Club Car 2005 FE290 Maintenance Service Supplement
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Club Car 2005 FE290 Maintenance Service Supplement

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2005
MAINTENANCE
SERVICE
SUPPLEMENT
FE290 GASOLINE VEHICLES
MANUAL NUMBER 102680409
EDITION CODE 1204B0205A

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Summary of Contents for Club Car 2005 FE290

  • Page 1 2005 MAINTENANCE SERVICE SUPPLEMENT FE290 GASOLINE VEHICLES MANUAL NUMBER 102680409 EDITION CODE 1204B0205A...
  • 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 30917-4658, USA, Attention: Technical Services, or contact a Club Car Technical Service Representative at (706) 863-3000, ext.
  • Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    Low Oil Warning Light ........................12-21 Fuel Gauge/Hour Meter ........................12-22 Fuel Level Sending Unit ........................12-23 RPM Limiter ............................12-23 Ignition Coil ............................12-24 Oil Level Sensor ..........................12-27 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page iii...
  • Page 6 Engine Control Linkage ........................14-5 General Information ........................14-5 Accelerator Rod ..........................14-6 Governor Cable ..........................14-8 Accelerator Cable ......................... 14-9 Closed Throttle or Idle Adjustment ....................14-11 Engine RPM Adjustment ......................14-11 Page iv 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 7 Fuel Shut-Off Valve .......................... 14-26 SECTION 15 – EXHAUST SYSTEM Muffler ............................... 15-1 Muffler Removal ..........................15-1 Muffler Installation ......................... 15-1 SECTION 16 – UNITIZED TRANSAXLE General Information .......................... 16-1 Lubrication ............................ 16-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page v...
  • Page 8 17-12 Driven Clutch Removal ......................... 17-12 Driven Clutch Disassembly ......................17-12 Driven Clutch Inspection ......................17-13 Driven Clutch Assembly ....................... 17-13 Driven Clutch Installation ......................17-16 SECTION i – INDEX Page vi 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 9: Section 10 - Periodic Maintenance

    • Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle. WARNING CONTINUED ON NEXT PAGE... 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10-1...
  • Page 10 • Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance, severe personal injury, or death. • Do not leave children unattended on vehicle. Page 10-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 11: 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 12 • If any problems are found during scheduled inspection or service, 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. Page 10-4 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 13: Periodic Lubrication Schedule

    SAE 5W20 below 32 °F (0 °C) API class cars) or annually, SE, SF, or SG Oil (or higher) whichever comes first. FLOORBOARD * If equipped with four-wheel brakes. ** Not applicable for DS Figure 10-2 Lubrication Points 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10-5...

  • Page 14: Engine Oil

    VENT SHUT-OFF VALVE CARBURETOR Full Level Safe Level Oil must be in the Safe Level. Level VENT TUBES Figure 10-3 Check Engine Oil Level Figure 10-4 Fuel Tank Page 10-6 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 15: Oil Viscosity

    See Preparing the Vehicle for Extended Storage in Section 3 of the appropriate maintenance and service man- ual. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10-7...

  • Page 16: Battery

    See preceding CAUTION and NOTE. 3. Replace fuel cap on tank. Make sure cap is tightened securely. 4. Replace seat bottom. BATTERY For periodic battery maintenance, see Battery, Section 12, Page 12-28. Page 10-8 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 17: Section 11 - Troubleshooting And Electrical System

    Section 13 – FE290 Engine Water or dirt in the fuel system and/or Section 14 – Fuel System carburetor; dirty or clogged fuel filter Troubleshooting Guide continued on next page... 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-1...
  • Page 18 Section 15 – Exhaust System carbon or other substance Section 11 – Troubleshooting and Ignition coil failed Electrical System Test Procedures 13, 14 and 15 Troubleshooting Guide continued on next page... Page 11-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 19 Accelerator pedal limit switch failed Limit Switch on page 11-13 Test Procedure 4 – Key Switch (Starter Key switch failed Circuit) on page 11-12 Troubleshooting Guide continued on next page... 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-3...
  • Page 20 Drive clutch malfunction Section 17 – Torque Converter Driven clutch malfunction Section 17 – Torque Converter Governor is sticking Section 16 – Unitized Transaxle Troubleshooting Guide continued on next page... Page 11-4 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 21 Electrical System, Test Procedures 4, 5 Carburetor is too lean; check main and Section 14 – Fuel System pilot jet sizes Carburetor throttle stop screw out of Section 14 – Fuel System adjustment 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-5...
  • Page 22 Troubleshooting Guide NEUTRAL LOCKOUT LIMIT SWITCH KILL LIMIT SWITCH Dashed lines indicate wiring present on Turf 1, Carryall 1, and Villager 4 vehicles only Figure 11-1 FE290 Gasoline Vehicle Wiring Diagram Page 11-6 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 23: Test Procedures

