Club Car FE350 2005 Maintenance Service Supplement
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Club Car FE350 2005 Maintenance Service Supplement

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2005
MAINTENANCE
SERVICE
SUPPLEMENT
FE350 GASOLINE VEHICLES
MANUAL NUMBER 102680410
EDITION CODE 0405A00000

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  • Page 1 2005 MAINTENANCE SERVICE SUPPLEMENT FE350 GASOLINE VEHICLES MANUAL NUMBER 102680410 EDITION CODE 0405A00000...
  • 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, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech- nical 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

    CONTENTS SECTION 10 – PERIODIC MAINTENANCE General Warning ..........................10-1 Periodic Service Schedule ........................ 10-3 Periodic Lubrication Schedule ......................10-5 Engine Oil ............................10-6 Engine Oil Level Check ........................ 10-6 Oil Viscosity ..........................10-7 Fueling Instructions ........................... 10-7 Battery .............................. 10-8 SECTION 11 –...
  • Page 6 Taillights ............................12-30 Taillight Bulb Removal ........................12-30 Voltage Limiter ..........................12-31 Headlight Switch ..........................12-32 Brake Light Relay ..........................12-33 Park Brake Limit Switch ........................12-34 Brake Pedal Limit Switch ......................... 12-35 Horn ..............................12-36 Horn switch ............................12-36 Battery ..............................
  • Page 7 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 ....................14-10 Engine RPM Adjustment ....................... 14-11 General Information ........................14-12 Choke Cable Removal ........................14-12 Choke Cable Installation .......................
  • Page 8 SECTION 16 – UNITIZED TRANSAXLE General Information ......................... 16-1 Lubrication ............................ 16-2 Axle Shaft ............................16-3 Axle Shaft and Oil Seal Removal ....................16-3 Axle Bearing ..........................16-4 Axle Shaft Installation ........................16-6 Unitized Transaxle Removal ......................16-7 Unitized Transaxle Installation ......................16-16 Forward/Reverse Shifter Cable ......................

  • Page 9: Section 10 - Periodic Maintenance

    SECTION 10 – PERIODIC MAINTENANCE GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser- viced. Service technicians should become familiar with these general safety statements, which can be found throughout this manual. Also, other specific safety statements appear throughout this manual and on the vehi- cle.
  • Page 10 PERIODIC MAINTENANCE General Warning ý WARNING • Moving parts! Do not attempt to service the vehicle while it is running. • Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning could result in severe burns. •...

  • Page 11: Periodic Service Schedule

    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 PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Monthly service by owner Check engine oil level; change if or trained technician necessary. See Periodic Lubrication Schedule on page 10-5. Engine Check engine cooling air intake; visually inspect unshrouded area around engine exhaust for grass and debris, and clean if necessary.

  • Page 13: Periodic Lubrication Schedule

    PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE See General Warning on page 10-1. PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINT Semiannually by Brake pedal shaft bearings Dry Moly Lube – CCI P/N 1012151 owner or trained technician Brake linkage and pivots Dry Moly Lube –...

  • Page 14: Engine Oil

    PERIODIC MAINTENANCE Engine Oil ENGINE OIL See General Warning on page 10-1. Even though the low oil warning light on the dash should illuminate if the engine oil level is low, the engine oil level should be checked monthly. The vehicle should be on a level surface when checking oil. ENGINE OIL LEVEL CHECK 1.

  • Page 15: Oil Viscosity

    PERIODIC MAINTENANCE Fueling Instructions OIL VISCOSITY Choose the viscosity according to the temperature as indicated by the oil viscosity chart (Figure 10-5, Page 10-7). See following NOTE. -20 °C -10 °C 0 °C 10 °C 20 °C 30 °C 40 °C SAE 40 SAE 30 SAE 10W-30/SAE 10W-40...

  • Page 16: Battery

    PERIODIC MAINTENANCE Battery Fueling Instructions, Continued: For Turf 2, Carryall 2, and Carryall 2 Plus vehicles: 1. Lift and remove seat bottom. 2. The fuel tank is located on the passenger side of the vehicle (Figure 10-4, Page 10-6). Remove fuel cap and fill the fuel tank with fresh, unleaded fuel only.

  • Page 17: Section 11 - Troubleshooting And Electrical System

    SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. GENERAL INFORMATION This section contains the information required to correctly troubleshoot the vehicle. A troubleshooting guide is provided for general troubleshooting.
  • Page 18 TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Engine starts but does not run Spark plug is fouled or in poor condition Section 13 – FE350 Engine smoothly. Spark plug wire is damaged or loose Section 13 –...
  • Page 19 TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loss of engine power, continued Throttle linkage out of adjustment Section 14 – Fuel System Low cylinder compression Section 13 – FE350 Engine Spark plug failed Section 13 – FE350 Engine Restricted fuel flow Section 14 –...
  • Page 20 TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Starter/generator does not charge Loose or broken wire in starter/generator Test Procedure 11 – Starter/Generator battery. circuit (Generator Function) on page 11-25. Test Procedure 11 – Starter/Generator Generator field coil is shorted (Generator Function) on page 11-25.
  • Page 21 TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Engine won’t stop running. Kill circuit wire is disconnected from the Test Procedure 13 – Disconnected Kill ignition coil Wire on page 11-26. Section 11 – Troubleshooting and Relay failure (key-start vehicle only) Electrical System Test Procedures 4 and 18...
  • Page 22 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams WIRING DIAGRAMS RIGHT HEADLIGHT LEFT HEADLIGHT – – NEUTRAL LOCKOUT LIMIT SWITCH LIGHT SWITCH KILL LIMIT SWITCH FUSE – Figure 11-1 Wiring Diagram for Turf 2 Page 11-6 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 23 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams – NEUTRAL LOCKOUT LIMIT SWITCH KILL LIMIT SWITCH – Figure 11-2 Wiring Diagram for Carryall 2 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page 11-7...
  • Page 24 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams RIGHT BRAKE HEADLIGHT LIGHT RELAY HORN – GROUND LEFT TERMINAL HEADLIGHT BLOCK – LIGHT SWITCH TWO PIN CONNECTOR PARK LIMIT SWITCH HORN ORANGE/WHITE BUTTON BRAKE LIMIT SWITCH Figure 11-3 Wiring Diagram for Carryall 6, Villager, and TransPorter Vehicles (Front) Page 11-8 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 25 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams NEUTRAL LOCKOUT LIMIT SWITCH COIL COIL SONIC WELD – RIGHT BRAKE LIGHT LEFT BRAKE – LIGHT Figure 11-4 Wiring Diagram for Carryall 6, Villager, and TransPorter Vehicles (Rear) 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page 11-9...
  • Page 26 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams RIGHT BRAKE HEADLIGHT LIGHT RELAY HORN – GROUND LEFT TERMINAL HEADLIGHT BLOCK – LIGHT SWITCH TWO PIN CONNECTOR PARK LIMIT SWITCH HORN ORANGE/WHITE BUTTON BRAKE LIMIT SWITCH Figure 11-5 Wiring Diagram for Turf 6 Vehicle (Front) Page 11-10 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 27 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams NEUTRAL LOCKOUT LIMIT SWITCH SONIC WELD – RIGHT BRAKE LIGHT LEFT BRAKE – LIGHT Figure 11-6 Wiring Diagram for Turf 6 Vehicle (Rear) 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page 11-11...
  • Page 28 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams – NEUTRAL LOCKOUT LIMIT SWITCH COIL COIL SONIC WELD – Figure 11-7 Wiring Diagram for Carryall 2 Plus Vehicle Page 11-12 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 29: Test Procedures

