Page 1 2001-2002 MAINTENANCE S E R V I C E TURF 272 AND CARRYALL 272 GASOLINE VEHICLES MANUAL NUMBER 102190010 EDITION CODE 0802A00000...
Page 3 Club Car distributor/dealer representative or by a Club Car factory- trained technician. It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl- edge and facilities so they can provide prompt and efﬁcient service for vehicle owners. Regional technical rep- resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support.
Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc., is continually working to further improve our vehicles and other products. These improvements may affect servicing procedures.
Page 5: Table Of Contents
CONTENTS SECTION 1 – SAFETY General Warning ..........................SECTION 2 – VEHICLE SPECIFICATIONS General Information .......................... SECTION 3 – GENERAL INFORMATION General Information .......................... Engine and Transaxle Identification ....................Serial Number Identification ......................Storage ............................. Returning The Stored Vehicle To Service ..................SECTION 4 –...
Page 6 Seat Support ............................ Seat Support Removal ......................... Seat Support Installation ......................Armrest Removal ......................... Armrest Installation ........................Cargo Bed ............................Cargo Bed Removal ........................Cargo Bed Installation ........................4-11 Bed Stop Bumper Adjustment ...................... 4-11 Rear Fender ............................. 4-11 Rear Fender Removal ........................4-11 Rear Fender Installation .......................
Page 7 Brake Drum Removal ........................6a-9 Front Wheel Brake Drum Removal ....................6a-9 Rear Wheel Brake Drum Removal ....................6a-10 Brake Shoe Removal ........................6a-11 Front Brake Shoe Removal ......................6a-11 Rear Brake Shoe Removal ......................6a-11 Brake Cluster Inspection and Cleaning .................... 6a-12 Brake Shoe Installation ........................
Page 8 Master Cylinder and Bell Crank Replacement ................. 6a-31 Bell Crank Removal ........................6a-31 Bell Crank Installation ........................6a-32 Master Cylinder Removal ......................6a-32 Master Cylinder Installation ......................6a-33 Bleeding the Hydraulic Brake System ....................6a-33 Purging the Hydraulic System ...................... 6a-35 Filling the Hydraulic System ......................
Page 9 Wheel Cylinder Replacement ......................6b-23 Front Wheel Cylinder Removal ..................... 6b-23 Front Wheel Cylinder Installation ....................6b-23 Rear Wheel Cylinder Removal ..................... 6b-24 Rear Wheel Cylinder Installation ....................6b-24 Brake Shoe Adjuster Replacement ....................6b-25 Front Brake Shoe Adjuster Removal .................... 6b-26 Front Brake Shoe Adjuster Installation ..................
Page 10 Steering Column ..........................Steering Column Removal ......................Steering Column Disassembly ..................... Steering Column Assembly ......................Steering Column Installation ......................Rack and Pinion ..........................Rack and Pinion Removal ......................Rack and Pinion Disassembly ...................... Rack and Pinion Assembly ......................7-11 Rack and Pinion Installation ......................7-12 Front Suspension ..........................
Page 11 Multi-Leaf Springs ..........................Multi-Leaf Spring Removal ......................Multi-Leaf Spring Installation ......................Snubber ............................Snubber Removal ......................... Snubber Installation ........................SECTION 10 – PERIODIC MAINTENANCE General Information .......................... 10-2 Pre-Operation and Daily Safety Checklist ..................10-3 Performance Inspection ........................ 10-3 Periodic Service Schedule ........................ 10-4 Periodic Lubrication Schedule ......................
Page 12 Circuit Testing ..........................11a-15 Testing the Starter Circuit and Generator Circuit ................. 11a-16 Testing the Engine Ignition Circuit ....................11a-17 Testing the Engine Kill Circuit ...................... 11a-17 Testing the Reverse Buzzer Circuit ....................11a-18 Testing the Low Oil Warning Circuit ..................... 11a-19 Testing the Lockout Cam Circuit ....................
Page 13 Key Switch ............................12a-16 Solenoid ............................12a-17 Fuse ..............................12a-18 Lockout Cam Limit Switch ........................ 12a-20 Lockout Cam ............................ 12a-21 Reverse Warning Buzzer ........................12a-22 Reverse Buzzer Limit Switch ......................12a-23 Oil Warning Light ..........................12a-24 Fuel Gauge/Hour Meter ........................12a-25 Fuel Level Sending Unit ........................
Page 14 SECTION 13 – FE350 AND FE400 ENGINES General Information ......................... 13-2 Special Engine Service Tools Available from Club Car ............... 13-3 Before Servicing ........................... 13-3 Mechanical Systems ........................13-3 Lubrication System ........................13-5 Hydraulic Lifters ........................... 13-6 Spark Plug ............................
Page 15 Crankshaft Axial Play Adjustment ..................... 13-45 Crankcase Cover Installation ......................13-48 Engine Assembly ..........................13-49 Service Specifications ........................13-51 Specifications for Resizing Cylinder Bore ..................13-52 Torque Specifications ........................13-52 Adjustment and Settings ....................... 13-53 SECTION 14 – FUEL SYSTEM General Information ..........................
Page 16 Fuel Pump ............................14-22 General Information ........................14-22 Fuel Pump Removal ........................14-24 Fuel Pump Disassembly ......................14-24 Fuel Pump Cleaning and Inspection .................... 14-25 Fuel Pump Assembly ........................14-25 Fuel Pump Installation ........................14-26 Fuel Tank ............................14-26 General Information ........................14-28 Fuel Tank Removal ........................
Page 17 Unitized Transaxle Component Inspection ..................16a-28 Idler Shaft Assembly ........................16a-28 Intermediate Gear Assembly ......................16a-29 Synchronizer Gear Assembly ....................... 16a-29 Shifter Fork Assembly ........................16a-31 Differential Gear Case Assembly ....................16a-31 Governor Gear Assembly ......................16a-33 Differential Gear Lock Housing Assembly ..................16a-33 Unitized Transaxle Assembly ......................
Page 18 Unitized Transaxle Component Inspection ..................16b-28 Idler Shaft Assembly ........................16b-28 Intermediate Gear Assembly ......................16b-29 Synchronizer Gear Assembly ....................... 16b-29 Shifter Fork Assembly ........................16b-31 Differential Gear Case Assembly ....................16b-31 Governor Gear Assembly ......................16b-33 Differential Gear Lock Housing Assembly ..................16b-33 Unitized Transaxle Assembly ......................
Page 19 SECTION ia – INDEX FOR FE400 KEY-START VEHICLES SECTION ib – INDEX FOR FE350 PEDAL-START VEHICLES 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page xvii...
Page 20 Page xviii 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 21: Section 1 - Safety
SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements contained within headings labeled DANGER, WARNING, CAUTION, or NOTE.
Page 22 SAFETY General Warning ∆ WARNING • Prior to servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF, remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels when servicing the vehicle. •...
Page 23 SAFETY General Warning AS SEEN FROM PASSENGER'S SIDE OF VEHICLE REMOVE NEGATIVE DISCONNECT BATTERY CABLES CABLE FIRST BEFORE WORKING ON VEHICLE GASOLINE VEHICLE BATTERY DISCONNECT Figure 1-1 Battery 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 1-3...
Page 25: Section 2 - Vehicle Specifications
SECTION 2 – VEHICLE SPECIFICATIONS GENERAL INFORMATION SPECIFICATIONS FE350 ENGINE FE400 ENGINE POWER SOURCE Engine: 4-cycle OHV, 351 cc, 11 hp rated, single-cylinder, air-cooled, with pressure lubrication • system Engine: 4-cycle OHV, 400 cc, 13 hp rated, single-cylinder, air-cooled, with pressure lubrication •...
Page 26 VEHICLE SPECIFICATIONS General Information SPECIFICATIONS FE350 ENGINE FE400 ENGINE Weight (dry): (with all-terrain tread) 1100 lb. (499.0 kg) 1106 lb. (501.7 kg) (with turf tread) 1060 lb. (480.8 kg) 1066 lb. (477.2 kg) Forward speed 17-19 mph (27-31 km/h) Governed RPM 3800 (±30) RPM 3850 (±30) RPM Curb clearance circle (diameter)
Page 27: Section 3 - General Information
This label identiﬁes the design of the transaxle and any model changes that may have been made to that speciﬁc model (Examples: MC010C-BS00 or MC012C-AS00). When contacting a Club Car, Inc. service department, distributor, or dealer it is important to include the speciﬁc information provided on these labels.
Page 28: Serial Number Identification
The dashboard must be removed to view this number. See following NOTE. NOTE: Always have the vehicle serial number at hand when ordering parts or making inquiries (Figure 3-1, Page 3-2). Club Car SERIAL NUMBER AD0201-583947 P O BOX 204658...
Page 29 GENERAL INFORMATION Storage Preparing The Vehicle For Extended Storage 1. Store vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be weak, charge it using an automotive-type 12-volt battery charger rated at 10 amps or less. 2.
Page 30: Returning The Stored Vehicle To Service
GENERAL INFORMATION Storage Preparing The Vehicle For Extended Storage, Continued: 8. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water (1 cup) (237 mL) baking soda per (1 gallon)(3.8 L) of water. Rinse solution off bat- teries.
Page 31 GENERAL INFORMATION Storage 6. Completely open fuel shut-off valve (Figure 3-6, Page 3-5). Make sure the valve is fully open. A partially closed fuel valve (Figure 3-7, Page 3-5) combined with the use of the choke, can result in a fouled spark plug and engine failure.
Page 33: Section 4 - Body And Trim
SECTION 4 – BODY AND TRIM ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 34: Cleaning The Vehicle
ﬁne grade (No. 00) steel wool. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.
Page 35: Front Body Repair
Mesh" acrylic polishing kit with abrasive papers from 1800 to 8000 grit will provide the best ﬁnal ﬁnish. Restore gloss with soft polishing compound, or Club Car’s Vehicle Care Kit (CCI P/N AM10021). It is not the intent of any of these processes to ’ﬁll-in’ material removed due to light scratches but rather to blend the ﬁn- ish of the surrounding area and the scratch together.
Page 36: Dashboard Installation
BODY AND TRIM Front Body Components Dashboard Removal, Continued: ® 2.1. Loosen the seven Tuﬂok screws around the panel, but do not remove the screws completely, as shown in Detail A (Figure 4-1, Page 4-5). 2.2. Remove Tuﬂok screws from dash panel as shown in Detail B. 2.3.
Page 37 BODY AND TRIM Front Body Components Figure 4-1 Dash Panel Removal 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 4-5...
Page 38: Front Fender Removal
To preserve seat appearance, clean regularly with mild soap or detergent applied with a sponge or soft cloth and use Club Car’s Vehicle Care Kit (CCI P/N AM10021) to preserve the fabric. Use a bristle brush to clean areas that are especially soiled. For other cleaning use the following guidelines: ∆...
