Club Car EX40D Service, Repair, And Rebuild Manual
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Club Car EX40D Service, Repair, And Rebuild Manual

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EX40 EFI Engine
Service, Repair, and
Rebuild Manual
Manual Number 105062943
Edition Code 0114A00000

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Summary of Contents for Club Car EX40D

  • Page 1 EX40 EFI Engine Service, Repair, and Rebuild Manual Manual Number 105062943 Edition Code 0114A00000...

  • Page 3: Table Of Contents

    CONTENTS Section Title Page 1. SPECIFICATIONS..........1 2.

  • Page 5: Specifications

    1. SPECIFICATIONS Model EX40D Air-Cooled, 4-Cycle, Slant Single-Cylinder, Type Horizontal P.T.O. Shaft, OHC Gasoline Engine 89 × 65 (3 .50 × 2 .56) Bore & Stroke mm (in.) 404 (24 .65) Piston Displacement ml (cu.in.) 8 .3 Compression Ratio per SAE J 1940 10 .4 (14)/3600...

  • Page 6: General Description Of Engine Components

    2. GENERAL DESCRIPTION OF ENGINE COMPONENTS 2-1 CYLINDER AND CRANKCASE The cylinder and crankcase are aluminum die-casting as a single piece . A special cast iron cylinder liner is molded into the aluminum die-casting . The crankcase has a mounting surface on the output shaft side to which the main bearing cover is attached .
  • Page 7 2-5 PISTON RINGS The piston rings are made of special cast iron . The profile of the top ring is a tapered face . The oil ring is designed for better sealing and less oil consumption, in combination with 3 pieces . BARREL RING TAPER...
  • Page 8 2-8 CYLINDER HEAD The cylinder head is on aluminum die-casting with a dome-shaped combustion chamber . The intake and exhaust ports are arranged in a cross direction to improve combustion efficiency . Fig .2-8 2-9 COOLING SYSTEM The engine uses a forced air-cooling system in which a synthetic resin cooling fan (which is separate from the flywheel), reduce noise and forces cooling air into the cylinder and cylinder head .
  • Page 9 2-12 IGNITION SYSTEM FLYWHEEL The ignition system is a flywheel magneto digital C .D .I . system . The magneto consists of a flywheel and ignition coil . The flywheel (cooling fan is separete from the flywheel) is directly mounted on the crankshaft and the ignition coil is directly mounted on the crankcase .

  • Page 10: Disassembly And Reassembly

    3. DISASSEMBLY AND REASSEMBLY 3-1 PREPARATIONS AND PRECAUTIONS (1) When disassembling the engine, memorize the location of each part so that you can reassemble the engine correctly . If necessary, attach identification tags with the required assembly information to the parts . (2) Store groups of parts in separate boxes .