    TROUBLESHOOTING AND ELECTRICAL SYSTEM Electrical System ELECTRICAL SYSTEM The electrical system on the gasoline vehicle is 12 volts DC with negative (–) ground to frame, and consists of twelve circuits that are easily identified: • Starter Circuit • Generator Circuit •...
  • Page 30 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Index of Test Procedures, Continued: 11. Starter/Generator (Generator Function) 12. Voltage Regulator 13. Disconnected Kill Wire 14. Ignition Spark 15. RPM Limiter 16. Ignition Coil 17. Kill Limit Switch 18. Key Switch (Engine Kill Circuit) 19.
  • Page 31 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 1 – BATTERY See General Warning, Section 10, Page 10-1. ý DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working near a battery. •...
  • Page 32 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 1 – Battery, Continued: 6. Hold the hydrometer vertically, ensuring that the float is not contacting the sides of the glass tube. Hold the hydrometer at eye level and read the scale at the level of electrolyte (Figure 11-8, Page 11-16). 7.
  • Page 33 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Voltage Test 1. Take a voltage reading with a multimeter set to 20 VDC by placing the red (+) probe on the positive (+) battery post and the black (–) probe on the negative (–) battery post. If it shows less than 12.4 volts, or if the lowest specific gravity reading from the Hydrometer Test is less than 1.225, recharge the battery.
  • Page 34 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 2 – Fuse, Continued: 5. Connect the probes of a multimeter, set to 200 ohms, to the fuse terminals. The reading should be con- tinuity. If there is no continuity, determine and repair the cause of the fuse failure. Replace the fuse with a properly rated new one.
  • Page 35 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Place black (–) probe on frame. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 OHM SETTING Disconnect the 6-gauge black wire from the battery. Place red (+) probe on disconnected end of cable. Figure 11-12 Battery Ground Cable Test TEST PROCEDURE 4 –...
  • Page 36 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures YELLOW BLUE –M –M GREEN ORANGE/WHITE WAVETEK WAVETEK OR BLUE BLUE 1000 1000 TO SOLENOID YELLOW WHITE / WHITE BLACK WHITE/BLACK 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V 200 OHM 200 OHM...
  • Page 37 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 4. Make sure the battery is disconnected. With the key switch in the OFF position, the Forward/Reverse handle in NEUTRAL, and the accelerator pedal in the UP position, the reading should be no continuity. With the accelerator pedal pressed, the reading should be continuity.
  • Page 38 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 7 – Solenoid, Continued: 9. With the Forward/Reverse handle still in NEUTRAL and the neutral lockout cam in the SERVICE (MAIN- TENANCE) position, set the multimeter to 20 volts DC and place the red (+) probe on the large post that does not have wires connected to it.
  • Page 39 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures LEVER DEPRESSED LEVER UP NEGATIVE (–) POSITIVE (+) POSITIVE (+) NEGATIVE (–) PROBE PROBE PROBE PROBE NO COM NO COM WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k TESTER LIGHT IS TESTER LIGHT ON. METER READS IS OUT.
  • Page 40 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 9 – Starter/Generator (Starter Function), Continued: 5. Using a multimeter set to 200 ohms, place the red (+) probe on the A1 terminal and the black (–) probe on the A2 terminal. The reading should be continuity. If the reading is incorrect, a possible open or poor contact in a brush assembly and/or open armature windings may be the cause.
  • Page 41 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 11 – STARTER/GENERATOR (GENERATOR FUNCTION) See General Warning, Section 10, Page 10-1. NOTE: Keep the battery connected while performing this test procedure. 1. Place the neutral lockout cam in the SERVICE (MAINTENANCE) position, put the Forward/Reverse han- dle in the NEUTRAL position, and chock the wheels.
  • Page 42 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20 VDC SETTING Figure 11-22 Voltage Regulator Test TEST PROCEDURE 13 – DISCONNECTED KILL WIRE See General Warning, Section 10, Page 10-1. NOTE: Keep the battery connected while performing this test procedure. 1.
  • Page 43 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures IGNITION GAP TEST TOOL SPARK PLUG WIRE SPARK PLUG Disconnect LIMITER white/black FRAME engine kill wire Figure 11-23 Ignition Spark Test Figure 11-24 White/Black Engine Kill Wire TEST PROCEDURE 14 – IGNITION SPARK See General Warning, Section 10, Page 10-1. NOTE: Keep the battery connected while performing this test procedure.
  • Page 44 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 15 – RPM LIMITER See General Warning, Section 10, Page 10-1. 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 11-25, Page 11-28). 3.
  • Page 45 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 OHM SETTING Figure 11-26 Primary Coil Resistance – In Vehicle Test WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20k OHM SETTING Figure 11-27 Secondary Coil Test – In Vehicle Test 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page 11-29...
  • Page 46 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 16A – Ignition Coil – In Vehicle Test, Continued: 2.2. If the resistance is not between 0.6 - 1.7 ohms, bench test the ignition coil. See Test Procedure 16B – Ignition Coil – Bench Test on page 11-32. 3.
  • Page 47 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20k OHM SETTING Figure 11-30 Spark Plug Cap Test WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20k OHM SETTING Figure 11-31 Secondary Coil Test Without Cap 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page 11-31...
  • Page 48 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 16A – Ignition Coil – In Vehicle Test, Continued: 5. Test the secondary coil separately from the spark plug cap. 5.1. Using a multimeter set to 20k ohms, place the red (+) probe of the meter into the end of the spark plug wire and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 11-31, Page 11-31).
  • Page 49 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20k OHM SETTING Figure 11-34 Secondary Coil Resistance – Bench Test 3.2. If the resistance is between 12.0k - 14.0k ohms, the secondary coil and spark plug cap are within acceptable limits;...
  • Page 50 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 17 – KILL LIMIT SWITCH See General Warning, Section 10, Page 10-1. The kill limit switch for pedal-start vehicles is located inside the electrical component box. The accelerator kill switch is the lower of the two limit switches and has a white/black wire and black wire connected to it. The kill limit switch for key-start vehicles is located inside the electrical component box and has a brown, red and orange wire connected to it.
  • Page 51 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 3. Disconnect wires from the (+M) and (–M) terminals of the key switch. 4. Place the red (+) probe on the (+M) terminal and the black (–) probe on the (–M) terminal. With the key switch OFF, the reading should be continuity.
  • Page 52 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 20 – REVERSE BUZZER LIMIT SWITCH See General Warning, Section 10, Page 10-1. NOTE: Keep the battery connected while performing this test procedure. The reverse buzzer limit switch is located on the Forward/Reverse shifter; red/white and orange wires are connected to it.
  • Page 53 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 23 – OIL LEVEL SENSOR See General Warning, Section 10, Page 10-1. NOTE: Keep the battery connected while performing this test procedure. 1. Place the neutral lockout cam in the SERVICE (MAINTENANCE) position, put the Forward/Reverse han- dle in the NEUTRAL position, turn the key switch to the OFF position, disconnect the spark plug wire, and chock the wheels.
  • Page 54 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 25 – Battery Test (Under Load), Continued: 6. If the reading is zero, there may be no continuity across the large posts of the solenoid. See Test Pro- cedure 7 – Solenoid on page 11-21. 7.
  • Page 55 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 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 14-23.
  • Page 56 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 28 – HOUR METER See General Warning, Section 10, Page 10-1. NOTE: Keep the battery connected while performing this test procedure. 1. Place the neutral lockout cam in the SERVICE (MAINTENANCE) position, put the Forward/Reverse han- dle in the NEUTRAL position, and chock the wheels.
  • Page 57 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 5. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m). 6. Using a multimeter set to 200 ohms, place the two probes onto the two normally closed (NC) terminals on the relay (Figure 11-43, Page 11-40).
  • Page 58 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures GROUND WAVETEK TERMINAL 1000 WAVETEK BLOCK 1000 20-AMP 2000 FUSE 200k 2000 200k COIL 200nA 1000 --- FUSED 750V 200nA 1000 --- FUSED 750V 20 VDC 200 OHM SETTING RELAY TEST SETTING ELECTRICAL COMPONENT BOX Figure 11-44 Starter/Generator and Neutral Lockout Figure 11-45 Battery Voltage Supply Test Circuits Relay Test...
  • Page 59 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 32 – HEADLIGHT SWITCH See General Warning, Section 10, Page 10-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2. Remove the center dash assembly. See Key Switch Removal, Section 12, Page 12-13. 3.
  • Page 60 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Some wires removed for clarity. Figure 11-47 Brake Light Relay Test TEST PROCEDURE 33 – BRAKE LIGHT RELAY See General Warning, Section 10, Page 10-1. 1. Inspect the brake light relay for proper operation. NOTE: The aid of an assistant will be required to inspect the brake light relay for proper operation.
  • Page 61 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 6.3. Using a multimeter set to 200 ohms, place the black (–) probe of the multimeter on the relay termi- nal marked COM (common). Place the red (+) probe on the relay terminal marked NO (normally open).
  • Page 62 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 33 – Brake Light Relay, Continued: 10. If the brake lights do not operate with the relay bypassed, there is most-likely a problem in the brake light circuit other than the brake light relay. Restore the wiring to the original configuration (not bypassed), and proceed to step 13 for additional test procedures.
  • Page 63 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures WAVETEK 1000 2000 200k Some wires 200nA 1000 --- FUSED 750V removed for clarity. 200 OHM SETTING Figure 11-50 Brake Light Relay Coil Test 13. If a problem was not detected in the previous steps, check the following items: •...
  • Page 64 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 34 – VOLTAGE LIMITER (VEHICLES WITH HEADLIGHTS) See General Warning, Section 10, Page 10-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2.
  • Page 65 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 35 – VOLTAGE AT TAILLIGHT SOCKET See General Warning, Section 10, Page 10-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2.
  • Page 66 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 37 – VOLTAGE AT HEADLIGHT SOCKET See General Warning, Section 10, Page 10-1. NOTE: Keep the battery connected while performing this test procedure. 1. Place the neutral lockout cam in the SERVICE (MAINTENANCE) position, put the Forward/Reverse han- dle in the NEUTRAL position, and chock the wheels.
  • Page 67 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 38 – PARK BRAKE LIMIT SWITCH See General Warning, Section 10, Page 10-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2.
  • Page 68 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 40 – VOLTAGE AT HORN See General Warning, Section 10, Page 10-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2.
  • Page 69 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 41 – HORN SWITCH See General Warning, Section 10, Page 10-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2. Disconnect the orange and red/white wires at the horn button from the wire harness. 3.