Page 39 BODY AND TRIM Seat TYPICAL 5 PLACES TYPICAL 6 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES FENDER SUPPORT TYPICAL 5 PLACES TYPICAL 4 PLACES Figure 4-2 Front Body Assembly 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 4-7...
Page 40: Seat Removal
Difﬁcult Stains – Dampen a soft, white cloth with a solution of 10% household bleach (sodium hypochlorite) and 90% water. Rub gently to remove stain, then rinse with a water dampened cloth to remove bleach concentration. Use Club Car’s Vehicle Care Kit (CCI P/N AM10021) to recondition the fabric.
Page 41: Seat Support Installation
BODY AND TRIM Cargo Bed 2.2.1. Remove park brake equalizer cable from park brake handle. See Equalizer Cable Removal, Section 6b, Page 6b-36. 2.2.2. Disconnect cable from differential lock control. See step 5.5 in Unitized Transaxle Removal, Section 16b, Page 16b-9. 3.
Page 42 BODY AND TRIM Cargo Bed Cargo Bed Removal, Continued: TYPICAL 4 PLACES Figure 4-3 Seat Support 2. Remove two 3/8-16 nylon lock nuts (8) from left and right tilt bed hinge/bolt assemblies. 3. Apply slight upward pressure (by hand) on the rear of the bed to relieve pressure on the hinges, and remove the 3/8 x 3-3/8-inch hinge bolts (9) from the hinge assemblies.
Page 43: Cargo Bed Installation
BODY AND TRIM Rear Fender CARGO BED INSTALLATION NOTE: Cargo bed removal and installation will be easier with a helper. 1. Hold bed at a slight angle (front of bed lower than rear of bed) to vehicle and place front edge of bed onto vehicle frame.
Page 44: Rear Fender Installation
BODY AND TRIM Tailskirt Rear Fender Removal, Continued: 2. MC010C-BS00 transaxle: 2.1. Remove the two 1/4-20 nylon lock nuts (5), fender washers (4) and 1/4-20 x 1-inch hex-head bolts (3) from the front surface of the fender (1) (Figure 4-6, Page 4-17). 2.2.
Page 45 BODY AND TRIM Tailskirt TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 4-4 Tilt Bed 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 4-13...
Page 46: Tailskirt Installation
BODY AND TRIM Trailer Hitch TAILSKIRT INSTALLATION The style of transaxle determines which tailskirt installation procedure will apply. See Transaxle Identiﬁca- tion, Section 6a, Page 6a-2. 1. MC012C-AS00 transaxle: 1.1. Insert upper edge of tailskirt (6) under, and in front of, back edge of rear body (Figure 4-5, Page 4-16).
Page 47: Floor Mat
BODY AND TRIM Floor Mat FLOOR MAT Read DANGER, WARNING, and CAUTION on page 4-1. FLOOR MAT REMOVAL 1. Remove the brake and accelerator pedals. See Accelerator Pedal Removal, Section 5, Page 5-4. Also see Brake Pedal Removal, Section 5, Page 5-2. 2.
Page 48 BODY AND TRIM Floor Mat TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 4-5 Rear Fender, Tailskirt, and Hitch – Vehicle with MC012C-AS00 Transaxle Page 4-16 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 49 BODY AND TRIM Floor Mat TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 4-6 Rear Fender, Tailskirt, and Hitch – Vehicle with MC010C-BS00 Transaxle 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 4-17...
Page 51: Section 5 - Accelerator And Brake Pedal Assemblies
SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 52: Brake Pedal
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. •...
Page 53: Brake Pedal Installation
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 5-1 Brake Pedal Assembly BRAKE PEDAL INSTALLATION 1. From the top side of the ﬂoorboard, insert the brake pedal weldment assembly (1) through the opening in the ﬂoor as shown (Figure 5-3, Page 5-4) and install the brake pedal stop bumper (2) and nut (3) (Figure 5-1, Page 5-3) on the brake pedal assembly, but do not tighten the jam nut at this time.
Page 54: Accelerator Pedal
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Brake Pedal Installation, Continued: Removal Installation Figure 5-2 Jack Stand Location on I-Beam Figure 5-3 Brake Pedal Weldment Through Floor 2. Attach the equalizer rod (10) to the brake pedal weldment assembly (1) as shown (Figure 5-1, Page 5-3).
Page 55: Accelerator Pedal Installation
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal 5. Disconnect the accelerator rod assembly (17, 18 and 19) (Figure 5-11, Page 5-10) at the front and rear ball studs and remove it from the vehicle. 6. Remove the nut (10) and ball stud (16) from the accelerator pivot rod (6) and spring retainer (11) assem- bly.
Page 56: Brake Pedal Adjustment
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal Adjustment Accelerator Pedal Installation, Continued: 10. Connect the spark plug wire to the spark plug. 11. Connect the battery cables, positive (+) cable ﬁrst, and tighten terminals to 20 ft-lb (27 N·m). BRAKE PEDAL ADJUSTMENT Read DANGER and WARNING on page 5-1.
Page 57: Accelerator Pedal Adjustment
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment 10. Observe the push rod while pressing the brake pedal. There should be at least 1/8 inch of free play (at the push rod) before the push rod begins to depress the master cylinder piston (Figure 5-6, Page 5-7). An accurate measurement is not necessary, but it must be a minimum of 1/8-inch (4.44 mm) so that the push rod does not contact the master cylinder piston when the pedal is at rest.
Page 58 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment Accelerator Pedal Adjustment, Continued: 6.2. Depress the accelerator pedal until the end of the tool rests against the ﬂoorboard. Using a rubber strap, hold pedal in position against the ﬂoorboard and tighten nut to 26 ft-lb (35.3 N·m) (Figure 5-9, Page 5-8).
Page 59 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment ∆ CAUTION • After accelerator rod adjustment, make sure approximately the same amount of thread is exposed at each end of the rod. • If lever on the limit switch in the electrical box is bent, replace limit switch. •...
Page 60 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment FLOORBOARD REMOVED FOR CLARITY Figure 5-11 Accelerator Pedal Assembly Page 5-10 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 61: Section 6A - Mc012C-As00 Transaxle: Hydraulic And Park Brake Sys
SECTION 6A – MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 62: General Information
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death.
Page 63: Brake System Inspection
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Inspection RUBBER DUST IDENTIFICATION IDENTIFICATION DECAL DECAL Figure 6a-1 MC012C-AS00 Transaxle Figure 6a-2 MC010C-BS00 Transaxle BRAKE SYSTEM INSPECTION Read DANGER and WARNING on page 6a-1. The hydraulic brake system and park brake system should be inspected immediately after any service to either of the brake systems.
Page 64 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Inspection REFERENCE FRONT TYPICAL BRAKE HOSE 2 PLACES BLEEDER TYPICAL VALVE 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 6a-3 Front Hydraulic Brake Cluster Assembly Master Cylinder Inspection •...
Page 65 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Inspection Brake Line and Hose Inspection • Inspect the brake lines. The brake lines should not be kinked, dented or damaged in any way. There should be no leakage from the brake lines or ﬁttings. If a leak is discovered, replace the brake line. See Hydraulic Line and Hose Replacement on page 6a-27.
Page 66: Brake System Troubleshooting
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting BRAKE SYSTEM TROUBLESHOOTING With normal scheduled maintenance and replacement of worn parts, the hydraulic and park brake systems should provide trouble-free operation. In the event that a problem does occur, the following troubleshooting guide will be helpful in identifying operating difﬁculties.
Page 67 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Hard pedal, continued Replace the brake shoes. See Brake Damaged or distorted brake shoes Shoe Removal on page 6a-11. Scored or barrel-shaped brake shoe Replace the brake drums.
Page 68 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Decreasing brake pedal travel, Replace the wheel cylinder. See Wheel Sticking wheel cylinder piston continued Cylinder Replacement on page 6a-23. Adjust brake adjusters. See Brake Shoe Overly adjusted brake adjusters Adjuster Replacement on page 6a-26.
Page 69: Brake Drum Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Removal BRAKE DRUM REMOVAL Read DANGER and WARNING on page 6a-1. FRONT WHEEL BRAKE DRUM REMOVAL ∆ WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components.
Page 70: Rear Wheel Brake Drum Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Removal Front Wheel Brake Drum Removal, Continued: NOTE: If the adjusters require more than 65 in-lb (7.3 N·m) of force to rotate, they must be replaced. See Brake Shoe Adjuster Replacement on page 6a-26. 7.
Page 71: Brake Shoe Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Removal 5.3. Rotate the brake drum slightly to remove it from the brake shoe cluster assembly. 6. Repeat steps 3 through 5 for the opposite rear wheel if necessary. BRAKE SHOE REMOVAL Read DANGER and WARNING on page 6a-1.
Page 72: Brake Cluster Inspection And Cleaning
DOT 5 brake ﬂuid. See Bleeding the Hydraulic Brake System on page 6a-33. NOTE: Factory installed brake shoes have non-asbestos linings (CCI P/N 102050201). When replacing brake shoes, Club Car, Inc., recommends non-asbestos replacement parts. 1. Remove the brake drum. See Front Wheel Brake Drum Removal on page 6a-9, and Rear Wheel Brake Drum Removal on page 6a-10.
Page 73 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Inspection and Cleaning 3. Clean the brake cluster back plate and all of the brake cluster components. 4. Check the brake shoe adjusters in each brake cluster assembly for proper operation. 4.1.
Page 74: Brake Shoe Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation Brake Cluster Inspection and Cleaning, Continued: BOSSES BOSSES Present on rear brake clusters only. Figure 6a-11 Lubricate Raised Bosses Figure 6a-12 Lubricate Rear Brake Cluster 10. Use a small brush to carefully apply a light coat of white lithium NLGI Number 2 grease (Dow Corning BR2-Plus or equivalent) on each of the six raised bosses on the brake cluster back plate (Figure 6a-11, Page 6a-14).
Page 75 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation 2. Install the cup washer and compression spring assembly (12) onto the pin of the adjuster assembly (3) of the brake shoe (Figure 6a-3, Page 6a-4). Compress the cup and spring with a pair of pliers or a brake tool and rotate 90°...
Page 76: Rear Brake Shoe Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation Front Brake Shoe Installation, Continued: 5. Install the remaining cup washer and compression spring assembly (12) onto the pin of the adjuster (3) of the brake shoe (Figure 6a-6, Page 6a-12) described in step 2 above. 6.
Page 77: Brake Drum Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation ∆ WARNING • Make sure to install and bend the cotter pin. Failure to bend the cotter pin could result in the separation of the wheel bolt ﬂange from the splined end of the axle. Loss of vehicle control could result, causing severe personal injury.