    10. Starter/Generator (Generator Function) 11. Voltage Regulator 12. Disconnected Kill Wire 13. Ignition Spark 14. RPM Limiter 15. Ignition Coil 16. Kill Limit Switch 17. Key Switch (Engine Kill Circuit) 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-7...
  • Page 24 °C). Never add acid to the battery to obtain a higher specific gravity (Figure 11-3, Page 11-9). ý 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. Page 11-8 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 25 For each 10 °F (5.6 °C) above 80 °F (27 °C), add 0.004 to the reading. For each 10 °F (5.6 °C) below 80°F (27 °C), subtract 0.004 from the reading. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-9...
  • Page 26 40 °F (4 °C) 9.3 V 30 °F (-1 °C) 9.1 V 20 °F (-7 °C) 8.9 V 10 °F (-12 °C) 8.7 V 0 °F (-18 °C) 8.5 V Page 11-10 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 27 If the connections are good and the reading is incorrect, repair or replace the cable. OIL FILLER FRAME GROUND BRACKET A2 TERMINAL FRAME I-BEAM Figure 11-4 Starter/Generator Ground Cable Test Figure 11-5 Engine Ground Cable Test 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-11...
  • Page 28 (–) 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 11-7, Page 11-13). Page 11-12 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 29 4. Set a multimeter to 200 (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 be 14 to16 (ohms). If the reading is not within limits, replace the solenoid. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-13...
  • Page 30 If the reading is incorrect, replace the solenoid (Figure 11-10, Page 11-14). 10. Disconnect the 6-gauge black cable from the negative (–) post of the battery before reconnecting the wires to the solenoid. Page 11-14 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 31 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2. Ensure that wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-15...
  • Page 32 (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, Page 12-1. Page 11-16 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 33 11 – Voltage Regulator on page 11-18. If the voltage does not rise, a tear-down inspection of the starter/generator will be necessary. See Starter/Generator Removal, Section 12, Page 12-1. 5. Connect the yellow wire to the DF terminal on the starter/generator. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-17...
  • Page 34 15.3 volts and continues to rise, replace voltage regulator. See Voltage Regulator Removal, Section 12, Page 12-12. WAVETEK 1000 2000 200k 200mA 1000 --- FUSED 750V Figure 11-14 Voltage Regulator Test Page 11-18 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 35 5. If the engine does not run, proceed to Test Procedure 13 – Ignition Spark on page 11-20. WHITE/BLACK ENGINE KILL WIRE LIMITER Figure 11-15 Disconnect White/Black Engine Kill Wire 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-19...
  • Page 36 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2. Disconnect both of the bullet terminals (Figure 11-17, Page 11-21). Page 11-20 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 37 (Figure 11-17, Page 11-21). 2.2. If the resistance is not between 0.6 - 1.7 (ohms), bench test the ignition coil. See Test Procedure 15B – Ignition Coil – Bench Test on page 11-24. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-21...
  • Page 38 (ohms), the spark plug cap and secondary coil must be tested independently from each other. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-19 Secondary Coil Test – In Vehicle Test Page 11-22 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 39 (Figure 11-22, Page 11-23). If there is no continuity, the cap has failed and must be replaced. Proceed to the next step with the spark plug cap still removed. Figure 11-22 Spark Plug Cap Test 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-23...
  • Page 40 6 on page 11-25. If the resistance is not between 6.0k - 11.0k (ohms), the spark plug cap and secondary coil must be tested independently from each other. Page 11-24 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 41 6.0k - 11.0k (ohms), the ignition coil has failed and must be replaced. 6. If the preceding tests indicate that the ignition coil resistance readings are within acceptable ranges, but the coil fails to function properly, replace the ignition coil and cap. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-25...
  • Page 42 Press the lever, and the reading should be continuity. If either reading is incorrect, replace the limit switch (Figure 11-27, Page 11-27). 4. Connect wires to limit switch and check for tight connections. Page 11-26 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 43 4. Turn the key switch ON, place the Forward/Reverse handle in FORWARD, and press 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. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-27...
  • Page 44 Then test the key switch. See Test Procedure 4 – Key Switch (Starter Circuit) on page 11-12. If the yellow wire and the key switch test okay, then replace the low oil warning light. Page 11-28 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 45 3.5. If all of the test results 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) on page 11-15. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-29...
  • Page 46 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, Section 14, Page 14-22. Page 11-30 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 47 The voltage reading should be the same as the full battery voltage reading obtained in step 4. If the reading is incorrect, replace fuel gauge/hour meter (Figure 11-31, Page 11-31). 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-31...
  • Page 48 • 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. Page 11-32 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 49: Section 12 - Electrical Components