  • Page 11: Disassembly Procedure

    3-3 DISASSEMBLY PROCEDURE Step Parts to remove Remarks and procedures Fasteners Drain the engine oill Remove a drain plug (M14 x 12mm) located on both 14 mm spanner sides of the case . Take care not to lose the gaskets . * To discharge oil quickly, remove the oil guage(M22) .
  • Page 12 Step Parts to remove Remarks and procedures Fasteners Blower housing (1) Remove the blower housing (synthetic resin) from 10 mm box spanner the crankcase . M6 x 16 mm : 5 pcs . M6 x 16 BOLT : 5 pcs. BLOWER HOUSING Fig .3-3 - 8 -...
  • Page 13 Step Parts to remove Remarks and procedures Fasteners Throttle body, Insulator Remove the carburetor from the cylinder head . Remove the insulator & operation bracket . ADAPTER (AIR INTAKE) GASKET INSULATOR GASKET THROTTLE BODY GASKET Fig .3-4 - 9 -...
  • Page 14 Step Parts to remove Remarks and procedures Fasteners Ignition coil Remove the spark plug cap from the spark plug and 10 mm box spanner remove the ignition coil from the crankcase . M6 x 25 mm ： 2 pcs . Washer Remove the starting pulley and cooling Blower from the 24 mm box spanner or...
  • Page 15 Step Parts to remove Remarks and procedures Fasteners Baffle 1 (Case) Remove the Baffle 1 from the crankcase . 12 mm box spanner M8 x 12 mm : 1 pc . M8 x 12 BAFFLE 1 (CASE) BOLT : 1 pc. Fig .3-8 - 11 -...
  • Page 16 Step Parts to remove Remarks and procedures Fasteners Wire clamp Disconnect the wire clamp . 10 mm box spanner M6 x 10 mm : 1 pc . NOTE: Disconnect the wire clamp in this step, also an engine which has the oil sensor . However, please make sure do not damaged (cut off) the oil sensor wire after disassembly procedure .
  • Page 17 Step Parts to remove Remarks and procedures Fasteners Rocker cover (1) Remove the rocker cover from the cylinder head . 10 mm box spanner (2) Remove the gasket (rocker cover) . M6 x 12mm : 4 pcs . Rocker arm Remove the pin (rocker arm) and the rocker arm from the cylinder head at the compression top dead center .
  • Page 18 Step Parts to remove Remarks and procedures Fasteners Main bearing cover Remove the flange bolts of main bearing cover from 12 mm box spanner the crankcase . M8 x 38mm : 8 pcs . Remove the main bearing cover while tapping gently around the cover using a plastic hammer or similar tool .
  • Page 19 Step Parts to remove Remarks and procedures Fasteners Tensioner, Camshaft (1) Remove the tensioner . (See Fig . 3-16) 10mm box spanner or Do not lose the pin (tensioner) . spanner (2) Remove the retaining bolt of pin (camshaft) from M6 x 12mm : 1 pc .
  • Page 20 Step Parts to remove Remarks and procedures Fasteners Cylinder head, (1) Remove the cylinder head from the crankcase . 12 mm box spanner Chain guide (2) Remove the cylinder head gasket from the cylinder head . M10 × 75mm : 4 pcs . Take care not to lose the dowel pin .
  • Page 21 Step Parts to remove Remarks and procedures Fasteners Connecting rod and piston (1) Scrape off any carbon from the cylinder and the 12 mm box spanner piston head, then remove the connecting rod bolt . M8 x 40mm : 2 pcs . (2) Remove the connecting rod cap .
  • Page 22 Step Parts to remove Remarks and procedures Fasteners Crankshaft (1) Remove the woodruff key (for the flywheel magneto) . (2) Remove the crankshaft from the crankcase Plastic hammer by tapping its magneto side end with a plastic hammer, taking care not to damage the oil seal . (See Fig .