Page 78 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation Front Wheel Brake Drum Installation, Continued: 3. Inspect the bearing cups (7) for wear or damage. If they are worn or pitted they must be replaced, along with their respective wheel hub as an assembly. 4.
Page 79: Rear Wheel Brake Drum Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation ∆ CAUTION • Do not apply more than 65 in-lb (7.3 N·m) of torque to any of the adjuster bolts. Over- tightening the adjuster bolts could result in damage to the brake cluster components or the separation of the bolt (4) from the adjuster (3) (Figure 6a-3, Page 6a-4 or Figure 6a-21, Page 6a-25).
Page 80: Brake Cluster Assembly Replacement
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement Rear Wheel Brake Drum Installation, Continued: NOTE: If brake drum installation is difﬁcult, the brake shoes may need to be adjusted vertically in the mounting slots. 2. Using a torque wrench and a Torx #T-27 driver, or hydraulic brake adjuster (CCI P/N 102169401), gently rotate the adjuster bolts to increase the clearance between the brake shoe lining and the brake drum (Figure 6a-16, Page 6a-19).
Page 81: Front Brake Cluster Assembly Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement 3. To avoid spilling brake ﬂuid, lift the hose above the brake cluster assembly and place a plastic bag over the hose ﬁtting to keep dirt and debris from entering the hydraulic brake system (Figure 6a-17, Page 6a-21).
Page 82: Rear Brake Cluster Assembly Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement Rear Brake Cluster Assembly Removal, Continued: 5. Slide the cable so that the coiled spring wire, covering the cable wire, can be fed through the slot in the support bracket, and then removed. 6.
Page 83: Wheel Cylinder Replacement
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement ∆ CAUTION • Do not substitute hex-head bolts for Torx-head bolts. Hex-head bolts can interfere with the proper operation of the brake shoe adjusters. 2. Connect the brake hose ﬁtting to the brake cluster wheel cylinder with a 3/8-inch ﬂare nut wrench. Tighten the ﬂare nut ﬁtting to 11 ft-lb (14.9 N·m) (Figure 6a-21, Page 6a-25).
Page 84: Rear Wheel Cylinder Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement Front Wheel Cylinder Installation, Continued: 2. Install a new banjo bolt (16) and new copper washers (17) to the front brake cluster wheel cylinder (7). Position the elbow of the brake hose toward the rear of the vehicle. Tighten the banjo bolt to 13 ft-lb (17.6 N·m) (Figure 6a-3, Page 6a-4).
Page 85 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement REFERENCE BRAKE HOSE BLEEDER VALVE TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL TYPICAL 4 PLACES 2 PLACES Figure 6a-21 Rear Hydraulic Brake Cluster Assembly 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 6a-25...
Page 86: Brake Shoe Adjuster Replacement
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Adjuster Replacement BRAKE SHOE ADJUSTER REPLACEMENT Read DANGER and WARNING on page 6a-1. ∆ WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components.
Page 87: Rear Brake Shoe Adjuster Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement REAR BRAKE SHOE ADJUSTER REMOVAL 1. Remove rear wheel brake drum. See Rear Wheel Brake Drum Removal on page 6a-10. 2. Remove rear brake shoes. See Rear Brake Shoe Removal on page 6a-11. 3.
Page 88: Front Brake Line Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement FRONT BRAKE LINE REMOVAL 1. Place chocks at the rear wheels, release the park brake and lift the front of the vehicle with a chain hoist or ﬂoor jack. Place jack stands under the outer front frame I-beam of the vehicle and lower the ﬂoor jack or chain hoist so that the vehicle is resting on the jack stands.
Page 89 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement TYPICAL BOTH SIDES TYPICAL 2 PLACES REFERENCE FRONT SUSPENSION REFERENCE MASTER CYLINDER REFERENCE FRONT BRAKE ASSEMBLY TYPICAL BOTH SIDES REFERENCE REAR BRAKE ASSEMBLY Figure 6a-22 Four-Wheel Hydraulic Brake System 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 6a-29...
Page 90: Front Brake Hose Assembly Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement FRONT BRAKE HOSE ASSEMBLY INSTALLATION 1. Install the 1/4-20 x 1-1/4-inch hex-head bolt (2) through washer (13) and through the T-manifold block (1) and frame bracket. Install and tighten the nylon lock nut (3) to 76 in-lb (8.6 N·m) (Figure 6a-22, Page 6a-29).
Page 91: Rear Brake Hose Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement REAR BRAKE HOSE REMOVAL 1. Place chocks at the rear wheels, release the park brake and lift the rear of the vehicle with a chain hoist or ﬂoor jack. Place jack stands under the rear axle tubes to support the vehicle and lower the ﬂoor jack or chain hoist so that the vehicle is resting on the jack stands.
Page 92: Bell Crank Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement Bell Crank Removal, Continued: 6. Inspect the needle bearing (14) and the inner race (15) for damage or wear and replace if necessary (Figure 6a-23, Page 6a-34). NOTE: The needle bearing (14) is press ﬁtted to the bell crank.
Page 93: Master Cylinder Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System MASTER CYLINDER INSTALLATION 1. Install master cylinder (1) into mounting bracket (19) and insert push rod (3), then seat boot (2) (Figure 6a-23, Page 6a-34). 2. Install the two bolts (7) and nylon lock nuts (8) that secure the master cylinder (1) to the master cylinder mounting bracket (19).
Page 94 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 6a-23 Master Cylinder Page 6a-34 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 95: Purging The Hydraulic System
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System Bleeding the Hydraulic Brake System, Continued: ∆ CAUTION • Do not apply more than 65 in-lb (7.3 N·m) of torque to any of the adjuster bolts. Over- tightening the adjuster bolts could result in damage to the brake cluster components or the separation of the bolt (4) from the adjuster (3) (Figure 6a-3, Page 6a-4 or Figure 6a-21, Page 6a-25).
Page 96: Filling The Hydraulic System
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System BLEEDER VALVE REGULATED AIR PRESSURE 12 - 15 PSI (.827- 1.034 Bars) Figure 6a-24 Front and Rear Brake Bleeding FILLING THE HYDRAULIC SYSTEM After purging the brake system and making any necessary repairs, bleed the brakes, adding DOT 5 brake ﬂuid until the system is full and virtually no air bubbles are present in the brake bleeder vacuum tubes.
Page 97: Park Brake System
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System PARK BRAKE SYSTEM Read DANGER and WARNING on page 6a-14. PARK BRAKE CABLE REMOVAL Equalizer Cable Removal 1. Chock the wheels and release the park brake. 2. Remove the two screws (3) that secure the park brake boot (2) to the seat support (Figure 6a-28, Page 6a-40).
Page 98 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Figure 6a-26 Position Wheel Brake Cable Figure 6a-27 Wheel Brake Cable Attachment Equalizer Cable Installation 1. Feed the equalizer cable (9) up between the pulley and frame, through the top seat support slot and hook the end of the cable into the handle (1) clevis slot from the passenger side (Figure 6a-28, Page 6a-40).
Page 99: Park Brake Handle Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System PARK BRAKE HANDLE REMOVAL 1. Remove the park brake equalizer cable. See Equalizer Cable Removal on page 6a-37. 2. Remove the two bolts (4), four washers (5) and two lock nuts (6) from the park brake handle (Figure 6a-28, Page 6a-40).
Page 100 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL EACH SIDE OF VEHICLE TYPICAL EACH SIDE OF VEHICLE Figure 6a-28 Park Brake System Page 6a-40 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 101 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Park Brake Adjustment, Continued: 4. With the park brake released (down), tighten the conical nut (23) until signiﬁcant resistance is observed in the equalizer cable in order to fully lock the brakes (Figure 6a-28, Page 6a-40). 5.
Page 103: Section 6B - Mc010C-Bs00 Transaxle: Hydraulic And Park Brake Sys
SECTION 6B – MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 104: General Information
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death.
Page 105: Brake System Inspection
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Inspection RUBBER DUST IDENTIFICATION IDENTIFICATION DECAL DECAL Figure 6b-1 MC010C-BS00 Transaxle Figure 6b-2 MC012C-AS00 Transaxle BRAKE SYSTEM INSPECTION Read DANGER and WARNING on page 6b-1. The hydraulic brake system and park brake system should be inspected immediately after any service to either of the brake systems.
Page 106 MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Inspection REFERENCE FRONT TYPICAL BRAKE HOSE 2 PLACES BLEEDER TYPICAL VALVE 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 6b-3 Front Hydraulic Brake Cluster Assembly Master Cylinder Inspection •...
Page 107 MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Inspection • Check the diaphragm inside the reservoir cap. The diaphragm should not have holes or other damage. If the diaphragm is damaged, replace it before placing the vehicle in service. Brake Line and Hose Inspection •...
Page 108: Brake System Troubleshooting
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting BRAKE SYSTEM TROUBLESHOOTING With regularly scheduled maintenance and replacement of worn parts, the hydraulic and park brake systems should provide trouble-free operation. In the event that a problem does occur, the following troubleshooting guide will be helpful in identifying operating difﬁculties.
Page 109 MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Hard pedal, continued Replace the brake shoes. See Brake Damaged or distorted brake shoes Shoe Removal on page 6b-11. Scored or barrel-shaped brake shoe Replace the brake drums.
Page 110 MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Decreasing brake pedal travel, Replace the wheel cylinder. See Wheel Sticking wheel cylinder piston continued Cylinder Replacement on page 6b-23. Adjust brake adjusters. See Brake Shoe Overly adjusted brake adjusters Adjuster Replacement on page 6b-25.
Page 111: Brake Drum Removal
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Removal BRAKE DRUM REMOVAL Read DANGER and WARNING on page 6b-1. FRONT WHEEL BRAKE DRUM REMOVAL ∆ WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components.
Page 112: Rear Wheel Brake Drum Removal
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Removal Front Wheel Brake Drum Removal, Continued: NOTE: If the adjusters require more than 65 in-lb (7.3 N·m) of force to rotate, they must be replaced. See Brake Shoe Adjuster Replacement on page 6b-25. 7.
Page 113: Brake Shoe Removal
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Removal 5.3. Rotate the brake drum slightly to remove it from the brake shoe cluster. 6. Repeat steps 3 through 5 for the opposite rear wheel if necessary. BRAKE SHOE REMOVAL Read DANGER and WARNING on page 6b-1.
Page 114: Brake Cluster Inspection And Cleaning
DOT 5 brake ﬂuid. See Bleeding the Hydraulic Brake System on page 6b-33. NOTE: Factory installed brake shoes have non-asbestos linings (CCI P/N 102050201). When replacing brake shoes, Club Car, Inc. recommends non-asbestos replacement parts. 1. Remove the brake drum. See Front Wheel Brake Drum Removal on page 6b-9, and Rear Wheel Brake Drum Removal on page 6b-10.