    3. Mark and disconnect the wires from the starter/generator (1). Loosen the two pivot nuts (7) and bolts (5) (Figure 12-1, Page 12-1). FRAME CONNECTION TERMINAL TERMINAL TERMINAL Figure 12-1 Starter/Generator Removal 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-1...
  • Page 50 2. Check the wear line on the side of the brush. If the end of the brush is within 1/16 inch (1.6 mm) of the wear line, replace all four brushes (Figure 12-4, Page 12-3). Page 12-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 51 Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs. Figure 12-5 Brush Spring Tension Test 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-3...
  • Page 52 3. To separate armature (33) from output end cover (36), remove nut (41), lock washer (40), pulley (39), shaft key (34), spacer (37), and bearing retainer screws (43) (Figure 12-7, Page 12-5). Page 12-4 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 53 Do not remove the bearings unless they are to be replaced. Figure 12-8 Bearing Play Inspection 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-5...
  • Page 54 Items to look for are listed below. • Burned, charred, or cracked insulation • Improperly cured varnish • Thrown solder Page 12-6 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 55 2. Using a micrometer, measure the outside diameter at two points along the commutator. If the commu- tator outside diameter is less than 1.535 inches (39 mm), replace the armature and bearings (Figure 12-11, Page 12-8). 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-7...
  • Page 56 (–) probe on the armature core. The reading should be no continuity. If the reading is incorrect, replace the armature and the two bearings (Figure 12-12, Page 12-8). ARMATURE WAVETEK 1000 2000 200k 200mA COMMUTATOR 1000 --- FUSED 750V ARMATURE SHAFT Figure 12-12 Armature Ground Test Page 12-8 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 57 5. Press a new ball bearing (35) onto the output end of the armature (Figure 12-7, Page 12-5). Press a new ball bearing onto the commutator end of the armature shaft. See following CAUTION. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-9...
  • Page 58 7. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m). See Figure 10-1, Section 10, Page 10-3. Coat terminals with Battery Terminal Protector Spray (CCI P/ N 1014305) to minimize corrosion. Page 12-10 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 59 8. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m). See Figure 10-1, Section 10, Page 10-3. Coat terminals with Battery Terminal Protector Spray (CCI P/ N 1014305) to minimize corrosion. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-11...

  • Page 60: Voltage Regulator

    5. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m). See Figure 10-1, Section 10, Page 10-3. Coat terminals with Battery Terminal Protector Spray (CCI P/ N 1014305) to minimize corrosion. Page 12-12 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 61: Key Switch

    NOTE: Bending the top right corner of the center dash inward during removal will prevent the terminals on the back of the key switch from touching the metal frame around the dash. Figure 12-16 Center Dash Panel Removal 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-13...

  • Page 62: Solenoid

    See Figure 11-1, Section 11, Page 11-6. 7. Tighten the hex nuts on the large solenoid posts to 60 in-lb (6.8 N·m). Tighten the nuts on the small sole- noid posts to 22 in-lb (2.5 N·m). Page 12-14 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 63: Fuse

    2. Remove electrical component box cover (1) (Figure 12-17, Page 12-16). 3. Disconnect the green wire and the orange wire from the accelerator pedal limit switch (11) (Figure 12-17, Page 12-16). 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-15...

  • Page 64: Kill Limit Switch

    See Test Procedure 16, Section 11, Page 11-26. Kill Limit Switch Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. Page 12-16 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 65: Neutral Lockout Limit Switch

    1. Install the neutral lockout limit switch (5) with two washers (6) and two nuts (2) (Figure 12-18, Page 12-18). Tighten to 5 in-lb (0.6 N·m). Place the Forward/Reverse handle in REVERSE to make sure that both switches actuate. See following CAUTION. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-17...

  • Page 66: Neutral Lockout Cam

    1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2. Remove the external snap ring (14) (Figure 12-19, Page 12-18). Page 12-18 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 67: Reverse Warning Buzzer

    3. Disconnect the wires from the reverse warning buzzer (2). Do not allow wires to touch (Figure 12-20, Page 12-19). 4. Remove the mounting screws (3) securing the buzzer to the center dash. REVERSE BUZZER VIEWED WITH FRONT BODY REMOVED Figure 12-20 Reverse Buzzer 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-19...

