108: Valve Clearance Check And Adjustment

    0.005 inch (0.127 mm) for both intake and exhaust (Figure 13-39, Page 13-21). 5. While keeping the adjuster from turning with the screw holder (5) (Club Car Part No. 1016413), tighten the locknut (3) to 90 in-lb (10 N·m) (Figure 13-39, Page 13-21).

  • Page 109: Installation Of Remaining Engine Components

    • 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...

  • Page 110: Crankcase

    4. 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...

  • Page 111: Crankcase Cover Removal

    • 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 Page 13-23...

  • Page 112: Oil Level Sensor

    4. Install screw (3) through wire clamp and into crankcase cover. Tighten to 30 in-lb (3.4 N·m). TYPICAL TYPICAL 4 PLACES 2 PLACES TYPICAL 2 PLACES Figure 13-48 Engine Mounting Plate Page 13-24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 113: Camshaft And Tappets

    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...
  • Page 114 • 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...
  • Page 115 Measure each position in 2 places 90° apart. Measure each side in 2 places 90° apart. Figure 13-55 Measure O.D. of Piston Pin Figure 13-56 Measure I.D. of Piston Pin Hole 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-27...

  • Page 116: Cylinder Block

    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...
  • Page 117 • 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 Page 13-29...

  • Page 118: Ignition Coil And Flywheel

    • 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.

  • Page 119: Oil Pump

    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 13-32). 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-31...

  • Page 120: Oil Pressure Relief Valve

    Oil Pressure Relief Valve Removal 1. Remove the oil pump cover. See Oil Pump Cover Removal, 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...
  • Page 121 (Figure 13-65, Page 13-32). After tightening bolts, check torque of first bolt. PUMP SLOT TANG Figure 13-70 Install Inner Rotor Figure 13-71 Oil Pressure Relief Valve Figure 13-72 Measure Free Length of Spring Figure 13-73 Counterbalance Guide Shaft and O-Ring 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-33...

  • Page 122: Crankshaft And Counterbalance

    (Figure 13-76, Page 13-36). Go to Link Rod Inspection, Page 13-36. 2. If the link rods need replacing, place the gear yoke (Club Car Part No. 1016418) under the spur gear with the small end of the connecting rod located opposite the crankpin (Figure 13-74, Page 13-35).
  • Page 123 CAMSHAFT (WHICH ALSO FUNCTIONS AS A POWER TAKE-OFF SHAFT) (FIGURE 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...

  • Page 124: Counterbalance Weight

    2. Using a telescoping 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...
  • Page 125 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 Page 13-37...
  • Page 126 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...

  • Page 127: Oil Screen

    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 driver (2) (Part of Club Car Bearing Driver Kit, Part No. 1016416), drive out the ball bearing (3) as shown.

  • Page 128: Oil Seals

    4. Using the 1.97 inch (50 mm) seal driver, press the oil seal 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...
  • Page 129 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...

  • Page 130: Piston And Connecting Rod Installation

    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). Page 13-42 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 131: Crankshaft Axial Play Adjustment

    (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...
  • Page 132 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 16.25...

  • Page 133: Crankcase Cover Installation

    • DO NOT REUSE THE GASKET. INSTALL A NEW ONE. • INSTALL 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...

  • Page 134: Engine Assembly

    • THE FLYWHEEL NUT HAS RIGHT-HAND THREADS. TURN IT CLOCKWISE TO TIGHTEN, OR COUNTERCLOCKWISE TO LOOSEN. • 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...
  • Page 135 14-14. 19. If initial checks indicate the engine is functional, place the neutral lock-out cam in OPERATE position. 20. Test-drive vehicle to ensure all systems are functional and correctly adjusted. 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-47...

  • Page 136: Service Specifications

    Valve Seat Angle (IN. EX.) Standard 45° 0.0197 to 0.0433 inch Valve Seat Width Standard (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...

  • Page 137: Specifications For Resizing Cylinder Bore

    Connecting Rod Bolts (Coat Threads with Engine Oil) 180 in-lb (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...

  • Page 138: Adjustments And Settings

    Valve Clearance (IN. and EX.) when engine is cold 0.006 inch (0.15 mm) 2700 RPM ± 30 (DS Golf Car, Villager 4) Engine RPM 2860 RPM ± 30 (Turf 1, Carryall 1) Page 13-50 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 139: Section 14 - Fuel System

    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...