Page 115 MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Inspection and Cleaning 3. Clean the brake cluster back plate and all of the brake cluster components. 4. Check the brake shoe adjusters in each brake cluster assembly for proper operation. 4.1.
Page 116: Brake Shoe Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation Brake Cluster Inspection and Cleaning, Continued: BOSSES BOSSES Present on rear brake clusters only. Figure 6b-11 Lubricate Raised Bosses Figure 6b-12 Lubricate Rear Brake Cluster 10. Use a small brush to carefully apply a light coat of white lithium NLGI Number 2 grease (Dow Corning BR2-Plus or equivalent) on each of the six raised bosses on the brake cluster back plate (Figure 6b-11, Page 6b-14).
Page 117 MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation 3. Attach the tensioning springs onto the shoe already installed, with the smaller spring on top and the larger spring on the bottom. Make sure that the park brake strut and lever are engaged into the slots pro- vided in each shoe, located immediately above the top spring attachment holes (Figure 6b-13, Page 6b-15).
Page 118: Rear Brake Shoe Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation Front Brake Shoe Installation, Continued: 6. After the shoes are installed, move them together up and down approximately 1/4 to 3/8-inch (6.3 to 9.5 mm) to make sure that they will slide easily without binding (Figure 6b-15, Page 6b-15). 7.
Page 119: Brake Drum Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation 4. Install the rear wheel brake drum. See Rear Wheel Brake Drum Installation on page 6b-19. 5. Repeat steps 1 through 4 for the remaining rear axle if necessary. 6. Bleed the rear brakes as instructed. See Bleeding the Hydraulic Brake System on page 6b-33. 7.
Page 120 MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation Front Wheel Brake Drum Installation, Continued: 8. Place the brake drum hub (8) onto the spindle and brake cluster (Figure 6b-4, Page 6b-9). 9. If the brake drum is difﬁcult to push over the brake shoes, use the following procedure: 9.1.
Page 121: Rear Wheel Brake Drum Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation 22. Lower the vehicle and ﬁnish tightening the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m). 23. Check the front wheel free play. See Front Wheel Free Play Inspection, Section 7, Page 7-21. 24.
Page 122: Brake Cluster Assembly Replacement
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement Rear Wheel Brake Drum Installation, Continued: 3. Rotate and gently press the brake drum to ensure that the drum is properly seated. 4. With the brake drum properly seated and secured, use a torque wrench with a Torx #T-27 driver, or hydraulic brake adjuster (CCI P/N 102169401), and gently adjust the clearance between the brake shoe lining and brake drum by turning each of the two adjuster bolt heads on the back of the brake cluster plate as shown (Figure 6b-16, Page 6b-19).
Page 123: Front Brake Cluster Assembly Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement PLASTIC WIRE TIE FLEX BRAKE HOSE Figure 6b-17 Front Brake Hose With Plastic Bag FRONT BRAKE CLUSTER ASSEMBLY INSTALLATION 1. Use only new hardware for this step. Install the brake cluster back plate to the front spindle ﬂange using four Torx-head bolts (18), washers (19) and lock nuts (20).
Page 124: Rear Brake Cluster Assembly Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement Rear Brake Cluster Assembly Removal, Continued: 8. Using a Torx #T-40 driver, remove the four Torx-head bolts (16), washers (17), and lock nuts (18) that secure the brake cluster back plate assembly to the axle tube ﬂange (Figure 6b-21, Page 6b-25). 9.
Page 125: Wheel Cylinder Replacement
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement 3. Install the park brake cable into the cable support bracket by sliding the coiled spring wire through the slot in the bracket and feed the clevis end to the park brake lever (Figure 6b-18, Page 6b-22). 4.
Page 126: Rear Wheel Cylinder Removal
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement Front Wheel Cylinder Installation, Continued: 2. Install a new banjo bolt (16) and new copper washers (17) to the front brake cluster wheel cylinder (7). Position the elbow of the brake hose toward the rear of the vehicle. Tighten the banjo bolt to 13 ft-lb (17.6 N·m) (Figure 6b-3, Page 6b-4).
Page 127: Brake Shoe Adjuster Replacement
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Adjuster Replacement REFERENCE BRAKE HOSE BLEEDER VALVE TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 6b-21 Rear Hydraulic Brake Cluster Assembly BRAKE SHOE ADJUSTER REPLACEMENT Read DANGER and WARNING on page 6b-1.
Page 128: Front Brake Shoe Adjuster Removal
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Adjuster Replacement FRONT BRAKE SHOE ADJUSTER REMOVAL 1. Remove front wheel brake drum. See Front Wheel Brake Drum Removal on page 6b-9. 2. Remove front brake shoes. See Front Brake Shoe Removal on page 6b-11. 3.
Page 129: Rear Brake Shoe Adjuster Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement REAR BRAKE SHOE ADJUSTER INSTALLATION NOTE: The adjusters must be replaced as pairs using new hardware. 1. Install bolt (4) through ﬂat washer (2) and through the brake cluster back plate (1) (Figure 6b-21, Page 6b-25).
Page 130 MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement TYPICAL BOTH SIDES TYPICAL 2 PLACES REFERENCE FRONT SUSPENSION REFERENCE MASTER CYLINDER REFERENCE FRONT HYDRAULIC BRAKE TYPICAL BOTH SIDES REFERENCE REAR HYDRAULIC BRAKE Figure 6b-22 Four-Wheel Hydraulic Brake System Page 6b-28 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 131: Front Brake Line Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement FRONT BRAKE LINE INSTALLATION 1. Connect the 7/16-inch ﬂare nut of the brake line (4) to the master cylinder and tighten ﬁnger-tight (Figure 6b-22, Page 6b-28). 2. Connect the 3/8-inch ﬂare nut of the brake line (4) to the T-manifold block (1) and tighten ﬁnger-tight (Figure 6b-22, Page 6b-28).
Page 132: Rear Brake Line Removal
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement Front Brake Hose Assembly Installation, Continued: 4. Using a 3/8-inch ﬂare nut wrench, connect the ﬂare ﬁtting on the front brake line (4) to the T-manifold block (1). Tighten to 11 ft-lb (14.9 N·m) (Figure 6b-22, Page 6b-28). 5.
Page 133: Rear Brake Hose Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement 5. Remove the horseshoe clip (12) that secures the rear brake hose (9) to the I-beam frame (Figure 6b-22, Page 6b-28) and remove the brake hose (9) through the D-shaped hole in the vehicle I-beam. 6.
Page 134: Master Cylinder Removal
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement Bell Crank Installation, Continued: 2. Install bolt (20) through push rod (3) and bell crank (13) and attach nylon lock nut (21). Tighten to 14 ft- lb (19 N·m) (Figure 6b-23, Page 6b-34). 3.
Page 135: Bleeding The Hydraulic Brake System
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System 6. Adjust the brake pedal as instructed in Section 5. See Brake Pedal Adjustment, Section 5, Page 5-6. 7. Fill the reservoir of the master cylinder and bleed the entire hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6b-33.
Page 136 MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System Bleeding the Hydraulic Brake System, Continued: TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 6b-23 Master Cylinder 8.
Page 137: Purging The Hydraulic System
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System 10. Monitor the ﬂuid as it ﬂows through the tubes of the vacuum bleeder tool. Continue to run the vacuum until there are almost no air bubbles in the lines. See following NOTE. NOTE: Do not allow the brake ﬂuid in the master cylinder reservoir to drop below the “min”...
Page 138: Filling The Hydraulic System
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Purging the Hydraulic System, Continued: Full Level Safe Level Level Figure 6b-25 Master Cylinder Reservoir 1. Perform steps 2 through 9 of the brake bleeding procedure on the two front wheels. See Bleeding the Hydraulic Brake System on page 6b-33.
Page 139: Park Brake Cable Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System 7. Remove the end of the park brake cable from handle (1) by pushing the equalizer cable in an upward direction and pulling the cable end toward the passenger side of the vehicle. 8.
Page 140: Park Brake Handle Removal
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Equalizer Cable Installation Continued: Figure 6b-26 Position Wheel Brake Cable Figure 6b-27 Wheel Brake Cable Attachmentl 5. Slide the boot shield (31) around the park brake handle (Figure 6b-28, Page 6b-40). 6.
Page 141: Park Brake Handle Installation
MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System PARK BRAKE HANDLE INSTALLATION 1. Attach the handle (1) to the seat support using two 3/8-16 x 1-1/4-inch hex-head bolts (4), 3/8 ﬂat wash- ers (5) and 3/8-16 lock nuts (6) (Figure 6b-28, Page 6b-40). Tighten the nuts (6) to 23 ft-lb (31.4 N·m). NOTE: Use new 3/8-16 lock nuts for this assembly procedure.
Page 142 MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL EACH SIDE OF VEHICLE TYPICAL EACH SIDE OF VEHICLE TYPICAL EACH SIDE OF VEHICLE Figure 6b-28 Park Brake System Page 6b-40...
Page 143: Section 7 - Steering And Front Suspension
SECTION 7 – STEERING AND FRONT SUSPENSION ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 144: General Information
STEERING AND FRONT SUSPENSION General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. •...
Page 145 STEERING AND FRONT SUSPENSION Steering Wheel TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-1 Steering Column 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 7-3...
Page 146: Steering Wheel Installation
STEERING AND FRONT SUSPENSION Steering Wheel Steering Wheel Removal, Continued: 8.3. Rotate the anvil screw (6) clockwise until the base plate contacts the bottom of the steering wheel where it attaches to the steering column (Figure 7-3, Page 7-4). 8.4. Using a 1/2-inch drive air impact wrench, tighten the anvil screw (6) until the steering wheel releases from the steering shaft.
Page 147: Steering Column
STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN Read DANGER and WARNING on page 7-1. STEERING COLUMN REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2. Access the engine compartment. See WARNING "For vehicles with cargo beds..." on page 7-2. 2.1.
Page 148: Steering Column Disassembly
STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN DISASSEMBLY 1. While supporting steering column (13) on a workbench, remove snap ring (5) from shaft (Figure 7-1, Page 7-3). NOTE: Do not allow the steering shaft to slide out of the steering tube when removing the snap ring. 2.
Page 149: Steering Column Installation
STEERING AND FRONT SUSPENSION Rack and Pinion 3. Install the wedge (8), spring (7), washer (6) and snap ring (5) onto the bottom end of the steering shaft (11) (Figure 7-5, Page 7-6). 4. Insert the shaft (11) from the bottom of the steering tube (13) (Figure 7-1, Page 7-3). 5.