  • Page 68: Reverse Buzzer Limit Switch

    5. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m). See Figure 10-1, Section 10, Page 10-3. Coat terminals with Battery Terminal Protector Spray (CCI P/ N 1014305) to minimize corrosion. Page 12-20 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 69: Low Oil Warning Light

    4. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m). See Figure 10-1, Section 10, Page 10-3. Coat terminals with Battery Terminal Protector Spray (CCI P/ N 1014305) to minimize corrosion. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-21...

  • Page 70: Fuel Gauge/Hour Meter

    Figure 12-22 Fuel Gauge/Hour Meter Installation Fuel Gauge/Hour Meter Installation 1. Install a new fuel gauge/hour meter into hole in dash until flange seats against dash (Figure 12-22, Page 12-22). Page 12-22 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 71: Fuel Level Sending Unit

    Use another flange-head bolt to secure the other side of the band. Make sure the band holds the RPM limiter securely in place. Tighten fasteners to 7 ft- lb (9.5 N·m). 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-23...

  • Page 72: Ignition Coil

    5. Cut the wire tie holding the wire harness to the stiffener (1) and remove the bolts (2) and nuts (3) securing the stiffener to the mounting plate (4) (Figure 12-25, Page 12-25). Page 12-24 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 73 9. Disconnect the 18-gauge black wire (12) from the spade terminal on the ignition coil (11) and remove the coil by removing two bolts (10) (Figure 12-27, Page 12-25). Figure 12-26 Fan Housing and Shroud Installation Figure 12-27 Coil Removal 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-25...
  • Page 74 Tighten the two mounting bolts (6) to 30 in-lb (3.4 N·m) (Figure 12-29, Page 12-26). SPARK PLUG 0.012 Inch (0.304 mm) Figure 12-28 Coil Installation Figure 12-29 Set Air Gap Page 12-26 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 75: Oil Level Sensor

    See Test Procedure 22, Section 11, Page 11-29. Oil Level Sensor Removal See Oil Level Sensor Removal, Section 13, Page 13-5. Oil Level Sensor Installation See Oil Level Sensor Installation, Section 13, Page 13-6. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-27...

  • Page 76: Battery

    Club Car recommends a group 70, side-post battery (CCI P/N 1012328), with a 650 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 clas- sification indicates battery size: 8-1/4 inches W x 6-1/2 inches D x 7-1/4 inches H (21.0 cm W x 16.5cm D x...
  • Page 77 See following NOTE. NOTE: Contact your local water department for mineral content analysis. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-29...
  • Page 78 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. Page 12-30 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 79 60 °F (16 °C) prior to charging. The battery will not charge effectively in cold temperatures for the same reasons that it does not discharge as rapidly in cold temperatures. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 12-31...

  • Page 80: Ground Cables

    • Do not jump-start a dead battery using another battery and jumper cables. GROUND CABLES See General Warning, Section 10, Page 10-1. Testing the Ground Cables See Test Procedure 3, Section 11, Page 11-11. Page 12-32 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 81: Section 13 - Fe290 Engine

    GENERAL INFORMATION See General Warning, Section 10, Page 10-1. All Club Car gasoline vehicles are powered by 4-cycle, overhead valve, single cylinder, air-cooled engines. The 4-cycle engine has an oil reservoir (crankcase) similar to automobiles, trucks, aircraft, heavy equipment, machinery and other applications designed for reliable heavy-duty service. The engine has two major compo- nent assemblies: the cylinder assembly and the crankcase assembly.
  • Page 82 Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible. Spark should be blue and strong and able to jump a 5/16-inch (8 mm) gap. Page 13-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 83: Cylinder Head

    See Engines and Drivetrain Components, Repair and Rebuild Man- ual for inspection and repair. CRANKCASE See General Warning, Section 10, Page 10-1. ENGINE REMOVAL To perform repairs on crankcase components, remove engine from the vehicle. See following CAUTION. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-3...

  • Page 84: Crankcase Cover Removal

    (5) (Figure 13-3, Page 13-4). 4. Remove the crankcase cover gasket completely. It may stick to the flanged surface of the crankcase. STARTER/ GENERATOR Figure 13-2 Oil Level Sensor Wire Figure 13-3 Crankcase Cover Page 13-4 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 85: Oil Level Sensor

    4. Remove the two mounting screws from the inside of the crankcase cover and remove the oil level sensor and bracket. 5. If necessary, remove the three screws (7) that hold the sensor to the bracket (5). 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-5...