  • Page 71: Section 12 - Electrical Components

    SECTION 12 – ELECTRICAL COMPONENTS ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. STARTER/GENERATOR See General Warning, Section 10, Page 10-1. Testing the Starter/Generator See Section 11, Test Procedure 9 – Starter/Generator (Starter Function) on page 11-23 and Test Pro- cedure 11 –...
  • Page 72 ELECTRICAL COMPONENTS Starter/Generator Starter/Generator Removal, Continued: 4. Remove the mounting/adjustment nut (12), washer (9) and bolt (11). Lower the starter/generator and remove the belt (4) from the pulley (10). 5. Support the starter/generator so that when the pivot bolts are removed the starter/generator will not fall to the ground.
  • Page 73 ELECTRICAL COMPONENTS Starter/Generator STARTER/GENERATOR BRUSH BRUSH HOLDER WEAR LINE Figure 12-4 Inspect Brushes Brush Spring Inspection and Replacement 1. Visually inspect springs. Replace all four springs if any spring is discolored from heat (straw or bluish in color). 2. Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 12-3, Page 12-2).
  • Page 74 ELECTRICAL COMPONENTS Starter/Generator Starter/Generator Assembly 1. Connect the brush wires to the holders using four lock washers (26) and four screws (25), making sure the crossover leads are connected also. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12-3, Page 12-2).
  • Page 75 ELECTRICAL COMPONENTS Starter/Generator Figure 12-7 Armature and Output End Cover Assembly Bearing Cleaning and Inspection 1. Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 12-8, Page 12-5). 2.