Page 150: Rack And Pinion Disassembly
STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Removal, Continued: 3. Remove the cotter pins (18) and ball joint retaining nuts (24) (Figure 7-20, Page 7-13). 4. Remove the ball joints (23) from the spindle assemblies (Figure 7-20, Page 7-13). Figure 7-7 Rack and Pinion Bolts 5.
Page 151 STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-8 Remove Rack and Pinion Figure 7-9 Ball Joint Figure 7-10 Drag Link 12. Inspect the bushing (17) and needle bearing (14) for excessive wear. If wear is excessive, replace the steering box assembly (CCI P/N 102010101) (Figure 7-20, Page 7-13). 13.
Page 152 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly, Continued: 13.3. Using a wrench, remove the ball joint (9) from the rack (2) (Figure 7-20, Page 7-13). 14. Remove the rack (2) from housing (1) (Figure 7-20, Page 7-13). Figure 7-11 Dust Bellows Clamp PRESS RAM PINION GEAR...
Page 153: Rack And Pinion Assembly
STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-16 Remove Pinion Figure 7-17 Remove Pinion Gear Assembly Figure 7-18 Remove Rack Figure 7-19 Remove Ball Joint RACK AND PINION ASSEMBLY 1. Apply a liberal amount of EP grease to the teeth of the rack (2), then slide the rack through the bushing (17) and housing (1) (Figure 7-20, Page 7-13).
Page 154: Rack And Pinion Installation
STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Assembly, Continued: 4. Install the snap ring (4) (Figure 7-20, Page 7-13). 5. Using a socket to apply pressure evenly, press in a new dust seal (Figure 7-21, Page 7-14). 6.
Page 155 STEERING AND FRONT SUSPENSION Rack and Pinion TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-20 Steering Gear 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 7-13...
Page 156: Front Suspension
STEERING AND FRONT SUSPENSION Front Suspension RUBBER MALET 15/16-INCH DEEP WELL SOCKET DUST SEAL IN PLACE Figure 7-21 Press In Dust Seal Figure 7-22 Rack and Pinion Adjustment 3/8 INCH, 1/4 DRIVE, DEEP WELL SOCKET Figure 7-23 Rack and Pinion Resistance Figure 7-24 Install Ball Joint FRONT SUSPENSION Read DANGER and WARNING on page 7-1.
Page 157 STEERING AND FRONT SUSPENSION Front Suspension NOTE: Prior to making any front suspension adjustments, inspect components for wear or damage and repair or replace as necessary. Toe-in Adjustment 1. On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead.
Page 158: Front Suspension Components
STEERING AND FRONT SUSPENSION Front Suspension Components Toe-in Adjustment, Continued: 6.2. Remove the lock nuts (24) (Figure 7-20, Page 7-13). 6.3. Rotate both of the ball joints an equal amount. To increase the toe-in, rotate both of the ball joints counterclockwise.
Page 159: A-Arm Removal
STEERING AND FRONT SUSPENSION Front Suspension Components 3. Inspect the kingpin bushings (16 and 18) (Figure 7-29, Page 7-18). If the bushings are worn or dam- aged, remove them and press in new ones. See following NOTE. NOTE: If the bushings are replaced, ream new bushings to .750-.752 of an inch (19.05-19.10 mm) in diam- eter.
Page 160 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL TYPICAL 4 PLACES TYPICAL 2 PLACES 4 PLACES TYPICAL 4 PLACES TYPICAL...
Page 161: A-Arm Installation
STEERING AND FRONT SUSPENSION Front Suspension Components A-Arm Removal, Continued: 5. Remove the wave washer (33) and inspect it. If the washer is broken or has a wave bottom to wave crest height dimension of less than .040 inch (0.10 cm), it must be replaced (Figure 7-29, Page 7-18). 6.
Page 162: Shock Absorber Installation
STEERING AND FRONT SUSPENSION Front Suspension Components Shock Absorber Removal, Continued: 2. Inspect the shock absorbers for damage or ﬂuid leakage on the shock absorber body. Leaking or dam- aged shock absorbers should be replaced. 3. Remove the bolt (2) and nut (9) attaching the shock absorber to the A-arm (Figure 7-30, Page 7-20). 4.
Page 163: Front Wheel Bearings And Hubs
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs Figure 7-31 Front Wheel Bearings and Hub FRONT WHEEL BEARINGS AND HUBS Read DANGER and WARNING on page 7-1. FRONT WHEEL FREE PLAY INSPECTION 1. Place chocks at the rear wheels, loosen the front wheel lug nuts and lift the front of the vehicle with a chain hoist or ﬂoor jack.
Page 165: Section 8 - Wheels And Tires
SECTION 8 – WHEELS AND TIRES ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 166: General Information
WHEELS AND TIRES General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. •...
Page 167: Wheel Installation
WHEELS AND TIRES Tires WHEEL INSTALLATION 1. Install wheel(s) and tighten the lug nuts, using a crisscross pattern, ﬁnger tight. 2. Lower the vehicle and ﬁnish tightening the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m). 3. Inspect the brake hoses at the front wheels. When turning the steering wheel all the way from left to right and back again, the hoses should not come in contact with any component, especially the wheels or tires.
Page 169: Section 9 - Rear Suspension
SECTION 9 – REAR SUSPENSION ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 170: General Information
REAR SUSPENSION General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic ﬂoor jack) with 1000 lb.
Page 171 REAR SUSPENSION Shock Absorbers TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE AXLE SADDLE Figure 9-1 Rear Suspension for MC012C-AS00 Transaxle 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 9-3...
Page 172 REAR SUSPENSION Shock Absorbers TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE AXLE SADDLE Figure 9-2 Rear Suspension for MC010C-BS00 Transaxle Page 9-4 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 173: Shock Absorber Installation
REAR SUSPENSION Multi-Leaf Springs Figure 9-3 Remove Shock Absorbers, MC012C Figure 9-4 Remove Shock Absorbers, MC010C SHOCK ABSORBER INSTALLATION NOTE: The following procedure is the same for both MC012C-AS00 and MC010C-BS00 transaxles. See Transaxle Identiﬁcation, Section 6a, Page 6a-2. When installing shock absorbers, make sure front shocks have identical part numbers and rear shocks have identical part numbers.
Page 174: Multi-Leaf Spring Installation
REAR SUSPENSION Multi-Leaf Springs Multi-Leaf Spring Removal, Continued: 2. Loosen the lug nuts on wheel(s) to be removed. 3. Place chocks in front of the front wheels and lift rear of vehicle with a chain hoist or ﬂoor jack. If using ﬂoor jack, place jack under transaxle as shown (Figure 9-5, Page 9-6).
Page 175: Snubber
REAR SUSPENSION Snubber 2. Place front of leaf spring (18) into front spring mounts and insert the grade eight bolt (21) through mount and leaf spring eye. Install lock nut (22) and tighten to 15 ft-lb (20.3 N·m). ∆ CAUTION •...
Page 176 REAR SUSPENSION Snubber SNUBBER MOUNTING BRACKET SNUBBER BRACKET Figure 9-7 Snubber Brackets Page 9-8 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 177: Section 10 - Periodic Maintenance
SECTION 10 – PERIODIC MAINTENANCE ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 178: General Information
Any vehicle not functioning correctly should be removed from use until it is repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car, Inc., dealer for repairs, semiannual and annual periodic service. AS SEEN FROM...
Page 179: Pre-Operation And Daily Safety Checklist
Periodic Service Schedule on page 10-4. Any problems should be corrected by your Club Car distributor/dealer or a trained technician. • General: All the parts should be in place and properly installed. Be sure that all nuts, bolts, and screws are tight.
Page 180: Periodic Service Schedule
PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE ∆ WARNING • Service, repairs, and adjustments must be made per instructions in this maintenance and service manual. NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, the preventive maintenance procedures should be performed more often than recommended in the periodic ser- vice and lubrication schedules.
Page 181: Periodic Lubrication Schedule
PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINT Semiannually by owner Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) or trained technician (every 50 hours of operation) Accelerator push rod pivots, Dry Moly Lube (CCI P/N 1012151) mounts, and shifter cable pivots Front suspension (2 ﬁttings)
Page 182: Master Cylinder
PERIODIC MAINTENANCE Master Cylinder MASTER CYLINDER The master cylinder is located under the passenger seat toward the center of the vehicle (Figure 10-3, Page 10-6). Raise or remove the seat to check the brake ﬂuid level. When checking the brake ﬂuid, also inspect the following: •...
Page 183: Oil Viscosity
PERIODIC MAINTENANCE Fueling Instructions full level safe level Level Level level Oil fill tube is located behind and under the passenger seat. Figure 10-4 Check Engine Oil Level OIL VISCOSITY Choose the viscosity according to the temperature as shown (Figure 10-5, Page 10-7). See following NOTE.
Page 184: Battery
PERIODIC MAINTENANCE Battery ∆ DANGER • To avoid electric arc caused by static electricity, the fuel storage/pumping device must be grounded. If the pump is not grounded, the vehicle must be grounded to the pump before and during the fueling operation. •...
Page 185: Section 11A - Troubleshooting And Electrical System: Fe400, Key-Start Engine
SECTION 11A – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 186: General Information
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death.
Page 187: Troubleshooting Guide
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difﬁculties should they occur. The guide includes the symptom, probable cause(s) and suggested checks. The procedures used in making these checks can be found in the referenced sections of this maintenance and service manual.
Page 188 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine turns but fails to start, Section 11a – Troubleshooting and continued. Kill circuit grounded Electrical System: FE400, Key-Start Engine, Test Procedures 14, 15, and 16 Engine overheats.
Page 189 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Starter fails to operate, continued. Section 11a – Troubleshooting and Fuse is blown Electrical System: FE400, Key-Start Engine, Test Procedure 2 Section 11a – Troubleshooting and Battery is dead Electrical System: FE400, Key-Start Engine, Test Procedure 1...
Page 190 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Transmission does not engage or Differential Gear Case Disassembly, Internal gears are damaged or worn disengage smoothly, continued. Section 16a, Page 16a-22 Synchronizer rings are worn, damaged or Synchronizer Gear Disassembly, jammed Section 16a, Page 16a-25...
Page 191: Electrical System
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Electrical System ELECTRICAL SYSTEM The electrical system on the FE400 key-start vehicles is 12 volts DC with negative ground to frame. It consists of ten circuits that are easily identiﬁed: • Starter Circuit •...
Page 192: Wiring Diagram
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagram WIRING DIAGRAM PASSENGER SIDE HEADLIGHT DRIVER SIDE HEADLIGHT SONIC WELD SONIC WELD LIGHT SWITCH Figure 11a-2 Wiring Diagram for FE400 Key-Start Vehicles (Front) Page 11a-8 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 193 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagram SONIC WELD SONIC WELD SONIC WELD Figure 11a-3 Wiring Diagram for FE400 Key-Start Vehicles (Rear) 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 11a-9...