  • Page 86: Crankcase Cover Installation

    130 in-lb (14 N·m). Then, repeating the sequence, tighten them to 250 in-lb (28.2 N·m) (Figure 13-6, Page 13-7). 5. Connect the yellow jumper wire (11) to the cord connector (12) (Figure 13-2, Page 13-4). Page 13-6 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 87: Ignition Coil And Flywheel

    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 13-8, Page 13-7). Loosen. Remove. Remove. Figure 13-7 Flywheel Housing Figure 13-8 Ignition Coil 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-7...
  • Page 88 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 13-10, Page 13-8). 3. Tighten the two ignition coil bolts to 30 in-lb (3.4 N·m). Crankcase Cover Installation See Crankcase Cover Installation on page 13-6. Page 13-8 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 89: Flywheel Installation

    4. Install muffler. See Muffler Installation, Section 15, Page 15-1. 5. Install starter/generator and belt. See Starter/Generator Installation, Section 12, Page 12-10. 6. Install the powertrain. See Unitized Transaxle Installation, Section 16, Page 16-16. Engine Installation, Continued: 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-9...
  • Page 90 12. Adjust the engine RPM setting. See Engine RPM Adjustment, Section 14, Page 14-11. 13. If initial checks indicate the engine is functional, place the neutral lockout cam in OPERATE position. 14. Test-drive vehicle to ensure all systems are functional and correctly adjusted. Page 13-10 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 91: Torque Specifications

    Ignition coil air gap (standard) 0.012 in. (0.304 mm) Compression pressure (min.) 156 psi (1076 kPa) 2700 (±30) RPM (DS Golf Car, Villager 4) Engine RPM 2860 (±30) RPM (Turf 1, Carryall 1) 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 13-11...

  • Page 93: Section 14 - Fuel System

    No adjustment is required for the pilot jet. If the vehicle idles roughly, turn the pilot air screw out until the vehicle idles smoothly. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-1...

  • Page 94: 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 14-2, Page 14-4). See following NOTE. Page 14-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 95 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 14-1 Carburetor Installation 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-3...
  • Page 96 8. Install the new main jet and tighten it to 12 in-lb (1.4 N·m). See following CAUTION and NOTE. ý CAUTION • Do not remove the valve/spring assembly from the float assembly. Doing so will damage the spring. Page 14-4 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 97: Engine Control Linkage

    See General Warning, Section 10, Page 10-1. 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. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-5...

  • Page 98: Accelerator Rod

    Accelerator Rod Installation and Adjustment 1. Before installing the accelerator rod, adjust accelerator pedal position. See Section 5 – Accelerator and Brake Pedal Group in the appropriate maintenance and service manual. Page 14-6 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 99 NUTS PARALLEL RETAINING WITH NUTS TOP VIEW OF THE ELECTRICAL COMPONENT Figure 14-4 DS Golf Car and Villager 4 Cam Position Figure 14-5 Turf 1 and Carryall 1 Cam Position 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-7...

  • Page 100: Governor Cable

    General Warning, Section 10, Page 10-1. 3. Remove the governor guard (5) (Figure 14-1, Page 14-3). 4. Disconnect the governor cable (2) at the carburetor throttle (Figure 14-7, Page 14-10). Page 14-8 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 101: Accelerator Cable

    8. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m). See Figure 10-1, Section 10, Page 10-3. Coat terminals with Battery Terminal Protector Spray (CCI P/ N 1014305) to minimize corrosion. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-9...
  • Page 102 FUEL SYSTEM Engine Control Linkage TYPICAL 2 PLACES CARBURETOR THROTTLE Figure 14-7 Governor and Accelerator Cables Page 14-10 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 103: Closed Throttle Or Idle Adjustment

    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 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-11...

  • Page 104: Choke And Air Intake System

    #12 screw (17) and adjust the choke lever (18) on the choke lever (6) (Figure 14-10, Page 14-14). Move the lever toward the choke button to increase choke engagement and away from the choke button to reduce choke engagement. Page 14-12 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 105: Air Box Removal

    2. Remove the front left wheel. See Section 8 – Wheels and Tires in the appropriate maintenance and service manual. 3. Remove the steering joint assembly (Figure 14-9, Page 14-13). TYPICAL 3 PLACES Figure 14-9 Compound Steering Joint 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-13...
  • Page 106 FUEL SYSTEM Choke and Air Intake System TYPICAL 2 PLACES REFERENCE CARBURETOR TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 14-10 Air Intake and Choke Assemblies Page 14-14 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 107: Intake Duct Installation

    Air Duct Repair Kit (CCI P/N 101971001). This kit includes repair materials and procedures for small cracks and holes. If the intake duct is badly torn or has larger holes, it will need to be replaced. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-15...