  • Page 23: Reassembly Procedure

    3-4 REASSEMBLY PROCEDURE 3-4-1 NOTES ON REASSEMBLY (1) Clean the each parts carefully, taking special care with the piston, cylinder, crankshaft, connecting rod and bearings . (2) Scrape off any carbon deposits on the cylinder head and the piston head . Be particularly careful when removing carbon from the piston ring grooves .
  • Page 24 (3) PISTON AND PISTON RINGS OPEN ENDS OF PISTON RING (a) Install each piston ring in the correct groove of the piston by widening it enough to slide it over the piston . NOTE: Be careful not to twist the rings too much, as they may be damaged .
  • Page 25 (4) PISTON AND CONNECTING ROD The piston is attached to the connecting rod by the piston pin . When assembling the piston and connecting rod, make sure to align the mark on the piston head with the ‘MAG’ mark on the connecting When assembling the rod .
  • Page 26 (b) Rotate the crankshaft down to the bottom dead center and lightly tap the piston head until the large end of the connecting rod touches the crank pin . (c) To mount the connecting rod, line up the matching marks and fit the clinch portions firmly together . ALIGNMENT ALIGNMENT MARKS...
  • Page 27 (7) CHAIN GUIDE Mount the chain guide to the crankcase . CHAIN GUIDE Models EX40 mounting positions Fig .3-36 Fig .3-37 (8) CYLINDER HEAD Inspect and repair any scratches on mounting surface and replace head gasket to new one before installing. Tightening Torque step step Cylinder head bolts Remarks 29 .0 - 31 .0 N ・ m (290 - 310 kgf ・...
  • Page 28 (9) SETTING THE TIMING CHAIN (a) Align the timing mark on the crankshaft sprocket with the mark plate of the timing chain. (b) A lign the timing mark on the camshaft sprocket with the mark plate of the opposite end of the timing chain. Number of oval steel link : 112 CHAIN GUIDE FITTING POSITION MARK PLATE The mark plate does not have a camshaft side or crankshaft sprocket side. TIMING MARK ROLL PIN CRANKSHAFT SPROCKET CAMSHAFT SPROCKET TIMING MARK TIMING MARK...
  • Page 29 (11) MOUNTING THE TENSIONER (TENSIONER) SPRING PIN (TENSIONER) (TENSIONER) TENSIONER Fig .3-41 Fig .3-42 (12) BALANCER SHAFT TIMING MARK for BALANCER GEAR Mount the balancer shaft on the crankcase, align the timing marks on the balancer gear BALANCER GEAR and the crankshaft gear. NOTE: I ncorrect alignment of the timing marks can result in malfunction of the engine, leading to damage due to interference of the parts. TIMING MARK for CHAIN Fig .3-43 - 25 -...
  • Page 30 (13) MAIN BEARING COVER Apply oil to the bearing and the oil seal lip when mounting the main bearing cover . Also apply sealant (Three Bond “1215”) to the surface of the crankcase . To avoid damaging the oil seal lip, wrap the crankshaft key-way portion with polyvinyl tape before mounting the main bearing cover .
  • Page 31 (14) Pass the pin (rocker arm) through the rocker arm and mount them on the cylinder head . ROCKER ARM NOTE 1: Conduct this job at the compression (EXHAUST VALVE SIDE) top dead center . (The position of two punch marks on cam sprocket is in parallel with the (ROCKER ARM) cylinder head surface at a time .)
  • Page 32 (16) ROCKER COVER Replace the gasket with a new one, and mount SPARK PLUG GASKET the rocker cover . (ROCKER COVER) M6 × 12 mm flange bolt : 4 pcs . Tightening torque 5 .0 - 7 .0 N ・ m (50 - 70 kgf ・...
  • Page 33 (19) FLYWHEEL, COOLING BLOWER and STARTING PULLEY NOTE: When mounting the flywheel, be sure to COOLING wipe off any oil on the tapered portion BLOWER of the crankshaft and flywheel . a) Mount the flywheel on the crankshaft . b) Install cooling blower and starting pulley to WASHER the crankshaft .
  • Page 34 (21) BAFFLE2, RECOIL BRACKET, BLOWER HOUSING, RECOIL STARTER and STOP SWITCH (1) Mount the stop switch to the blower housing . (M4 × 12 mm screw and washer : 2 pcs .) *Tighten the wire 2 (ground) with the stop switch . (See Detail C) (2) Mount the blower housing on the crankcase .（M6 ×...
  • Page 35 (23) MUFFLER (1) M ount the muffler and the gasket on the cylinder head. NOTE : Be sure to remove any tape or cloth used to cover the exhaust port to MUFFLER when the engine was disassembled . GASKET GASKET (Attention to the direction of bulge forming) (Attention to the Bulge forming direction of bulge forming)

  • Page 36: Engine Oil

    4. ENGINE OIL Using engine oil of the correct grade and viscosity greatly lengthens engine life and improves performance . Too much or too little oil can also result in serious problems, including engine damage . 4-1 CLASSIFICATION BY OIL GRADE API (American Petroleum Institute) Classification Grades suited for Robin Engine: SE or higher (SG,SH or SJ in recomended)

  • Page 37: Ignition System

    5. IGNITION SYSTEM The ignition system is controlled by the digital CDI, and the ignition timing is variable according to engine speed . The flywheel (cooling fan is separate from the flywheel) is directly mounted on the crankshaft and the ignition coil is directly mounted on the crankcase .

  • Page 38: Oil Sensor

    7. OIL SENSOR 7-1 SPECIFICATIONS Float type Type (with lead switch incorporated) Resistance 100 M ohms or over (at FULL oil level) OIL SENSOR Operating -30 to +180 degree Celsius Temperature Fig .7-1 7-2 CONSTRUCTION AND OPERATION The oil sensor is composed of the float, permanent magnet incorporated into the float and the lead switch .