Page 194: Electrical Circuits
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Electrical Circuits ELECTRICAL CIRCUITS STARTER CIRCUIT The starter circuit consists of a 12-volt battery, fuse, key switch, lockout cam limit switch, solenoid, starter/gen- erator, and connecting wires (Figure 11a-4, Page 11a-10). The battery is the source of power for the system. The fuse provides protection to the solenoid activating circuit.
Page 195: Engine Ignition Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Electrical Circuits Figure 11a-5 Key-Start Generator Circuit ENGINE IGNITION CIRCUIT The engine ignition circuit is independent of all other circuits except the kill circuit. It consists of the ignition coil with internal igniter, spark plug, RPM limiter, and connecting wires (Figure 11a-6, Page 11a-11). SPARK PLUG RPM LIMITER ENGINE KILL...
Page 196: Reverse Buzzer Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Electrical Circuits Figure 11a-7 Engine Kill Circuit REVERSE BUZZER CIRCUIT The reverse buzzer is a safety warning device that sounds when the Forward/Reverse handle is in REVERSE. It functions to remind the operator not to leave the vehicle in reverse and to warn anyone in the area that the vehicle is in reverse.
Page 197: Lockout Cam Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Electrical Circuits The light receives power through the key switch when the key switch is turned to the ON position. When the oil level in the crankcase is low, the oil level sensor closes the circuit to ground and illuminates the low oil warning light.
Page 198: Fuel Gauge And Sending Unit Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Electrical Circuits Figure 11a-11 Lockout Cam Circuit FUEL GAUGE AND SENDING UNIT CIRCUIT The fuel gauge and sending unit circuit consists of the fuel gauge/hour meter, fuel level sending unit, key switch and connecting wires. The fuel gauge sending unit picks up power from the key switch when the key switch is turned to the ON position.
Page 199: Hour Meter Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Circuit Testing HOUR METER CIRCUIT The hour meter circuit consists of the fuel gauge/hour meter, key switch, solenoid, and connecting wires (Figure 11a-13, Page 11a-15). Figure 11a-13 Key-Start Hour Meter Circuit LIGHTING CIRCUIT The headlights receive power through the fuse block when the light switch is pulled to the ON position (Figure 11a-14, Page 11a-15).
Page 200: Testing The Starter Circuit And Generator Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Circuit Testing TESTING THE STARTER CIRCUIT AND GENERATOR CIRCUIT Read DANGER and WARNING on page 11a-1. Use these charts (Figure 11a-15, Page 11a-16 and Figure 11a-16, Page 11a-16) to begin troubleshooting problems with the starter and generator circuits. ENGINE WILL NOT CRANK (STARTER DOES NOT ROTATE) SOLENOID DOES NOT CLICK...
Page 201: Testing The Engine Ignition Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Circuit Testing TESTING THE ENGINE IGNITION CIRCUIT Read DANGER and WARNING on page 11a-1. Use this chart (Figure 11a-17, Page 11a-17) to begin troubleshooting engine ignition circuit problems. STARTER ROTATES – ENGINE WILL NOT RUN IGNITION GAP TEST (TEST PROCEDURE 14) IGNITION GAP TEST...
Page 202: Testing The Reverse Buzzer Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Circuit Testing TESTING THE REVERSE BUZZER CIRCUIT Read DANGER and WARNING on page 11a-1. Use this chart (Figure 11a-19, Page 11a-18) to begin troubleshooting the reverse buzzer circuit. REVERSE BUZZER WILL NOT FUNCTION CHECK FUSE (TEST PROCEDURE 2) GOOD FUSE...
Page 203: Testing The Low Oil Warning Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Circuit Testing TESTING THE LOW OIL WARNING CIRCUIT Read DANGER and WARNING on page 11a-1. Use this chart (Figure 11a-20, Page 11a-19) to begin troubleshooting the low oil warning circuit. LOW OIL LIGHT WILL NOT ILLUMINATE WHEN ENGINE OIL IS LOW CHECK WIRE CONNECTION...
Page 204: Testing The Lockout Cam Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Circuit Testing TESTING THE LOCKOUT CAM CIRCUIT Read DANGER and WARNING on page 11a-1. A failure in the lockout cam circuit will prevent the starter from rotating. See Testing the Starter Circuit and Generator Circuit on page 11a-16.
Page 205: Testing The Lighting Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TESTING THE LIGHTING CIRCUIT Read DANGER and WARNING on page 11a-1. Use this chart (Figure 11a-22, Page 11a-21) to begin troubleshooting the lighting circuit. NO LIGHTS WORK CHECK FUSE NO CONTINUITY (TEST PROCEDURE 2) REPLACE FUSE CONTINUITY OK...
Page 206 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Index of Test Procedures, Continued: 9. Wire Continuity 10. Diode (Generator Circuit) 11. Starter/Generator (Generator Function) 12. Voltage Regulator 13. Disconnected Kill Wire 14. Ignition Spark 15. RPM Limiter 16. Ignition Coil 17.
Page 207 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 1. Place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. 2. Check for loose or corroded battery terminal connections. Clean, tighten, and replace connections as necessary. Hydrometer Test A hydrometer (CCI P/N 1011478) measures the speciﬁc gravity.
Page 208 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 °F (27 °C). The readings obtained as described above must be corrected for temperature. 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.
Page 209 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures MINIMUM CRANKING IF TEMPERATURE IS VOLTAGE 20 °F (-7 °C) 8.9 V 10 °F (-12 °C) 8.7 V 0 °F (-18 °C) 8.5 V 4. If the battery is found to be good, or if the electrical problem continues after the battery has been replaced with a good one, test the electrical circuits.
Page 210 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 3 – Ground Cables, Continued: The engine ground is attached to the WIRE TO FRAME NEXT oil filler bracket, TO BATTERY and the frame I-beam. A2 TERMINAL Figure 11a-25 Test Starter/Generator Ground Strap Figure 11a-26 Test Engine Ground Strap Place black (–) probe on...
Page 211 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 4 – KEY SWITCH (STARTER CIRCUIT) Read DANGER and WARNING on page 11a-1. 1. Place the Forward/Reverse shifter handle in NEUTRAL. Chock the wheels and disconnect the battery, negative (–) cable ﬁrst. 2.
Page 212 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 5 – Key Switch (Accessory Terminal), Continued: 4. Insert the key and turn the switch to the ON position. With the multimeter set to 200 Ω (ohms), place the red (+) probe of the multimeter on the (B) terminal and the black (–) probe on the (L) terminal of the key switch (Figure 11a-28, Page 11a-27).
Page 213 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 10. Disconnect the 6-gauge black wire from the negative post of the battery before reconnecting the wires to the solenoid. 11. Reconnect the solenoid. See Fuse Installation, Section 12a, Page 12a-20. See also following WARNING.
Page 214 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE 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 Ω Ω TESTER LIGHT IS TESTER LIGHT ON.
Page 215 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures YELLOW YELLOW WIRE WIRE WAVETEK 1000 2000 200k Ω JUMPER WIRE Ω 200nA 1000 --- FUSED 750V Figure 11a-34 Check Starter Terminal Continuity Figure 11a-35 Jumper Wire Ground – DF to A2 7.
Page 216 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 10 – Diode (Generator Circuit), Continued: RED FROM VOLTAGE REGULATOR Some wires RED FROM DIODE omitted for WHITE FROM DIODE clarity. ANGLED I-BEAM RED FROM FUSE BLOCK WHITE FROM STARTER/GENERATOR RED FROM BATTERY...
Page 217 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK WAVETEK 1000 1000 WHITE WIRE 2000 2000 200k 200k Ω Ω Ω Ω 200nA 200nA 1000 --- FUSED 1000 --- 750V FUSED 750V RED WIRE DIODE DIODE Figure 11a-37 Diode Test Figure 11a-38 Diode Test –...
Page 218 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 12 – Voltage Regulator, Continued: 3. Check the engine RPM setting to ensure that it is adjusted correctly. See Engine RPM Adjustment, Section 14, Page 14-14. 4. With the battery in good condition and fully charged, run the engine for several minutes to bring the volt- age regulator to operating temperature.
Page 219 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures ∆ WARNING • When the white/black engine kill wire is disconnected, the engine will not stop running after the key switch is turned to the OFF position. It will be necessary to pull and hold the choke handle until the engine stops running.
Page 220 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 15 – RPM LIMITER Read DANGER and WARNING on page 11a-1. 1. Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels and disconnect the bat- tery cables, negative (–) cable ﬁrst. 2.
Page 221 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11a-43 Primary Coil Resistance – In Vehicle Test 3. Using a multimeter set to 20k Ω (ohms), measure the resistance of the secondary coil and spark plug cap together.
Page 222 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11a-44 Secondary Coil Test – In Vehicle Test Figure 11a-45 Ignition Coil and Cap Figure 11a-46 Spark Plug Cap Removal Page 11a-38 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 223 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11a-47 Spark Plug Cap Test 5. Test the secondary coil separately from the spark plug cap. 5.1. Using a multimeter set to 20k Ω (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 11a-48, Page 11a-40).
Page 224 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Ignition Coil – Bench Test, Continued: WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11a-48 Secondary Coil Test Without Cap WAVETEK SECONDARY COIL 1000 WAVETEK 1000 2000 200k Ω...
Page 225 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11a-51 Secondary Coil Resistance – Bench Test 4. If not previously tested, test the spark plug cap separately from the secondary coil. 4.1.
Page 226 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 17 – Key Switch (Engine Kill Circuit), Continued: 4. Place the red (+) probe on the (M) terminal and the black (–) probe on the (G) terminal. With the key switch OFF, the reading should be continuity.
Page 227 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 2. Move the Forward/Reverse handle to REVERSE and listen for an audible click from the limit switch. If there is no click, check the switch for proper alignment and switch arm movement. 3.
Page 228 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 22 – Oil Warning Light, Continued: 2. Remove the center dash assembly. See Key Switch Removal, Section 12a, Page 12a-16. 3. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary (Figure 11a-9, Page 11a-13).
Page 229 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 1. Turn the key switch to the OFF position, put the Forward/Reverse handle in the NEUTRAL position, dis- connect the battery cables, negative (–) cable ﬁrst, and chock the wheels. 2. Disconnect the orange wire from the center post of the fuel level sending unit. 3.
Page 230 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 26 – FUEL GAUGE Read DANGER and WARNING on page 11a-1. 1. Place the Forward/Reverse handle in NEUTRAL, chock the wheels and disconnect the battery cables, negative (–) cable ﬁrst. 2.
Page 231 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 4. Allow the engine to idle for at least six minutes (the meter records in six-minute increments). See fol- lowing DANGER. ∆ DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison.