  • Page 76: Bearing Removal

    ELECTRICAL COMPONENTS Starter/Generator Bearing Removal 1. Place the wedge attachment tool (CCI P/N 1012812) between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller (CCI P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
  • Page 77 ELECTRICAL COMPONENTS Starter/Generator • Worn, burned, or glazed commutator • Loose or raised commutator bars • Bruised or damaged armature core laminations • Worn armature bearing or shaft • Dirty or oily commutator POLE PIECE SCREW RETAINING NUT POLE PIECE INSULATOR HOUSING FIELD COIL...
  • Page 78 ELECTRICAL COMPONENTS Starter/Generator 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). Measure each position in 2 places, 90 apart.
  • Page 79 ELECTRICAL COMPONENTS Starter/Generator Visual Inspection of Field Coils If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings.
  • Page 80 ELECTRICAL COMPONENTS Starter/Generator Starter/Generator Assembly, Continued: ý CAUTION • To prevent damage to the retainer, use care while pressing new bearing onto the output end of the shaft. • Press against the inner race of the new bearing until it is fully seated. 6.
  • Page 81 ELECTRICAL COMPONENTS Starter/Generator TYPICAL 2 PLACES END VIEW Figure 12-13 Starter/Generator Installation Figure 12-14 Belt Tension Gauge Belt Tension Adjustment Belt tension should be checked periodically. If the belt slips when starter/generator motor operates, adjust belt to correct tension. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1.

  • Page 82: Voltage Regulator

    ELECTRICAL COMPONENTS Voltage Regulator VOLTAGE REGULATOR See General Warning, Section 10, Page 10-1. Testing the Voltage Regulator See Test Procedure 12, Section 11, Page 11-25. Voltage Regulator Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1.

  • Page 83: Key Switch

    ELECTRICAL COMPONENTS Key Switch white wire (2) and blue wire (3) at the small post on the solenoid, the yellow wire (4) at the bullet con- nector, the two black wires (5) and (6) at the (NO) and (COIL) terminals on the relay, and the black wire (7) at the battery frame ground (Figure 12-16, Page 12-12).

  • Page 84: Solenoid

    ELECTRICAL COMPONENTS Solenoid Figure 12-17 Center Dash Panel Removal Key Switch Installation 1. Reverse removal procedures to install key switch in the dash. Connect wires to key switch. See the appropriate wiring diagram in Section 11 – Troubleshooting and Electrical System, starting on page 11-6.
  • Page 85 ELECTRICAL COMPONENTS Solenoid Solenoid Installation 1. Install the solenoid in the electrical component box. Use two screws to secure the solenoid to the box and tighten to 14 in-lb (1.6 N·m). 2. Connect all wires as indicated. See the appropriate wiring diagram in Section 11 – Troubleshooting and Electrical System, starting on page 11-6.

  • Page 86: Fuse

    ELECTRICAL COMPONENTS Fuse Solenoid Installation, Continued: 3. 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). 4. Install the snap-on electrical box cover by pressing down firmly on all corners and install the screw, tight- ening to 18 in-lb (2 N·m).
  • Page 87 ELECTRICAL COMPONENTS Kill Limit Switch 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. 2. Remove electrical component box cover (1) (Figure 12-18, Page 12-17). 3.

  • Page 88: Neutral Lockout Limit Switch

    ELECTRICAL COMPONENTS Neutral Lockout Limit Switch Kill Limit Switch Installation, Continued: 6. 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 89: Neutral Lockout Cam

    ELECTRICAL COMPONENTS Neutral Lockout Cam return to the ON position and the engine should idle. With the Forward/Reverse handle still in the NEU- TRAL position, the engine should shut off when pressing the accelerator pedal. If the engine does not stop, turn the key switch OFF and readjust the shift linkage.
  • Page 90 ELECTRICAL COMPONENTS Reverse Warning Buzzer REVERSE WARNING BUZZER See General Warning, Section 10, Page 10-1. Testing the Reverse Warning Buzzer See Test Procedure 21, Section 11, Page 11-36. Front Reverse Warning Buzzer Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1.

  • Page 91: Reverse Buzzer Limit Switch

    ELECTRICAL COMPONENTS Reverse Buzzer Limit Switch 5. Install the bed or seat. See Section 5 – Body and Trim in the appropriate maintenance and service manual. AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED Figure 12-21 Front Reverse Warning Buzzer Figure 12-22 Rear Reverse Warning Buzzer REVERSE BUZZER LIMIT SWITCH See General Warning, Section 10, Page 10-1.

  • Page 92: Low Oil Warning Light

    ELECTRICAL COMPONENTS Low Oil Warning Light Reverse Buzzer Limit Switch Installation, Continued: 3. Place the Forward/Reverse handle in REVERSE and make sure that both switches actuate. 4. Connect the orange wire to the common (COM) terminal and the red/white wire to the normally open (NO) terminal of the reverse buzzer limit switch (4) (Figure 12-19, Page 12-19).
  • Page 93 ELECTRICAL COMPONENTS Fuel Gauge/Hour Meter The hour meter displays the number of hours of use in increments of 0.1 hour, but does not record additional time unless the engine is running. When the hour meter is recording, the hourglass icon at the left of the field blinks slowly.

  • Page 94: Fuel Level Sending Unit

    ELECTRICAL COMPONENTS Fuel Level Sending Unit FUEL LEVEL SENDING UNIT See General Warning, Section 10, Page 10-1. The fuel level sending unit is an integral part of the fuel tank and should never be removed. Thoroughly test the fuel level sending unit before replacing the fuel tank. Testing the Fuel Level Sending Unit See Test Procedure 26, Section 11, Page 11-38.

  • Page 95: Ignition Coil

    ELECTRICAL COMPONENTS Ignition Coil RPM Limiter Installation 1. Place the RPM limiter damper on the front of the RPM limiter mounting bracket (Figure 12-25, Page 12-24). 2. Place the RPM limiter on the damper squarely so that RPM limiter fits tightly against the damper. 3.

  • Page 96: Ignition Coil Installation

    ELECTRICAL COMPONENTS Ignition Coil Ignition Coil Removal, Continued: Figure 12-26 Stiffener Removal Remove Figure 12-27 Fan Housing Removal Figure 12-28 Ignition Coil Removal Ignition Coil Installation NOTE: If a new ignition coil is being installed, the spark plug cap, gasket, protector tube and grommet must be removed from the old coil and installed on the new coil.
  • Page 97 ELECTRICAL COMPONENTS Ignition Coil SPARK PLUG 0.012 INCH (0.304 mm) Figure 12-29 Spark Plug Wire Figure 12-30 Mount Ignition Coil Using Feeler Gauge 3. Remove the gasket (1) and protector tube (3) from the old coil. See following NOTE. NOTE: Moisten the spark plug wire with water to make gasket removal and installation easier. 4.

  • Page 98: Oil Level Sensor

    ELECTRICAL COMPONENTS Oil Level Sensor Ignition Coil Installation, Continued: 15. Install the stiffener with four hex-head bolts and lock nuts. Tighten the hardware to 23 ft-lb (30.5 N·m). 16. Install the fan shroud with four pan-head bolts (5). Tighten to 50 in-lb (5.7 N·m) (Figure 12-27, Page 12-26).