  • Page 140: How The Carburetor Works

    The intake air draws fuel, metered by the pilot jet (6) (Figure 14-3, Page 14-3), Page 14-2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 141 CARBURETOR BORE TO ENGINE MAIN AIR JET MIXTURE MIXTURE INTAKE CYLINDER CYLINDER THROTTLE VALVE MAIN NOZZLE BLEED PIPE MAIN JET FLOAT FUEL INLET FUEL INLET FLOAT CHAMBER Figure 14-3 Carburetor 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-3...

  • Page 142: Choke And Fresh Air System

    • 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. Page 14-4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 143: Main Jet Elevation/Size Chart

    5. Remove the 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...
  • Page 144 • 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 Figure 14-6 Carburetor Installation Page 14-6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 145 Check for spring to look spring seated like this by... in recess of float body. Figure 14-7 Changing the Main Jet 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-7...

  • Page 146: Engine Control Linkage

    Read Danger and Warning on page 14-1. GENERAL INFORMATION For proper vehicle operation, it is important the accelerator pedal, governor linkage, and throttle adjustments are done correctly and in the proper sequence. See following CAUTION. Page 14-8 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 147: Accelerator Rod

    2. Install the ball joint on the ball stud at the accelerator pedal (Figure 14-8, Page 14-9). 3. Remove seat or lift bed to access engine compartment. 4. Remove the electrical box cover (Figure 14-9, Page 14-10). 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-9...
  • Page 148 first, at each end of the accelerator rod. RETAINING RETAINING NUTS NUTS 15 - Figure 14-10 Turf 1, Carryall 1 and Villager 4 Figure 14-9 DS Golf Car Cam Position Cam Position Page 14-10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 149: Governor Cable

    6. While holding the arm and shaft in the fully counterclockwise position, tighten the governor arm lever nut to 36 in-lb (4.0 N·m). 7. Check the engine RPM adjustment. See Engine RPM Adjustment, Page 14- 14. 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-11...
  • Page 150 FUEL SYSTEM Engine Control Linkage TYPICAL 2 PLACES REFERENCE EXHAUST SECTION Figure 14-12 Governor and Accelerator Cables Page 14-12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 151: Accelerator Cable

    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. IDLE SCREW Figure 14-13 Idle Screw 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-13...

  • Page 152: Engine Rpm Adjustment

    3. Place the Forward/Reverse handle in the NEUTRAL position and place the neutral lockout cam in the SERVICE position. 4. Connect a tachometer (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.

  • Page 153: Choke Button Installation

    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. 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-15...

  • Page 154: Intake Duct Repair

    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.
  • Page 155 FUEL SYSTEM Choke and Air Intake System TYPICAL 2 PLACES REFERENCE CARBURETOR TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 14-15 Air Intake and Choke Assemblies 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-17...

  • Page 156: Fuel Filters

    • 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.
  • Page 157 3. Turn the fuel shut-off valve to the ON position (Figure 14-22, Page 14-26). 4. Connect the battery cables, positive (+) cable first, and tighten terminals to 20 ft-lb (27.1 N·m). 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-19...

  • Page 158: Fuel Pump

    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).

  • Page 159: Fuel Pump Cleaning And Inspection

    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 Page 14-21...

  • Page 160: Fuel Pump Installation

    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...

  • Page 161: Fuel Tank Removal

    (Figure 14-19, Page 14-24). Do NOT remove the lower nut on the center stud of the sending unit. WARNING • MAKE SURE THE KEY SWITCH IS OFF BEFORE DETACHING WIRING. 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-23...

  • Page 162: Fuel Tank Disposal

    2.2. Install the screws (12) into the speed nuts (11). Tighten screws and nuts to 25 in-lb (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. Page 14-24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 163 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 Page 14-25...

  • Page 164: Fuel Lines

    WITH OFF MARKINGS ON THE SIDES OF VALVE) VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE 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...
  • Page 165 FUEL SYSTEM Fuel Shut-Off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 14-23 Incorrect Fuel Shut-off Valve 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-27...

  • Page 167: Section 15 - Exhaust System

    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 Page 15-1...

  • Page 168: Muffler

    • ANY TIME THE MUFFLER IS REMOVED FROM THE VEHICLE, INSTALL A 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).
  • Page 169 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.