Page 232 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 29 – HEADLIGHT DIODE Read DANGER and WARNING on page 11a-1. 1. Place the Forward/Reverse handle in NEUTRAL, chock the wheels and disconnect the battery cables, negative (–) cable ﬁrst. 2.
Page 233 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 30 – VOLTAGE AT HEADLIGHT SOCKET Read DANGER and WARNING on page 11a-1. NOTE: Keep the battery connected while performing this test procedure. 1. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2.
Page 235: Section 11B - Troubleshooting And Electrical System: Fe350, Pedal-Start Engine
SECTION 11B – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 236: General Information
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death.
Page 237: Troubleshooting Guide
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difﬁculties should they occur. The guide includes the symptom, probable cause(s) and suggested checks. The procedures used in making these checks can be found in the referenced sections of this maintenance and service manual.
Page 238 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Engine turns but fails Section 11b – Troubleshooting and to start, continued. Kill circuit grounded Electrical System: FE350, Pedal-Start Engine, Test Procedures 13, 14, and 15 Fuel pump malfunction or failure Section 14 –...
Page 239 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Starter fails to operate. Section 11b – Troubleshooting and Electrical System: FE350, Pedal-Start Lockout cam is in the wrong position Engine, Neutral Lockout Circuit on page 11b-13 Section 11b –...
Page 240 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Transmission does not engage or Transmission shifter linkage is binding or Section 16b – MC010C-BS00 Unitized disengage smoothly. is out of adjustment Transaxle with Differential Lock Idle RPM setting is set too high Section 14 –...
Page 241: Electrical System
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Electrical System ELECTRICAL SYSTEM The electrical system on the FE350 pedal-start vehicle is 12 volts DC with negative ground to frame. It con- sists of ten circuits that are easily identiﬁed: • Starter Circuit •...
Page 242 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Wiring Diagram WIRING DIAGRAM GROUND PASSENGER SIDE TERMINAL HEADLIGHT BLOCK DRIVER SIDE HEADLIGHT SONIC WELD LIGHT SWITCH Figure 11b-2 Wiring Diagram for FE350 Pedal-Start Vehicle (Front) Page 11b-8 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 243 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Wiring Diagram SONIC WELD SONIC WELD SONIC WELD Figure 11b-3 Wiring Diagram for FE350 Pedal-Start Vehicle (Rear) 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 11b-9...
Page 244: Starter Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Wiring Diagram STARTER CIRCUIT The starter circuit consists of a 12-volt battery, fuse, key switch, accelerator pedal limit switch, neutral lockout limit switch, solenoid, starter/generator, and connecting wires (Figure 11b-4, Page 11b-10). The battery is the source of power for the system.
Page 245: Engine Ignition Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Wiring Diagram Figure 11b-5 Pedal-Start Generator Circuit ENGINE IGNITION CIRCUIT The engine ignition circuit is independent of all other circuits except the kill circuit. It consists of the ignition coil with internal igniter, spark plug, RPM limiter, and connecting wires (Figure 11b-6, Page 11b-11). SPARK PLUG RPM LIMITER ENGINE KILL...
Page 246: Reverse Buzzer Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Wiring Diagram SONIC WELD Figure 11b-7 Engine Kill Circuit Figure 11b-8 Reverse Buzzer Circuit REVERSE BUZZER CIRCUIT The reverse buzzer is a safety warning device that sounds when the Forward/Reverse handle is in REVERSE. It functions to remind the operator not to leave the vehicle in reverse and to warn anyone in the area that the vehicle is in reverse.
Page 247: Neutral Lockout Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Wiring Diagram Figure 11b-9 Low Oil Warning Circuit NEUTRAL LOCKOUT CIRCUIT The neutral lockout circuit prevents the operator from starting the vehicle in NEUTRAL. Also, if the vehicle is started in FORWARD or REVERSE and then shifted to NEUTRAL, the engine will stop running. The neutral lockout circuit consists of the connecting wires, a limit switch that is located on the Forward/ Reverse shifter assembly, which is activated by a neutral lockout cam, and a limit switch that is located in the electrical component box, which is activated by the accelerator pedal (Figure 11b-12, Page 11b-14).
Page 248: Fuel Gauge And Sending Unit Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Wiring Diagram Neutral Lockout Circuit, Continued: NOTE: Be sure to return the cam to the OPERATE position after servicing the vehicle, or the vehicle will not run. NEUTRAL NEUTRAL OPERATE POSITION SERVICE POSITION Figure 11b-10 Service Position For Figure 11b-11 Operate Position For Neutral Lockout Cam...
Page 249: Hour Meter Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Wiring Diagram TO WIRE HARNESS Figure 11b-13 Fuel Gauge and Sending Unit Circuit Figure 11b-14 Pedal-Start Hour Meter Circuit HOUR METER CIRCUIT The hour meter circuit consists of the fuel gauge/hour meter, key switch, solenoid and connecting wires (Figure 11b-14, Page 11b-15).
Page 250: Testing The Starter Circuit And Generator Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Circuit Testing CIRCUIT TESTING Read DANGER and WARNING on page 11b-1. Before testing the electrical circuits to determine the source of an electrical problem, test the vehicle battery to determine whether or not it is the source of the problem. A hydrometer, multimeter, and 160 ampere load tester will be required.
Page 251: Testing The Engine Kill Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Circuit Testing ENGINE CRANKS – CAR WILL NOT RUN IGNITION GAP TEST (TEST PROCEDURE 13) IGNITION GAP TEST IGNITION GAP TEST GOOD NOT GOOD REPLACE SPARK PLUG DISCONNECT ENGINE KILL WIRE ENGINE RUNS ENGINE DOES NOT RUN GOOD SPARK NO SPARK...
Page 252 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Circuit Testing ENGINE WILL NOT STOP RUNNING WHEN KEY SWITCH IS IN OFF POSITION CHECK KEY SWITCH (TEST PROCEDURE 17) INCORRECT CORRECT CONTINUITY READING CONTINUITY READING REPLACE KEY SWITCH CHECK CONNECTIONS OF CIRCUIT WIRING WIRES CORRECTLY WIRES INCORRECTLY CONNECTED...
Page 253: Testing The Reverse Buzzer Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Circuit Testing TESTING THE REVERSE BUZZER CIRCUIT Read DANGER and WARNING on page 11b-1. Use the following chart (Figure 11b-21, Page 11b-19) to begin troubleshooting the reverse buzzer circuit. REVERSE BUZZER WILL NOT FUNCTION CHECK FUSE (TEST PROCEDURE 2) GOOD FUSE...
Page 254: Testing The Low Oil Warning Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Circuit Testing TESTING THE LOW OIL WARNING CIRCUIT Read DANGER and WARNING on page 11b-1. Use the following chart (Figure 11b-22, Page 11b-20) to begin troubleshooting the low oil warning circuit. LOW OIL LIGHT WILL NOT ILLUMINATE WHEN ENGINE OIL IS LOW CHECK WIRE CONNECTION...
Page 255: Testing The Fuel Gauge And Sending Unit Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Circuit Testing ENGINE RUNS WITH ACCELERATOR PEDAL DEPRESSED AND SHIFTER IN NEUTRAL POSITION CHECK NEUTRAL LOCKOUT LIMIT SWITCH (TEST PROCEDURE 7) INCORRECT CORRECT CONTINUITY READING CONTINUITY READING REPLACE LIMIT SWITCH CHECK CONNECTIONS OF CIRCUIT WIRING WIRES CORRECTLY WIRES INCORRECTLY CONNECTED...
Page 256: Testing The Lighting Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Circuit Testing TESTING THE LIGHTING CIRCUIT Read DANGER and WARNING on page 11b-1. Use the two charts below (Figure 11b-25, Page 11b-22 and Figure 11b-26, Page 11b-22) to begin trouble- shooting the lighting circuit. HEADLIGHTS NOT WORKING CHECK FUSE NO CONTINUITY...
Page 257: Index Of Test Procedure
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURES INDEX OF TEST PROCEDURE 1. Battery 2. Fuse 3. Ground Cables 4. Key Switch (Starter Circuit) 5. Accelerator Pedal Limit Switch 6. Solenoid 7. Neutral Lockout Limit Switch 8. Starter/Generator (Starter Function) 9.
Page 258 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURE 1 – BATTERY Read DANGER and WARNING on page 11b-1. ∆ DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working around a battery.
Page 259 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Performing the Hydrometer Test 1. Be sure that the battery has sufﬁcient water to cover the plates by approximately 1/2-inch (13 mm) and is fully charged prior to beginning the test. If water must be added, recharge the battery before perform- ing the hydrometer test (Figure 11b-28, Page 11b-25).
Page 260 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table: SPECIFIC GRAVITY APPROXIMATE (TEMPERATURE STATE OF CHARGE CORRECTED) 1.250-1.280 100% 1.220-1.240 1.190-1.210 1.160-1.180 If the difference between the cells is 0.020 or more, the low cell should be suspected.
Page 261 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures The engine ground is attached to the WIRE TO FRAME NEXT oil filler bracket, TO BATTERY and the frame I-beam. A2 TERMINAL Figure 11b-29 Test Starter/Generator Ground Cable Figure 11b-30 Test Engine Ground Cable TEST PROCEDURE 3 –...
Page 262 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 4 – Key Switch (Starter Circuit), Continued: Place black (–) probe on frame. WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Disconnect the 6-gauge black wire from the battery. Place red (+) probe on disconnected end of wire.
Page 263 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURE 5 – ACCELERATOR PEDAL LIMIT SWITCH Read DANGER and WARNING on page 11b-1. The accelerator pedal limit switch is the top switch located in the electrical component box. There is an 18- gauge green wire and an 18-gauge orange wire connected to this limit switch.
Page 264 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 8. Place the Forward/Reverse handle in NEUTRAL and place the neutral lockout cam in the SERVICE posi- tion. Turn the key switch to the ON position. With the accelerator in the up position, the reading on the multimeter should be no continuity.
Page 265 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 4. Check to be sure the lobes on the cam are depressing the neutral lockout limit switch as the Forward/ Reverse shifter is being shifted. The limit switch should make an audible click as it is depressed. If it does not, check for wear on the cam lobes.
Page 266 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 8 – Starter/Generator (Starter Function), Continued: 5. Using a multimeter set to 200 Ω (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 267 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURE 10 – STARTER/GENERATOR (GENERATOR FUNCTION) Read DANGER and WARNING on page 11b-1. NOTE: Keep the battery connected while performing this test procedure. 1. Place the neutral lockout cam in the SERVICE position, put the Forward/Reverse handle in the NEU- TRAL position, and chock the wheels.
Page 268 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11b-40 Test Voltage Regulator TEST PROCEDURE 12 – DISCONNECTED KILL WIRE Read DANGER and WARNING on page 11b-1. NOTE: Keep the battery connected while performing this test procedure. 1.