  • Page 99: Headlights

    ELECTRICAL COMPONENTS Headlights Relay Installation 1. Slide the relay (38) onto the mounting bracket (11) until the relay is locked in place. 2. Connect the wires to the terminals on the relay (Figure 12-31, Page 12-29). 3. Secure the relay and mounting bracket to the electrical component box. Tighten hardware to 22 in-lb (2.5 N·m) (Figure 12-31, Page 12-29).

  • Page 100: Taillights

    ELECTRICAL COMPONENTS Taillights Headlight Bulb Installation NOTE: When handling halogen bulbs, do not touch glass portion of bulb. Oil from finger tips can cause premature failure of bulb. 1. Connect wire harness (4) to the halogen bulb assembly (6). The retaining tab should lock onto the halo- gen bulb assembly (Figure 12-32, Page 12-29).

  • Page 101: Voltage Limiter

    ELECTRICAL COMPONENTS Voltage Limiter Taillight Bulb Installation 1. Align the small pins on the side of the light bulb with the slots in the light socket. Slide the bulb into the socket and turn one quarter-turn clockwise (Figure 12-33, Page 12-30). 2.

  • Page 102: Headlight Switch

    ELECTRICAL COMPONENTS Headlight Switch Voltage Limiter Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2. Remove the center dash panel. See Key Switch Removal on page 12-13. 3.

  • Page 103: Brake Light Relay

    ELECTRICAL COMPONENTS Brake Light Relay 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. BRAKE LIGHT RELAY See General Warning, Section 10, Page 10-1.

  • Page 104: Park Brake Limit Switch

    ELECTRICAL COMPONENTS Park Brake Limit Switch Brake Light Relay Installation, Continued: 3. Connect the two brake light wires to the COM (common) and NO (normally open) terminals of the brake light relay. 4. Install the front body. See Front Body Installation in Section 4 of the appropriate maintenance and service manual.

  • Page 105: Brake Pedal Limit Switch

    ELECTRICAL COMPONENTS Brake Pedal Limit Switch 2. Connect the 16-gauge orange/white wire to the NC terminal and the 16-gauge brown wire to the COM terminal. Tighten the screws to 10 in-lb (1.1 N·m). 3. Install pad to brake pedal, tightening the screws until the pad is secure. 4.

  • Page 106: Horn

    ELECTRICAL COMPONENTS Horn HORN See General Warning, Section 10, Page 10-1. Testing the Horn See Test Procedure 40, Section 11, Page 11-52. Horn Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2.

  • Page 107: Battery

    ELECTRICAL COMPONENTS Battery FLAT WASHER FLOORBOARD HEX HEAD BOLT NYLON LOCK NUT Figure 12-42 Horn Assembly Figure 12-43 Horn Switch Assembly Horn Switch Installation 1. Install the jam nut (3) until it makes contact with the body of the horn switch. 2.
  • Page 108 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 109 ELECTRICAL COMPONENTS Battery BATTERY CAP PLATES WATER LEVEL AT LEAST 1/2 INCH (13 MM) ABOVE PLATES OR TO LEVEL INDICATOR Figure 12-44 Battery Water Level Vibration Damage The battery hold-down clamp should always be tight enough to keep the battery from bouncing. Battery life may be severely shortened if the clamp is too loose.
  • Page 110 ELECTRICAL COMPONENTS Battery Battery Removal See General Warning, Section 10, Page 10-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2. Remove the battery hold-down clamp from the battery. 3.

  • Page 111: Ground Cables

    ELECTRICAL COMPONENTS Ground cables Battery Storage See General Warning, Section 10, Page 10-1. See also DANGER on page 12-37. 1. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 12-38. 2. The battery cables should be disconnected from the battery so the battery can be connected to the charger.

  • Page 113: Section 13 - Fe350 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 114 FE350 ENGINE General Information Spark Plug Removal See General Warning, Section 10, Page 10-1. ý CAUTION • Before removal and disassembly, clean the engine. Remove all dirt from plug base in the cylinder head before removing plug. Use a 13/16-inch deep well socket wrench or 13/16-inch spark plug wrench to loosen the plug.

  • Page 115: Cylinder Head

    FE350 ENGINE Cylinder Head Setting the Spark Gap 1. Before setting the spark gap on a used plug, pass a contact point file between the electrodes to produce flat, parallel surfaces to facilitate accurate gauging. 2. Use a wire type gauge. Bend the outside or ground electrode so only a slight drag on the gauge is felt when passing it between the electrode.

  • Page 116: Crankcase

    FE350 ENGINE Crankcase CRANKCASE See General Warning, Section 10, Page 10-1. ENGINE REMOVAL To perform repairs on crankcase components, the engine must be removed from the vehicle. ý CAUTION • Before removal and disassembly, clean the engine. 1. Remove the powertrain. See Unitized Transaxle Removal, Section 16, Page 16-7. See following NOTE.
  • Page 117 FE350 ENGINE Crankcase TYPICAL TYPICAL 4 PLACES 2 PLACES TYPICAL 2 PLACES Figure 13-2 Engine Mounting Plate STARTER/ GENERATOR Figure 13-3 Oil Level Sensor Wire Figure 13-4 Crankcase Cover 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page 13-5...

  • Page 118: Oil Level Sensor

    FE350 ENGINE Crankcase OIL LEVEL SENSOR Testing the Oil Level Sensor See Test Procedure 23, Section 11, Page 11-37. Oil Level Sensor Removal 1. If not already removed, remove crankcase cover. See Crankcase Cover Removal on page 13-4. 2. Disconnect the oil level sensor wire (2) from the cord connection (1) (Figure 13-5, Page 13-6). 3.

  • Page 119: Ignition Coil And Flywheel

    FE350 ENGINE Ignition Coil and Flywheel 2. Install crankcase cover. Using HANDS ONLY, seat cover completely against the crankcase. If the cover will not seat, the camshaft is not installed correctly. 3. Install and finger tighten evenly the eight cover mounting bolts (Figure 13-7, Page 13-7). 4.
  • Page 120 FE350 ENGINE Ignition Coil and Flywheel Ignition Coil and Flywheel Removal, Continued: 3. Hold the flywheel (4), not the fan (7), with a strap wrench (5) and, using a 25 mm socket, remove the fly- wheel nut (and flat washer) by turning it counterclockwise (Figure 13-10, Page 13-8). See following CAUTION.