  • Page 108: Air Filter

    • If air box is extremely dirty, remove air box from vehicle and clean thoroughly. • Use only Club Car replacement air filters (CCI P/N 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 109: Fuel Filter Removal

    SERVICE (MAINTENANCE) position. Start the engine and check for fuel leaks. See following DANGER. ý DANGER • Repair all fuel leaks before operating the vehicle. 6. Place the neutral lockout cam in the OPERATE position. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-17...
  • Page 110 48.5 in. (123.2 cm) 39.0 in. (99.1 cm) 44.5 in. (113.0 cm) 39.0 in. (99.1 cm) ** Front fuel strap present on Carryall and Turf vehicles only. Figure 14-11 Fuel and Vent Lines Page 14-18 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 111: Fuel Pump

    If leaking occurs, all new gaskets and diaphragms must be installed. NOTE: A fuel pump rebuild kit is available from Club Car (CCI P/N 1014524). This kit includes all gaskets, diaphragms, and valves.

  • Page 112: Fuel Pump Cleaning And Inspection

    CHAMBER FUEL OUTLET OUTLET VENT FRONT COVER FUEL INLET FUEL INLET VALVE ASSEMBLY DIRECTION OF FUEL FLOW IMPULSE LINE BACK COVER Figure 14-12 Fuel Pump Figure 14-13 Fuel Pump Orientation Page 14-20 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 113: Fuel Pump Installation

    See following DANGER. ý DANGER • Repair all fuel leaks before operating the vehicle. 8. Place the neutral lockout cam in the OPERATE position. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-21...

  • Page 114: Fuel Tank

    ý WARNING • Do not attempt to siphon fuel using a hose that does not have a built-in suction device. • Do not attempt to siphon fuel using your mouth. Page 14-22 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 115: Fuel Tank Disposal

    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. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-23...

  • Page 116: Fuel Tank Installation

    14.1. Check all of the fuel line clamps at the carburetor, fuel filters, fuel pump, and fuel tank for leaks. 14.2. Inspect each fuel line to ensure that the lines are not cracked, cut, or worn. Page 14-24 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 117: Fuel Lines

    Small spring steel band clamps are used on all hose connections except at the carburetor. A screw band clamp (16) should be used at the carburetor (Figure 14-11, Page 14-18). 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 14-25...

  • Page 118: Fuel Shut-Off Valve

    PARTIALLY CLOSED FULL OPEN (ON) POSITION POSITION VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE Figure 14-17 Open Fuel Shut-off Valve Figure 14-18 Incorrect Fuel Shut-off Valve Page 14-26 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 119: Section 15 - Exhaust System

    7. Tighten the muffler clamp (6) to 40 in-lb (4.5 N·m). NOTE: Removing and installing the governor cable bracket may change the RPM setting. See Engine RPM Adjustment, Section 14, Page 14-11. 8. Connect the spark plug wire. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 15-1...
  • Page 120 11. After checking the exhaust and engine for proper operation, return the neutral lockout cam to the OPER- ATE position. TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 15-1 Exhaust System Page 15-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 121: Section 16 - Unitized Transaxle

    • See General Warning, Section 10, Page 10-1. 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 vehi- cle direction, the engine, drive clutch, belt, and driven clutch rotate in the same direction;...

  • Page 122: Lubrication

    Fill with 27 oz. (0.8 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). Tighten the plug to 20 ft-lb (27.1 N·m). Page 16-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 123: Axle Shaft

    6. Use 90° internal snap ring pliers (0.090-in. tip) to remove internal retaining ring (1) from axle tube (Figure 16-3, Page 16-3). 7. Carefully pull the axle shaft (2) straight out of the axle tube (Figure 16-3, Page 16-3). Figure 16-3 Retaining Ring 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-3...

  • Page 124: Axle Bearing

    (70) is smaller than the outer diameter of the bearing (71), the ring must be in place on the axle before a new bearing and collar are pressed on. Page 16-4 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 125 UNITIZED TRANSAXLE Axle Shaft REFERENCE PASSENGER SIDE CASE REFERENCE DRIVER SIDE CASE Figure 16-6 Differential Gear Case/Axle Tubes 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-5...

