Intake Duct Repair; Air Filter - Club Car FE350 2005 Maintenance Service Supplement

FUEL 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. Install the bolt and lock washer on the upper universal joint
and tighten to 15 ft-lb (20 N·m).
6. Install front left wheel. Tighten the wheel rim mounting nuts to 55 ft-lb (75 N·m).
7. Install front body.
8. Check for proper operation.
Turf 6, Carryall 6, TransPorter and Villager:
1. Remove front seat and insert air duct through the hole in the floorboard under the seat.
2. Guide air duct into the hole at the front of the air box assembly mounting plate. Position air duct so the
air box will fit correctly onto the air duct.
3. Install two pop rivets (25) and four flat washers (26) to secure air duct retaining bracket (27) around air
duct as shown (Figure 14-9, Page 14-14).
4. Install air box assembly. See Air Box Installation on page 14-15.

INTAKE DUCT REPAIR

If the air intake duct has a crack of 1/16 inch (1.5 mm) or less, and does not exceed 11 inches (27.5 cm) in
length, or has a round shaped hole no greater than 1/2 inch (13 mm) in diameter, it may be repairable with an
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.

AIR FILTER

General Information
The air filter should be checked every year or 100 hours. More frequent service may be required in extremely
dirty operating environments. Need for immediate servicing will be indicated by a loss of power, sluggish
acceleration, or an engine which runs roughly with excessive black exhaust smoke.
Air Filter Replacement
1. Lift two latches (3) on the side of the air box (Figure 14-8, Page 14-13 or Figure 14-9, Page 14-14).
2. Remove the hose clamp (15) from the air hose and remove hose from the air box assembly.
3. Standing on driver side of vehicle, grasp air hose mounting inlet and open box fully. Remove filter ele-
ment (12).
4. Using a clean cloth, wipe away any dust or dirt from inside the air box. Remove all dirt build-up around
the inside lip of the box or the box will not seal properly.
5. Install new air filter by inserting back edge first, and pushing down using the palm of your hand to seat
filter evenly onto inside lip of air box. Ensure filter fits correctly and that the wire latches are not caught
between lid and air box. Close the lid.
6. Fasten wire latches (3). Make sure latches securely engage the bottom half of the box. See following
CAUTION.
2005 FE350 Gasoline Vehicle Maintenance and Service Supplement
Choke and Air Intake System
Page 14-17
14