  • Page 121: Flywheel Installation

    FE350 ENGINE Flywheel Installation FLYWHEEL INSTALLATION 1. Insert the flywheel key into the keyway in the crankshaft. Then align the keyway in the flywheel to the key and push the flywheel and fan assembly onto the crankshaft until it seats. Install flat washer and nut fin- ger tight.
  • Page 122 FE350 ENGINE Engine Installation Engine Installation, Continued: 7. Install oil drain plug in the crankcase and tighten to 20 ft-lb (27.1 N·m). Apply a light film of oil on the seal of a new oil filter and install the filter on the crankcase. Fill the crankcase to the proper level with the cor- rect type of oil.

  • Page 123: Torque Specifications

    FE350 ENGINE Engine Installation TORQUE SPECIFICATIONS ITEM SIZE LIMITS Flywheel retaining nut 100 ft-lb (135 N·m) Crankcase cover to block bolts 22 ft-lb (31 N·m) Starter/Generator 16.5 ft-lb (23 N·m) bracket to block bolts Oil drain plug 16.5 ft-lb (23 N·m) Fan housing screws 90 in-lb (10 N·m) Fan shroud screws...

  • Page 125: Section 14 - Fuel System

    SECTION 14 – FUEL SYSTEM ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. GENERAL INFORMATION The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The car- buretor atomizes the fuel, mixes it with air, and feeds the combustible mixture into the cylinder.

  • Page 126: Main Jet Elevation/Size Chart

    FUEL SYSTEM Carburetor MAIN JET ELEVATION/SIZE CHART FE350 ENGINE ALTITUDE MAIN JET SIZE 0-3000 ft. (0-914.4 m) 3000-5000 ft. (914.4-1524 m) 5000-8000 ft. (1524-2438.4 m) 8000-10,000 ft. (2438.4-3048 m) 10,000 ft. and over (3048 m and over) CHANGING THE MAIN JET See General Warning, Section 10, Page 10-1.
  • Page 127 FUEL SYSTEM Carburetor NOTE: Make sure the fuel bowl gasket (9) remains properly seated in the carburetor body when the fuel bowl is removed (Figure 14-2, Page 14-4). During normal operation, the fuel bowl retains the float pivot pin (6). Make sure that the float pivot pin does not fall out of the carburetor body after the fuel bowl is removed.
  • Page 128 FUEL SYSTEM Carburetor Changing the Main Jet, Continued: 6. Remove the main jet (8) from the carburetor body and discard it (Figure 14-2, Page 14-4). NOTE: Make sure the fuel nozzle (7) does not fall out of the carburetor body after removal of the main jet. This is best accomplished by positioning the carburetor upside down during main jet removal (Figure 14-2, Page 14-4).

  • Page 129: Engine Control Linkage

    FUEL SYSTEM Engine Control Linkage NOTE: Inspect the main jet nozzle (7), and pilot jet (4) to ensure they are free from contamination. Replace any part that is clogged with contamination. Replace the float if it is damaged, or if the float valve is damaged or worn.

  • Page 130: Accelerator Rod

    FUEL SYSTEM Engine Control Linkage ACCELERATOR ROD ý DANGER • To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push rod, do the following: • Turn key switch OFF and remove key, place Forward/Reverse handle in the NEUTRAL position, and chock wheels prior to servicing the vehicle.
  • Page 131 FUEL SYSTEM Engine Control Linkage ý CAUTION • Be sure that approximately an equal number of threads are exposed at each end of the accelerator rod. 6. Install the accelerator rod on the bell crank ball joint on the electrical component box (Figure 14-5, Page 14-7).

  • Page 132: Governor Cable

    FUEL SYSTEM Engine Control Linkage Accelerator Rod Installation and Adjustment, Continued: 10. Check rod adjustment for proper switch activation. 11. After the pedal group and accelerator rod are properly adjusted, adjust the engine RPM setting. See Engine RPM Adjustment on page 14-11. 12.

  • Page 133: Accelerator Cable

    FUEL SYSTEM Engine Control Linkage TYPICAL 2 PLACES CARBURETOR THROTTLE Figure 14-6 Governor and Accelerator Cables ACCELERATOR CABLE Accelerator Cable Removal 1. Access the engine compartment. 2. Remove the electrical box screw and cover and loosen the cable housing retaining nuts (Figure 14-4, Page 14-7).

  • Page 134: Closed Throttle Or Idle Adjustment

    FUEL SYSTEM Engine Control Linkage Accelerator Cable Installation 1. Connect the cable to the cam (17) in the electrical box (Figure 14-6, Page 14-9). 2. Insert the cable housing into the mounting slot in the wall of the electrical box, with approximately the same number of threads visible between the jam nuts as are visible from the nut inside the box to the end of the cable housing (Figure 14-4, Page 14-7).

  • Page 135: Engine Rpm Adjustment

    FUEL SYSTEM Engine Control Linkage ENGINE RPM ADJUSTMENT ý DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 1. If the governor is adjusted, proceed to step 2; otherwise, adjust the governor. See Governor Cable Installation and Adjustment on page 14-8.

  • Page 136: General Information

    FUEL SYSTEM Choke and Air Intake System CHOKE AND AIR INTAKE SYSTEM See General Warning, Section 10, Page 10-1. GENERAL INFORMATION The choke system is a simple mechanism requiring very little or no maintenance. The system consists of a choke assembly that is attached to the driver side of the front body, an air filter housing with a hose that is attached to the carburetor, and an air duct that provides the engine with air from outside the engine compart- ment.
  • Page 137 FUEL SYSTEM Choke and Air Intake System REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 14-8 Turf 2, Carryall 2 and Carryall 2 Plus Air Intake and Choke Assemblies 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page 14-13...
  • Page 138 FUEL SYSTEM Choke and Air Intake System REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 14-9 Turf 6, Carryall 6, TransPorter, and Villager Air Intake and Choke Assemblies Page 14-14 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 139: Air Box Removal

    FUEL SYSTEM Choke and Air Intake System AIR BOX REMOVAL 1. Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1.

  • Page 140: Intake Duct Installation

    FUEL SYSTEM Choke and Air Intake System Turf 6, Carryall 6, TransPorter and Villager: 1. Remove three screws (23) and flat washers (22) from the bottom of the air box assembly (Figure 14-9, Page 14-14). 2. Lift air box assembly off the intake duct. Be careful that the intake seal on the bottom of the air box assembly is not dislodged in the process.

  • Page 141: Intake Duct Repair

    FUEL SYSTEM Choke and Air Intake System 5.1. Position steering joint assembly (1) on vehicle as shown. Install three lock washers and three bolts and tighten to 15 ft-lb (20.3 N·m) (Figure 14-10, Page 14-16). 5.2. Align the flat portion of the steering shaft spline with the bolt hole in the universal joint and then slide the shaft into the upper universal joint.