  • Page 39: Troubleshooting

    8. TROUBLESHOOTING The following three conditions must be fulfilled for satisfactory engine start . (1) The cylinder filled with a proper fuel-air mixture . (2) Good compression in the cylinder . (3) Good spark, properly timed, to ignite the mixture . The engine cannot be started unless these three conditions are met .
  • Page 40 8-1 STARTING DIFFICULTIES Phenomenon Possible causes Remedy 1) Battery discharged Charge battery 2) Poor connection between battery and starter motor Clean or repair 1 . Low engine 3) Poor connection between battery and ground Clean or repair speed at starting 4) Electric starter faulty Repair or replace Replace with recommended...
  • Page 41 8-2 INSUFFICIENT OUTPUT Phenomenon Possible causes Remedy 1) Loosen spark plug Retighten or replace gasket 2) Cylinder head gasket leakage Retighten or replace gasket 3) Piston ring(s) seizure or wear Replace 1 . Low 4) Piston or cylinder wear Repair or replace compression 5) Incorrect valve and seat contact Repair or replace...
  • Page 42 8-4 ROUGH IDLING Phenomenon Possible causes Remedy 1) Low idling speed Adjust 1 . Throttle body 2) Throttle body slow system passage clogged Check, clean and replace 2 . Intake system 1) Air mixing from connecting portion of air intake system Check, tighten or replace gasket 3 .
  • Page 43 8-6 HIGH FUEL CONSUMPTION Phenomenon Possible causes Remedy 1) Throttle body faulty Check or replace 1 . Fuel system 2) Pulsation damper faulty Check or replace 3) Fuel pump faulty Check or replace 1) Low compression Check or repair 2 . Engine core components Check and adjust load and/or 2) Over cooling...
  • Page 44 8-9 ENGINE MISFIRE Phenomenon Possible causes Remedy 1) Improper spark plug gap or damaged electrode Cealn, adjust or replace 2) Ignition coil faulty Replace 1 . Ignition system Check with failure diagnosis 3) Damaged ignition system wirings system and replace Check with failure diagnosis 4) Poor connection of ignition system wirings system and connect properly...

  • Page 45: Electric Fuel Injection System

    9. ELECTRIC FUEL INJECTION SYSTEM This engine is equipped with Electronic Fuel Injection system (FI system) Integrated with ECU (Engine Control Unit) . The Fl system consists of throttle body, ECU, MAP (Manifold Absolute Pressure) sensor, injector, engine case temperature sensor, electric fuel pump . The fuel system is calibrated after careful testing for optimum all-round performance (including starting, acceleration, fuel consumption, output power characteristics) .
  • Page 46 9-1 FUNCTIONS AND CONSTRUCTION 9-1-1 FUEL INJECTOR Fuel is metered by the fuel injector that is actuated electronically by ECU . The fuel is injected into the throttle bore and mixed with air from the air cleaner . 9-1-2 ENGINE CONTROL UNIT (ECU) The ECU (engine control unit) on bottom of the throttle body is powered by DC battery .
  • Page 47 9-3 EFI SYSTEM 9-3-1 CHECKING ECU CONNECTOR 1 . Disconnect the connector, and check their terminals for contamination and deformation . 2 . Check to see that cable is not broken or terminals are not shelled off . 3 . If any damaged parts are found, repair or replace them .
  • Page 48 9-3-2 ECU CONNECTOR VOLTAGE (Main Circuit) 1 . Turn on the main switch . (Do not start engine .) 2 . Measure the voltage between terminal 9 (+)and terminal 10 (-) . 3 . It is OK if the voltage equals to the battery voltage . (Sensor Voltage) 1 .
  • Page 49 Connector (harness side) 9-3-4 ENGINE CASE TEMPERATURE SENSOR 1 . Disconnect the connector from the engine case temperature sensor . 2 . Measure the resistance with an ohmmeter across the terminal 1 and 2 of engine case temperature Engine Case Temperature Sensor sensor 3 .
  • Page 50 9-3-6 MAP SENSOR 1 . Connect the connector of MAP sensor (3P) . 2 . Turn the key switch to the ON position . Map sensor 3 . Measure the voltage between the terminal 3 and body earth with voltage range of circuit tester . 4 .
  • Page 51 9-3-7 IGNITION COIL Ignition coil NOTE ; • When the diagnosis lamp is flashing, check the procedures below in order. • If the result is within factory specification, there is a problem with ECU. Replace the ECU and throttle body. 1 .
  • Page 52 9-4 FAILURE DIAGNOSIS MODE TABLE This engine has the failure diagnosis system to know that low voltage of DC battery and each wiring whether disconnecting or electrical short circuit . The ECU monitors engine various conditions for the system when turn the key to the “RUN”(ON) position . DISPLAY MODE (WHEN IGNITION SWITCH ON) DISPLAY MODE CONDITION...