  • Page 171: Section 16 - Unitized Transaxle

    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;...
  • Page 172 C l u b C a r with bottom of level indicator hole. SHIFTER SHIFTER F N R DRAIN LEVER PLUG Figure 16-1 Shifter Positions Figure 16-2 Lubricant Level Page 16-2 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 173: Lubrication

    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...
  • Page 174 UNITIZED TRANSAXLE Axle Shaft Axle Shaft, Continued: REFERENCE PASSENGER SIDE CASE REFERENCE DRIVER SIDE CASE Figure 16-5 Differential Gear Case/Axle Tubes Page 16-4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 175: Axle Shaft And Oil Seal 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.
  • Page 176 THIS COULD DAMAGE THE AXLE SHAFT WHEN THE BEARING AND COLLAR ARE PRESSED BEARING PULLER WEDGE ATTACHMENT PRESS RAM AXLE SEAL TOOL AXLE SEAL Figure 16-7 Bearing and Collar Figure 16-8 Axle Seal Tool Page 16-6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 177: Axle Shaft Installation

    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).
  • Page 178 (Figure 16-17, Page 16-9). 3.10. 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). Page 16-8 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 179 Lower the floor jack to allow the jack stands to support the vehicle (Figure 16-27, Page 16-12). 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-9...
  • Page 180 15.1. Grasp belt midway between drive and driven clutch and pull up on belt to force the driven clutch sheaves apart. Roll the belt counterclockwise while pulling it off driven clutch (Figure 16-25, Page 16-11). Page 16-10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 181 ENGINE DRIVEN CLUTCH APPROX. 6 IN. DRIVE CLUTCH Figure 16-24 Position Powertrain Figure 16-25 Remove Drive Belt 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-11...
  • Page 182 (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...
  • Page 183 Figure 16-32 Governor Cable Bracket Figure 16-33 Accelerator Cable Bracket TRANSAXLE MOUNTING BOLT AND NUT (TYPICAL 4 PLACES) WOODEN BLOCKS TRANSAXLE MOUNTING NUT (TYPICAL 2 PLACES) Figure 16-34 Transaxle Mounting 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-13...

  • Page 184: Unitized Transaxle Disassembly

    • 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...
  • Page 185 GEAR CASE slightly loosened in their seatings. 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...
  • Page 186 10. Remove the synchronizer gear assembly and shifter fork assembly as a unit from the case (Figure 16- 38, Page 16-16). 11. 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).

  • Page 187: Component Disassembly

    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 Page 16-17...
  • Page 188 UNITIZED TRANSAXLE Component Disassembly Differential Gear Case Disassembly, Continued: REFERENCE DRIVER SIDE CASE REFERENCE PASSENGER SIDE CASE Figure 16-42 Unitized Transaxle Page 16-18 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 189 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).

  • Page 190: Shifter Fork Disassembly

    • 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).

  • Page 191: Idler Shaft Disassembly

    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 puller 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).

  • Page 192: Unitized Transaxle Component Inspection

    3/4 in. or less o.d. arbor, and a ARBOR wedge attachment (Club Car Part No. 1012812) WEDGE ATTACHMENT Figure 16-52 Remove Idler Shaft Figure 16-53 Inspect Bearings Page 16-22 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 193: Component Assembly

    Synchro ring must be replaced when (x) distance is less than .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 Page 16-23...
  • Page 194 13. 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). Page 16-24 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 195: Shifter Fork Assembly

    (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 Service Supplement Page 16-25...

  • Page 196: Differential Gear Case Assembly

    ...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...
  • Page 197 DOWEL PIN to 18 ft-lb (24.4 N-m)..then tap ring gear onto the differential gear case. DOWEL HOLE Figure 16-65 Ring Gear Figure 16-66 Retaining Bolts 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-27...

  • Page 198: Governor Gear Assembly

    Press two new oil seals (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.
  • Page 199 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 16-33).
  • Page 200 (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...
  • Page 201 Cutaway view of shifter fork and synchronizer SLOT gear assembly being inserted as a unit into casing. Figure 16-75 Oil Guide Figure 16-76 Synchronizer Ring Gear 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-31...
  • Page 202 Unitized Transaxle Assembly Unitized Transaxle Assembly, Continued: 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).
  • Page 203 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...