  • Page 142: Fuel Filters

    • 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 143 FUEL SYSTEM Fuel Filters NO. 6 FUEL TANK VENT TUBE TYPICAL 2 PLACES NO. 2 FUEL LINE NO. 1 FUEL LINE NO. 3 FUEL LINE NO. 5 CARBURETOR AIR VENT TUBE NO. 7 NO. 4 IMPULSE FUEL LINE LINE LENGTH LENGTH FUEL (Turf 2,CA 2, CA 2 Plus)

  • Page 144: Fuel Pump

    FUEL SYSTEM Fuel Pump Fuel Filter Installation, Continued: 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 145: Fuel Pump Disassembly

    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 146: Fuel Pump Assembly

    FUEL SYSTEM Fuel Pump FUEL PUMP ASSEMBLY 1. Install the fuel gasket (35) and diaphragm (34) on the back cover (36) (Figure 14-12, Page 14-21). 2. Install the valve assembly in the pumping chamber (30). See following CAUTION. ý CAUTION •...

  • Page 147: Fuel Tank

    FUEL SYSTEM Fuel Tank FUEL TANK See General Warning, Section 10, Page 10-1. GENERAL INFORMATION The vehicle is equipped with a high impact plastic, seven gallon (26.5 liter) fuel tank. ý WARNING • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure.

  • Page 148: Fuel Tank Disposal

    FUEL SYSTEM Fuel Tank Fuel Tank Removal, Continued: ý WARNING • Make sure the key switch is OFF before disconnecting wiring. 10. Remove the vent tube (6) and fuel line (1) from the fuel tank (Figure 14-11, Page 14-19). 11. Loosen the straps (13 and 18) by removing the screws (12) from the speed nuts (11). 12.

  • Page 149: Fuel Tank Installation

    FUEL SYSTEM Fuel Tank 4. Store the tank upside down, with the cap installed, in a well-ventilated area. VENT SHUT-OFF VALVE TO CARBURETOR VENT TUBES Figure 14-15 Fuel Tank FUEL TANK INSTALLATION 1. With the retaining straps correctly positioned, install the fuel tank in the vehicle. 2.

  • Page 150: Fuel Lines

    FUEL SYSTEM Fuel Lines Fuel Tank Installation, Continued: 11. Check to be sure the fuel shut-off valve on top of the fuel tank is in the open (ON) position (Figure 14-17, Page 14-27 and Figure 14-18, Page 14-27). 12. Turn the key switch to the ON position and press the accelerator pedal to start the engine. See following DANGER.
  • Page 151 FUEL SYSTEM Fuel Shut-Off Valve FUEL SHUT-OFF VALVE See General Warning, Section 10, Page 10-1. The fuel shut-off valve is located on top of the fuel tank (Figure 14-15, Page 14-25). The fuel shut-off valve should always be turned to the closed (OFF) position during vehicle storage, towing or trailering (Figure 14-16, Page 14-27).

  • Page 153: Section 15 - Exhaust System

    SECTION 15 – EXHAUST SYSTEM ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. MUFFLER MUFFLER REMOVAL 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1.
  • Page 154 EXHAUST SYSTEM Muffler Muffler Installation, Continued: 9. 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 10.

  • Page 155: 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 156: Lubrication

    UNITIZED TRANSAXLE General Information Governor System The governor system regulates vehicle ground speed. It is mounted inside the unitized transaxle and is driven by transaxle gears. If any of the governor linkages are removed in order to service other components, read- justment of the governor linkage is required.

  • Page 157: Axle Shaft

    UNITIZED TRANSAXLE Axle Shaft AXLE SHAFT See General Warning, Section 10, Page 10-1. Removal of the unitized transaxle is not required for servicing or replacing axle shafts, axle bearings, or axle shaft oil seals. If the unitized transaxle is to be removed from the vehicle, then do not remove the wheels, axle shafts, or axle tubes first.

  • Page 158: Axle Bearing

    UNITIZED TRANSAXLE Axle Shaft Axle Shaft and Oil Seal Removal, Continued: 8. Position a 16-inch (40 cm) rolling head prybar (Figure 16-4, Page 16-4) under the inside lip of the seal and pull oil seal out (Figure 16-5, Page 16-4). See following CAUTION. ý...
  • Page 159 UNITIZED TRANSAXLE Axle Shaft REFERENCE PASSENGER SIDE CASE REFERENCE DRIVER SIDE CASE Figure 16-6 Differential Gear Case/Axle Tubes 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page 16-5...

  • Page 160: Axle Shaft Installation

    UNITIZED TRANSAXLE Axle Shaft Axle Bearing Installation 1. Ensure that the retaining ring (70) is loosely placed on the axle shaft. See preceding NOTE. 2. Install a new axle bearing (71) on axle (67 or 68). Push bearing onto axle until bearing is flush against axle shoulder (Figure 16-6, Page 16-5).

  • Page 161: Unitized Transaxle Removal

    UNITIZED TRANSAXLE Unitized Transaxle Removal 5. Place a 1/4 to 3/8-inch (6-10 mm) diameter rod against the retaining ring and tap lightly at four to five locations to ensure it is properly seated. See following WARNING. ý WARNING • Be sure bearing retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components.
  • Page 162 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal, Continued: 4. Detach all wires, hoses, etc. connecting the powertrain to the vehicle. 4.1. Disconnect the carburetor vent tube from the carburetor (Figure 16-9, Page 16-8). 4.2. Disconnect the air intake hose from the carburetor (Figure 16-10, Page 16-8). VENT TUBE Figure 16-9 Fuel Vent Tube Figure 16-10 Air Intake Hose...
  • Page 163 UNITIZED TRANSAXLE Unitized Transaxle Removal 4.5. Remove the cover from the electrical component box. Then loosen the hardware securing the accelerator cable to the box. Disconnect the cable from the actuator cam and remove it from the box (Figure 16-13, Page 16-9). 4.6.
  • Page 164 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal, Continued: 4.9. Disconnect the engine oil level sensor wire (18-gauge yellow) at the connector just to the rear of the starter/generator) (Figure 16-17, Page 16-10). 4.10. Disconnect the engine kill switch wire (18-gauge white/black) from the bullet connector at the lower right front of the engine (Figure 16-18, Page 16-10).
  • Page 165 UNITIZED TRANSAXLE Unitized Transaxle Removal 6. Remove the lower shock mounting hardware from both rear shocks (Figure 16-20, Page 16-11). 7. If equipped with a stabilizer bar, remove the two belts securing the stabilizer bar to the stabilizer bar links. See Section 9 –...
  • Page 166 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal, Continued: 11. Continue raising vehicle until frame or trailer hitch is higher than the top of the unitized transmission (enough to allow transaxle and engine to be rolled under and out of vehicle) (Figure 16-24, Page 16-12). 12.
  • Page 167 UNITIZED TRANSAXLE Unitized Transaxle Removal 16. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor (Figure 16-28, Page 16-13). See following NOTE. NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from the engine.
  • Page 168 UNITIZED TRANSAXLE Unitized Transaxle Removal 20. Remove screws (1) securing the governor cable bracket to transaxle (Figure 16-32, Page 16-14). 21. Remove screws (1) securing the accelerator cable bracket to transaxle (Figure 16-33, Page 16-14). BRACKET Figure 16-32 Governor Cable Bracket Figure 16-33 Accelerator Cable Bracket 22.
  • Page 169 UNITIZED TRANSAXLE Unitized Transaxle Removal REFERENCE FORWARD/ REVERSE SHIFTER Figure 16-35 Transaxle Gear Casing and Brackets 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page 16-15...