  • Page 53: Standard Repair Tables

    10. STANDARD REPAIR TABLES “STD” in the following table is the parts dimension from the brand new engine or the spare parts . Whereas, “Limit” shows the maximum allowance for the parts to be used on the engine . If the measurement exceeds beyond the “Limit”, the part needs to be replaced and/or repaired . 10-1 STANDARD DIMENSIONS AND LIMITS OF USE Unit: mm (in .) ITEM...
  • Page 54 Unit: mm (in .) ITEM Limit CYLINDER * Inner diameter To be rebored when the 89 .000 - 89 .022 difference between max . Standard (3 .5039 - 3 .5040) and min . of diameter reached to 0 .1 (0 .004) . 89 .250 - 89 .272 First reboring Ditto...
  • Page 55 Unit: mm (in .) ITEM Limit PISTON * Ring groove side clearance 0 .050 - 0 .090 0 .15 (0 .0020 - 0 .0035) (0 .0059) Oil ring 0 .030 - 0 .125 (three-piece) (0 .0012 - 0 .0049) * Piston pin hole 20 .989 - 21 .022 21 .045 (0 .8263 - 0 .8276)
  • Page 56 Unit: mm (in .) ITEM Limit CONNECTING ROD * Large end inner diameter 38 .000 - 38 .016 38 .1 (1 .4961 - 1 .4967) (1 .5000) * Clearance between large end and crank pin 0 .030 - 0 .060 0 .2 (0 .0012 - 0 .0024) (0 .0079)
  • Page 57 Unit: mm (in .) ITEM Limit CAMSHAFT 35 .658 - 35 .758 35 .61 * Cam peak height (intake and exhaust) Intake (1 .4039 - 1 .4078) (1 .4020) Cam peak EXHAUST height INTAKE 39 .408 - 39 .508 39 .36 Exhaust (1 .5515 - 1 .5554) (1 .5496)

  • Page 58: Service Data (The Following Are Only For Your Reference.)

    Unit: mm (in .) ITEM Limit VALVE SPRING FREE LENGTH 36 .5 (1 .4370) VALVE SEAT ANGLE (INTAKE AND EXHAUST) * Valve cutter angle (a) * Valve contact width (b) a: 90° Intake b: 0 .7 - 1 .0 2 .0 Exhaust (0 .0276 - 0 .0394) (0 .0787)

  • Page 59: Tightening Torque

    10-3 TIGHTENING TORQUE Tightening Torque ITEM N ・ m kgf ・ cm ft ・ lb Re-use 29 .0 - 31 .0 290 - 310 21 .0 - 22 .4 When replace to new M10×75 flange bolt Cylinder head bolts cylinder head and 37 .0 - 39 .0 370 - 390 26 .7 - 28 .2...

  • Page 60: Periodic Maintenance

    11.PERIODIC MAINTENANCE 18-1 PERIODIC MAINTENANCE SCHEDULE TABLE Every Every Every Every Every 1000 8 hours 50 hours 200 hours Maintenance Items hours (Daily) (Weekly) (Monthly) hours ● Clean engine and check bolts and nuts (Daily) ● Check and refill engine oil (Refill daily up to upper level) ●...
  • Page 61 18-2 ENGINE STORAGE (1) Carry out the maintenance jobs described in step 18-1 above . (2) To prevent rust in the cylinder bore, inject 5cc oil through the spark plug hole, run motor 1~2 seconds and then put back the spark plug . (3) Clean the exterior of the engine with an oiled cloth .
  • Page 62 NOTES...
  • Page 64 Club Car, LLC www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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