Engine Installation - Club Car 2007 Carryall 295 Maintenance And Service Manual

HONDA GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Figure 13b-1 Engine Mounting Bolts

ENGINE INSTALLATION

See General Warning, Section 1, Page 1-1.
1. Before a new engine is installed, the following components must be installed:
• Exhaust Manifold (new gaskets required) – Tighten the hardware to 21 ft-lb (28 N·m)
• Oil Filter Adapter (new o-rings required)
• Carburetor Spring
• Governor Wire
• Engine Governor Cable Bracket
• Engine Governor Arm
• Carburetor Adapter (new gasket required) – Tighten the hardware to 78 in-lb (9 N·m)
2. Lower the engine into the engine compartment and closely align the base mount with holes in the engine
plate.
2.1. Remove the engine cover plate lift tab and bolt.
3. Secure the engine oil inlet and outlet hoses to the engine ports with new clamps. See Oil Filter Hose
Installation on page 13b-16.
4. Loosely install new flange-head bolts and flange-head locknuts on the engine base slotted mounts. See
following NOTE.
NOTE: Engine block bolts will be tightened after the engine and transmission are aligned, the clutch inner
cover is installed, and the cover bolts are tightened to maintain the alignment.
5. Connect all electrical connections. See Figure 11b-1, Section 11b, Page 11b-6.
5.1. Connect the two ground wires on the frame to the starter case.
5.2. Connect the two female bullet connectors to the charge coil.
5.3. Connect the female bullet connector to the fuel solenoid.
5.4. Connect the male bullet connector to the engine kill circuit.
5.5. Connect all wires attached to the two terminal posts on the starter solenoid.
6. Use new gaskets and install the exhaust manifold. Tighten the hardware to 21 ft-lb (28 N·m).
7. Install the clutch inner cover. See Clutch Inner Cover Installation on page 13b-40.
2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
13B
Gasoline Engine
Page 13b-3