  • Page 170: Unitized Transaxle Installation

    UNITIZED TRANSAXLE Unitized Transaxle Installation UNITIZED TRANSAXLE INSTALLATION See General Warning, Section 10, Page 10-1. 1. Install the wheels. See Wheel Installation, Section 8 – Wheels and Tires, in the appropriate main- tenance and service manual. 2. Install the leaf springs. See Leaf Spring Installation, Section 9 – Rear Suspension, in the appropri- ate maintenance and service manual.
  • Page 171 UNITIZED TRANSAXLE Unitized Transaxle Installation 13. Remove the blocks from under the engine and roll the powertrain into position under the vehicle. Then lift the front of the powertrain and place the snubber into the snubber bracket in the vehicle frame (Figure 16-39, Page 16-17).
  • Page 172 UNITIZED TRANSAXLE Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 17. If equipped with a stabilizer bar, use the floor jack to position the powertrain, and install the stabilizer bar. See Section 9 – Rear Suspension in the appropriate maintenance and service manual. 18.
  • Page 173 UNITIZED TRANSAXLE Unitized Transaxle Installation 24. Connect the Forward/Reverse shifter and bracket to the transaxle. 24.1. Install the three screws (2) securing the Forward/Reverse shifter cable bracket (1) to the transaxle and tighten them to 135 in-lb (15.3 N·m) (Figure 16-35, Page 16-15). 24.2.
  • Page 174 UNITIZED TRANSAXLE Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 29. Connect the impulse line to the fuel pump and secure it with the hose clamp (Figure 16-50, Page 16-20). 30. Connect air intake hose to carburetor and secure hose clamp (Figure 16-51, Page 16-20). IMPULSE LINE Figure 16-50 Impulse Line Figure 16-51 Air Intake Hose...

  • Page 175: Forward/Reverse Shifter Cable

    UNITIZED TRANSAXLE Forward/Reverse Shifter Cable ý WARNING • If wires are removed or replaced, make sure wiring and wire harness are properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death. 35.
  • Page 176 UNITIZED TRANSAXLE Forward/Reverse Shifter Cable Forward/Reverse Shifter Cable Installation, Continued: 5. Install the ball joint socket (2) on the Forward/Reverse shifter assembly ball stud (3) (Figure 16-53, Page 16-22). See following NOTE. 6. Install wire tie (8) to secure wire harness to cable at the support bracket near the Forward/Reverse shifter assembly.

  • Page 177: Forward/Reverse Shifter Cable Adjustment

    UNITIZED TRANSAXLE Forward/Reverse Shifter Cable FORWARD/REVERSE SHIFTER CABLE ADJUSTMENT With the shifter lever of the unitized transaxle in the NEUTRAL position (Figure 16-54, Page 16-23), the For- ward/Reverse handle (9) (Figure 16-53, Page 16-22) should be straight up. For minor adjustments, the nut (1) may be loosened and the ball joint socket (2) rotated to get the proper adjustment (Figure 16-53, Page 16-22).

  • Page 179: 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 180: 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 181: 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 182: Drive Clutch Removal

    1. Remove the drive belt as instructed. See Drive Belt Removal on page 17-3. 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 10-2. Use Club Car clutch holder while tightening or loosening drive VEHICLE BODY clutch retaining bolt.

  • Page 183: 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 vehicle frame at the front spring mounts. This will allow the centerline of the drive clutch to drop below the frame I-beam for access to the bolt securing the drive clutch.
  • Page 184 TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES Figure 17-5 Drive Clutch Assembly Page 17-6 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement...

  • Page 185: 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 186 TORQUE CONVERTER Drive Clutch Remove these 1/4-20 BOLT items from ribs: FLAT WASHER 10-24 MACHINE SCREW FLAT WASHER WEIGHT DRIVE BUTTON DRIVE BUTTON TAKE UP SPRING WEIGHT SLOTS IN HUB RIBS CASTING Figure 17-8 Drive Button Mounting Figure 17-9 Weight Position 5.

  • Page 187: 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 188: 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 189 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 190: 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 191: 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 192 TORQUE CONVERTER Driven Clutch TYPICAL 3 PLACES Figure 17-18 Driven Clutch Assembly Page 17-14 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 193 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 194: 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 195 INDEX breather valve (reed valve) ........13-3 accelerator cable carburetor ............14-1 installation ..........14-10 closed throttle or idle adjustment ....14-10 removal ............14-9 jet, main ............14-2 pedal limit switch elevation/size chart ........14-2 testing ............11-20 choke and air intake system ......14-12 choke cable installation and adjustment ......14-6 installation ............14-12 removal ............14-6 removal ............14-12...
  • Page 196 INDEX removal ............13-4 ground cable testing ........11-18 rotation ............. 13-1 RPM adjustment ..........14-11 headlight bulb engine oil ............10-6 installation ............12-30 removal ............12-29 headlight switch flywheel installation ............12-32 installation ............13-8 removal ............12-32 removal ............
  • Page 197 INDEX starter circuit testing (pedal-start) ....11-19 removal ............12-34 kill circuit, engine park brake pedal limit switch testing ..........11-26, 11-35 testing ............11-51 kill limit switch periodic lubrication schedule ......10-5 periodic service schedule ........10-3 installation ............12-17 removal ............12-17 kill limit switch, engine testing ............11-34 reed valve see breather valve...
  • Page 198 INDEX specifications 11 – starter/generator ........11-25 torque ............13-11 12 – voltage regulator ........11-25 starter/generator 13 – engine kill circuit ........11-26 armature 14 – ignition test ..........11-27 ground test ..........12-8 15 – RPM limiter ..........11-28 inspection ............
  • Page 199 INDEX testing ............11-48 voltage regulator installation ............12-12 removal ............12-12 testing ............11-25 wire continuity testing ........11-24 wiring diagram ............11-6 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement Page i-5...
  • Page 201 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement...
  • Page 204 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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