  • Page 126: Axle Shaft Installation

    4. Install the bearing retaining ring (70) in the axle tube (Figure 16-6, Page 16-5). See also Figure 16-3, Page 16-3. Page 16-6 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 127: Unitized Transaxle Removal

    2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 3. Close the fuel shut-off valve on fuel tank. See Figure 14-16, Section 14, Page 14-26. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-7...
  • Page 128 1/4-inch bolt (Figure 16-12, Page 16-8). IMPULSE LINE FUEL LINE Figure 16-11 Impulse Line Figure 16-12 Fuel Line Page 16-8 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 129 GROUND WIRE TOP VIEW YELLOW WIRE AT A2 TERMINAL WHITE WIRE Pull spring release back to remove shifter NUTS cable from lever. Figure 16-15 Shifter Cable Figure 16-16 Generator Wires 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-9...
  • Page 130 5.1. Remove bow tie pins (1), brake cable clevis pins (2), and E-clips (3) (Figure 16-19, Page 16-10). 5.2. Remove the cable from the cable support bracket (Figure 16-19, Page 16-10). AS SEEN FROM DRIVER-SIDE OF VEHICLE REAR OF VEHICLE Figure 16-19 Brake Cable Page 16-10 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 131 9. Remove the bolts securing the leaf springs to their front mounts (Figure 16-23, Page 16-11). Remove bolts, then rotate shackles up and away from spring. Figure 16-22 Rear Shackles Figure 16-23 Spring Retainer Bolts 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-11...
  • Page 132 (Figure 16-27, Page 16-12). SNUBBER BRACKET Lower snubber to the ground. Lift snubber out of bracket. Roll entire powertrain out from under vehicle body. Figure 16-26 Snubber Figure 16-27 Remove Powertrain Page 16-12 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 133 18. Loosen, but do not remove, the governor arm retaining bolt (1) (Figure 16-31, Page 16-13). Remove the governor arm from the shaft. Do not disconnect cables. RETAINING BOLT Figure 16-30 Driven Clutch Figure 16-31 Governor Arm 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-13...
  • Page 134 23. Remove leaf springs, wheels and brake assemblies from the transaxle. TRANSAXLE MOUNTING BOLT AND NUT (TYPICAL 4 PLACES) WOODEN BLOCKS TRANSAXLE MOUNTING NUT (TYPICAL 2 PLACES) Figure 16-34 Transaxle Mounting Page 16-14 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 135 UNITIZED TRANSAXLE Unitized Transaxle Removal REFERENCE FORWARD/ REVERSE SHIFTER Figure 16-35 Transaxle Gear Casing and Brackets 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-15...

  • Page 136: Unitized Transaxle Installation

    10. 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 16-38, Page 16-17). 11. Install the drive belt. See Drive Belt Installation, Section 17, Page 17-3. Page 16-16 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 137 15. Adjust the vehicle height with the floor jack to position the leaf springs for mounting in the shackles. Install the mounting bolts, and lock nuts (Figure 16-41, Page 16-17). TRAILER HITCH BRACKET Figure 16-40 Leaf Springs Figure 16-41 Leaf Springs and Shackles 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-17...
  • Page 138 30 in-lb (3.4 N·m) (Figure 16-45, Page 16-18). GROUND WIRE YELLOW WIRE STARTER GENERATOR WHITE WIRE YELLOW OIL SENDING UNIT JUMPER WIRE Figure 16-44 Oil Level Sensor Jumper wire Figure 16-45 Starter/Generator Page 16-18 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 139 26. Remove the 1/4-inch bolt from the fuel line and connect the fuel line to the carburetor and secure with a hose clamp (Figure 16-49, Page 16-19). TOP VIEW RETAINING NUTS Figure 16-48 Connect Cable to Cam Figure 16-49 Connect Fuel Line 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-19...
  • Page 140 31. Fill transaxle with 27 oz. (0.8 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-lb (28.5 N·m). 32. Ensure that all wiring is secured properly. See following WARNING. Page 16-20 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 141: Forward/Reverse Shifter Cable

    3. Secure the cable with a retaining nut (5) on each side of the shifter cable support bracket at the Forward/ Reverse assembly. Tighten nuts to 43 in-lb (4.9 N·m). 4. Install the ball joint socket (10) on the shifter lever ball stud (11) on the transaxle. 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-21...

  • Page 142: Forward/Reverse Shifter Cable Adjustment

    • Be sure threads of cable are engaged in ball joint socket at least 1/4 inch (6.35 mm). If ball joint socket comes loose from the cable, the Forward/Reverse shifter will not operate properly. Page 16-22 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 143 22 ft-lb (29.8 N·m); retighten nuts at the Forward/Reverse assembly to 43 in-lb (4.9 N·m). TOP VIEW SHIFTER SHIFTER F N R LEVER Figure 16-55 Forward/Reverse Positions 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-23...

  • Page 145: Section 17 - Torque Converter

    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 146: Drive Belt

    TORQUE CONVERTER Drive Belt Troubleshooting, Continued: 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.

  • Page 147: Drive Belt Removal

    TORQUE CONVERTER Drive Belt DRIVE BELT REMOVAL 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2. Disconnect the spark plug wire from the spark plug. See WARNING “To avoid unintentionally start- ing...”...