  • Page 204: Unitized Transaxle Installation

    11. 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). 12. Install the drive belt. See Section 17 – Torque Converter. Page 16-34 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 205 2. Turn shaft counterclockwise. Install two governor cable bracket mounting screws. 3. Pull governor arm rearward. Figure 16-87 Governor Cable Bracket Figure 16-88 Governor Arm 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-35...
  • Page 206 48 in-lb (5.4 N·m). Connect the 16 gauge yellow wire to the DF post on the starter/generator and tighten to 30 in-lb (3.4 N·m) (Figure 16-96, Page 16-37). Page 16-36 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 207 Connect yellow wire. Connect ground STARTER wire at A2 terminal. GENERATOR Connect white wire. YELLOW OIL SENDING UNIT JUMPER WIRE Figure 16-95 Oil Level Sensor Jumper wire Figure 16-96 Starter/Generator 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-37...
  • Page 208 Figure 16-98 Engine Ground Wire TOP VIEW Connect fuel line Connect accelerator cable to and tighten clamp. cam and tighten retaining nuts. Figure 16-99 Connect Cable to Cam Figure 16-100 Connect Fuel Line Page 16-38 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 209: Forward/Reverse (F&R) Shifter Cable

    1. Remove the ball joint socket (2) from the F&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...

  • Page 210: F&R Shifter Cable Installation

    • 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 16-40 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 211: F&R Shifter Cable Adjustment

    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...

  • Page 213: Section 17 - Torque Converter

    (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 Page 17-1...
  • Page 214 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).

  • Page 215: Troubleshooting

    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.

  • Page 216: Drive Belt Installation

    • 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. Page 17-4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 217: Drive Clutch Removal

    (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 Maintenance and Service Supplement Page 17-5...
  • Page 218 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. TYPICAL 3 PLACES (ONE SPRING PER CLUTCH) Figure 17-5 Drive Clutch Assembly Page 17-6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 219: Drive Clutch Disassembly

    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).

  • Page 220: 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...

  • Page 221: Drive Clutch Assembly

    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 Page 17-9...
  • Page 222 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). Page 17-10 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 223: Drive Clutch Installation

    (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...
  • Page 224 5. Connect the battery cables, positive (+) cable first. 6. Connect the spark plug wire to the plug. 7. Drive the vehicle and check for proper operation. TYPICAL 3 PLACES Figure 17-16 Driven Clutch Assembly Page 17-12 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 225: Driven Clutch

    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).

  • Page 226: Driven Clutch Inspection

    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).

  • Page 227: Driven Clutch Installation

    • 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 lightly with a plastic mallet until the cam seats against the retaining ring.
  • Page 229 ............13-7 camshaft inspection ........... 13-25, 13-41 installation ............. 13-45 diagram, schematic ........... 11-6 removal ............13-25 differential carburetor ............14-4 see unitized transaxle choke and fresh air system ......14-4 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page i-1...
  • Page 230 ..........11-6 flywheel removal ............13-30 forward/reverse idler shaft cable assembly ............16-23 adjustment ..........16-41 disassembly ...........16-21 installation ..........16-40 ignition removal ............. 16-39 testing ............11-29 handle (lever) ........... 16-2 Page i-2 2000 FE290 Gasoline Vehicle Maintenance and Service Manual...
  • Page 231 ........11-12 kill circuit, engine ..........11-9 testing ........11-28, 11-31, 11-32 periodic lubrication schedule ......10-4 kill limit switch periodic service schedule ......... 10-3 installation ............. 12-16 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page i-3...
  • Page 232 ..........11-33 gap adjustment ........13-7, 14-4 reverse buzzer ..........11-33 installation ............13-7 reverse buzzer limit switch ......11-33 removal ............13-6 RPM limiter ............11-29 solenoid ............11-23 testing .............. 13-7 Page i-4 2000 FE290 Gasoline Vehicle Maintenance and Service Manual...
  • Page 233 ....13-20 inspection ............13-16 installation ............. 13-17 removal ............13-10 voltage regulator installation ............. 12-12 removal ............12-12 testing ............11-27 wire continuity testing ........... 11-27 wiring diagram ........... 11-6 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page i-5...
  • Page 236 Golf Cars and Utility Vehicles Club Car Inc. P.O. Box 204658 Augusta, GA 30917-4658...

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