  • Page 148: Drive Clutch

    2. Loosen the starter/generator mounting and adjusting hardware and then remove the starter belt. See WARNING “Moving parts! Do not...” in General Warning, Section 10, Page 10-1. Use Club Car clutch holder VEHICLE BODY REMOVED FOR while tightening or loosening drive CLARITY clutch retaining bolt.

  • Page 149: Drive Clutch Cleaning And Inspection

    TORQUE CONVERTER Drive Clutch 3. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Place jack stands 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.
  • Page 150 TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES Figure 17-5 Drive Clutch Assembly Page 17-6 2005 FE 290 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 151: Drive Clutch Disassembly

    TORQUE CONVERTER Drive Clutch DRIVE CLUTCH DISASSEMBLY ý CAUTION • The drive clutch is balanced as an assembly. Before disassembly, make match marks on the drive clutch hub and on the moveable face assembly so they can be reassembled in the same positions (Figure 17-6, Page 17-7).
  • Page 152 TORQUE CONVERTER Drive Clutch Remove these items from ribs: 1/4-20 SCREW 10-24 SCREW FLAT WASHER FLAT WASHER WEIGHT DRIVE BUTTON DRIVE BUTTON TAKE UP SPRING WEIGHT RIBS SLOTS IN HUB CASTING Figure 17-8 Drive Button Mounting Figure 17-9 Weight Position 5.

  • Page 153: Inspection Of Drive Clutch Parts

    TORQUE CONVERTER Drive Clutch 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) must be replaced with new ones (Figure 17-5, Page 17-6).

  • Page 154: Drive Clutch Assembly

    TORQUE CONVERTER Drive Clutch Inspection of Drive Clutch Parts, Continued: 6. Inspect the pins on the primary weights (2). There should be no measurable wear. Replace them if they are worn, scratched, or damaged. 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.
  • Page 155 TORQUE CONVERTER Drive Clutch 12. Install the 1/4-20 bolts and washers (2) and tighten them to 10 ft-lb (13 N·m) (Figure 17-5, Page 17-6). See following NOTE. 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 bolt.

  • Page 156: Drive Clutch Installation

    TORQUE CONVERTER Driven Clutch 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 (Figure 17-5, Page 17-6). See fol- lowing NOTE.

  • Page 157: Driven Clutch Inspection

    TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH CAM PULLER PULLER PLUG Figure 17-16 Remove Retaining Ring Figure 17-17 Driven Clutch Disassembly DRIVEN CLUTCH INSPECTION 1. Inspect the cam (4) for excessive wear. Replace it if necessary (Figure 17-18, Page 17-14). 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.
  • Page 158 TORQUE CONVERTER Driven Clutch TYPICAL 3 PLACES Figure 17-18 Driven Clutch Assembly Page 17-14 2005 FE 290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 159 TORQUE CONVERTER Driven Clutch Driven Clutch Assembly, Continued: 5. 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).

  • Page 160: Driven Clutch Installation

    TORQUE CONVERTER Driven Clutch Driven Clutch Assembly, Continued: 5.2.3. Slide the bolt (1) through the clutch body (5) until the threaded bolt, washers, bearing, and hub guide are against the fixed face hub (Figure 17-20, Page 17-15). 5.2.4. Hold the clutch assembly and cam installation tool together and place the fixed face down on spaced blocks (Figure 17-19, Page 17-15).
  • Page 161 .......11-7 neutral lockout circuit ........11-7 carburetor ............14-1 reverse buzzer circuit ........11-7 closed throttle or idle adjustment ....14-11 starter circuit ............11-7 jet, main ............14-2 engine elevation/size chart ........14-2 assembly ............13-9 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page i-1...
  • Page 162 ............12-17 installation ............12-15 removal ............12-15 testing ............11-11 low oil warning light ........... 11-7 installation ............12-21 governor removal ............12-21 governor system ..........16-2 testing ............11-28 Page i-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 163 ............12-1 removal ............12-19 rework ..............12-9 testing ............11-28 testing ..........11-15, 11-17 RPM adjustment ..........14-11 RPM limiter installation ............12-23 removal ............12-23 test procedure testing ............11-20 accelerator pedal limit switch ......11-13 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page i-3...
  • Page 164 ............16-16 lubrication ............16-2 removal ............16-7 service ............. 16-2 voltage regulator installation ............12-12 removal ............12-12 testing ............11-18 wire continuity testing ..........11-17 Page i-4 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 165 2. Ease of Finding Information 3. Clarity of Illustrations 4. Index Usability 5. Troubleshooting Chart Usability Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 168 Club Car, Inc. www.clubcar.com Phone 1.706.863.3000 P.O. Box 204658 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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