Page 269 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures IGNITION GAP TEST TOOL SPARK PLUG WIRE SPARK PLUG Disconnect FRAME white/black LIMITER engine kill wire. Figure 11b-41 Ignition Spark Test Figure 11b-42 Disconnect White/Black Engine Kill Wire TEST PROCEDURE 13 – IGNITION SPARK Read DANGER and WARNING on page 11b-1.
Page 270 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 14 – RPM Limiter, Continued: 4. This test will ﬁnd most bad RPM limiters. Some of them may bench test okay but fail under a load due to heat while operating. Another method of testing is to replace the RPM limiter and then run the engine. If the engine runs properly, keep the new RPM limiter in the circuit.
Page 271 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11b-44 Primary Coil Resistance – In Vehicle Test WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11b-45 Secondary Coil Test –...
Page 272 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 15 – Ignition Coil, Continued: 4.2. Remove the cap from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire (Figure 11b-47, Page 11b-38). Figure 11b-46 Ignition Coil and Cap Figure 11b-47 Spark Plug Cap Removal 4.3.
Page 273 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11b-49 Secondary Coil Test Without Cap Ignition Coil – Bench Test 1. Remove the coil from the engine. See Ignition Coil Removal, Section 12b, Page 12b-27. 2.
Page 274 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 15 – Ignition Coil, Continued: WAVETEK SECONDARY COIL 1000 WAVETEK 1000 2000 200k Ω 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Ω 200nA 1000 --- FUSED 750V Figure 11b-50 Primary Coil Resistance –...
Page 275 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 5. Test the secondary coil separately from the spark plug cap. 5.1. Using a multimeter set to 20k Ω (ohms), place the red (+) probe of the meter into the end of the spark plug wire and place the black (–) probe on the core (2) (Figure 11b-52, Page 11b-40).
Page 276 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 17 – Key Switch (Engine Kill Circuit), Continued: 4. Using a multimeter, set to 200 Ω (ohms). Place the red (+) probe on the black wire terminal of the key switch and the black (–) probe on the white/black wire terminal.
Page 277 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 3. If the switch is being activated but the buzzer does not function, place the red (+) probe of the multimeter on one terminal and the black (–) probe on the other terminal of the limit switch (Figure 11b-8, Page 11b-12).
Page 278 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 22 – Oil Warning Light, Continued: 5. Turn the key switch to the ON position. The oil light should illuminate. If it does not, check continuity of the yellow wire that connects the key switch to the oil light (through a sonic weld within the wire harness). If there is no continuity in the wire, replace the wire.
Page 279 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 2. Disconnect the orange wire from the center post of the fuel level sending unit. 3. With a multimeter set to 2 kΩ (ohms), place the red (+) probe of the multimeter on the center post of the sending unit.
Page 280 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURE 26 – FUEL GAUGE Read DANGER and WARNING on page 11b-1. 1. Place the neutral lockout cam in the SERVICE position, put the Forward/Reverse handle in NEUTRAL, chock the wheels and disconnect the battery cables, negative (–) cable ﬁrst. 2.
Page 281 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures ∆ DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. Engine produces carbon monoxide, which is an odorless, deadly poison. 4. If the reading does not change after six minutes, then replace the fuel gauge/hour meter. GROUND WAVETEK TERMINAL...
Page 282 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 29 – Light Switch, Continued: GROUND WAVETEK TERMINAL 1000 BLOCK 2000 200k Ω Ω 200nA 1000 --- FUSED 750V LIGHT SWITCH Figure 11b-60 Test Light Switch 4. Connect the red (+) probe to the light switch terminal with the blue wire connected to it. See following CAUTION.
Page 283 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures ∆ CAUTION • Before connecting battery cables, make sure no electrical components touch any part of the vehicle frame. 5. Connect the battery, positive (+) cable ﬁrst. GROUND TERMINAL BLOCK WAVETEK 1000 2000 200k...
Page 284 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 31 – Voltage at Headlight Socket, Continued: 6. If there is no voltage reading at the wire harness, check continuity of the 16-gauge blue wire from the headlight to the light switch. Using a multimeter set to 20 volts DC, attach using an alligator clip, the black (–) probe of multimeter onto the negative battery terminal and place the red (+) probe into the blue wire terminal of the wire harness.
Page 285: Section 12A - Electrical Components: Fe400, Key-Start Engine
SECTION 12A – ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 286: Starter/Generator
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. •...
Page 287 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Starter/Generator Removal 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2. Access the engine compartment. See WARNING "For vehicles with cargo beds..." on page 12a-2. 2.1.
Page 288 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Disassembly of the Starter/Generator to Service the Brushes, Continued: 2. Remove brush covers (29 and 30), screws (25) and lockwashers (26), brush springs (28), and brushes (27) (Figure 12a-4, Page 12a-4). See following NOTE. NOTE: To clean and inspect the armature/commutator and the bearings, see Disassembly of the Starter/Generator to Service the Armature/Commutator on page 12a-6.
Page 289 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator ∆ CAUTION • When checking brush spring tension, do not push springs beyond the point they would normally be if there were new brushes installed. Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs. Replace springs which apply a force of less...
Page 290 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator BRUSH BEING HELD BY BRUSH SPRING Figure 12a-7 Pull Brushes Away From Center of the Commutator End Cover Disassembly of the Starter/Generator to Service the Armature/Commutator 1. If the brushes are not removed, contact between the brushes and commutator as the commutator end cover is being removed or installed could damage the brushes.
Page 291 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator 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 12a-9, Page 12a-7). 2.
Page 292 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Field Coil Removal 1. Remove the retaining nut from each ﬁeld coil terminal and slide the insulator out of the slots in the hous- ing. Remove the four pole piece screws from the housing. Remove the four pole pieces from inside the housing.
Page 293 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator ∆ CAUTION • Never use emery cloth on the commutator. Particles of emery are conductive and may short- circuit the commutator bars. Never use oil or lubricants on the commutator or brushes. 2. Using a micrometer, measure the outside diameter at four points; two points 90° to each other to the out- side of the commutator (A1 and A2), and two points 90°...
Page 294 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE 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 295 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Starter/Generator Assembly 1. Place the ﬁeld coil into the housing. The two insulators that look alike ﬁt into the slots next to the F1 and F2 markings on the outside of the housing. The insulator that looks different slides into the slot next to the DF marking.
Page 296 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Starter/Generator Installation, Continued: 2. Install two 3/8 hex-head pivot bolts (5) into the mounting bracket with the heads of the bolts facing towards the driver side of the vehicle. Position the starter/generator in the mounting bracket so that the bolts will go through the starter/generator before going through the bracket.
Page 297: Voltage Regulator
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Voltage Regulator 5. Push the starter/generator down so it is at the lowest point of its adjustment travel. With the starter/gen- erator belt fully in place around the drive clutch pulley, install the starter/generator belt (3) around the pul- ley (10) on the end of the starter/generator.
Page 298: Diode
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Diode Voltage Regulator Installation, Continued: 4. Connect the battery cables, positive (+) cable ﬁrst, and tighten terminals to 20 ft-lb (27.1 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 5. With the Forward/Reverse handle in NEUTRAL, start the engine and check regulator for proper func- tioning as described in the voltage regulator test procedure.
Page 299 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Diode 6.1. Observe color orientation of the wires with the terminal locations on the solenoid. The 12-gauge red wire from the diode should be attached to the same terminal as the red wire from the fuse block, and the red wire from the battery.
Page 300: Key Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Key Switch Large Style Diode Installation 1. Thoroughly clean and dry the area of the I-beam where the new diode is to be attached. 2. Peel the protective ﬁlm from both sides of the new thermal pad (1) (Figure 12a-19, Page 12a-15). See following CAUTION.
Page 301: Solenoid
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Solenoid 4.1. Loosen seven Tuﬂok screws, but do not remove screws completely, as shown in Detail A (Figure 12a-21, Page 12a-19). 4.2. Remove Tuﬂok screws from dash panel as shown in Detail B. 4.3. Pull forward on top of dash panel to access back side of key switch. There is sufﬁcient slack in wiring to allow for this as shown in Detail C.
Page 302: Fuse
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuse Solenoid Removal, Continued: 3. Disconnect the battery cables, negative (–) cable ﬁrst. See WARNING "To avoid unintentionally start- ing..." on page 12a-1. 4. Remove electrical component box cover. 5. Disconnect all the wires from the solenoid. 6.
Page 303 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuse 4. Remove electrical component box cover. 5. Remove the fuse from the fuse block. Figure 12a-21 Center Dash Panel Removal 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 12a-19...
Page 304: Lockout Cam Limit Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Lockout Cam Limit Switch Fuse Installation 1. Install the fuse. See following WARNING. ∆ WARNING • If a fuse is blown, determine the cause of the failure and make necessary repairs before installing a new fuse. Use the appropriately rated fuse; if a fuse with a higher amp rating is used, damage to the vehicle electrical system may occur.
Page 305: Lockout Cam
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Lockout Cam 3. Connect battery cables, positive (+) cable ﬁrst, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 4. Check limit switch operation. 4.1.
Page 306: Reverse Warning Buzzer
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Reverse Warning Buzzer Lockout Cam Installation 1. Install the cam (11) (Figure 12a-23, Page 12a-21). 2. Install the spring (13) and the plastic washer (12). 3. Install the external snap ring (14) onto the shaft. Be sure the snap ring is installed in the groove on the shaft.
Page 307: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Reverse Buzzer Limit Switch BLACK GROUND RED/WHITE Figure 12a-24 Front Reverse Warning Buzzer REVERSE BUZZER LIMIT SWITCH Read DANGER and WARNING on page 12a-1. Testing the Reverse Buzzer Limit Switch See Test Procedure 19, Section 11a, Page 11a-42. Reverse Buzzer Limit Switch Removal 1.
Page 308: Oil Warning Light
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Oil Warning Light Reverse Buzzer Limit Switch Installation, Continued: 3. Place the Forward/Reverse handle in REVERSE to make sure that only the reverse buzzer limit switch is actuated. 4. Connect the orange wire to the black (COM) wire terminal and the red/white wire to the blue wire, nor- mally open (NO) terminal of the reverse buzzer limit switch (4) (Figure 12a-22, Page 12a-21).
Page 309: Fuel Gauge/Hour Meter
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuel Gauge/Hour Meter Figure 12a-25 Fuel Gauge/Hour Meter and Oil Warning Light Installation FUEL GAUGE/HOUR METER Read DANGER and WARNING on page 12a-1. Testing the Fuel Gauge/Hour Meter See Test Procedure 26, Section 11a, Page 11a-46. Also see Test Procedure 27 – Hour Meter on page 11a-46 With the key switch in the OFF position, the fuel gauge/hour meter ﬁelds are blank.
Page 310: Fuel Level Sending Unit
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuel Level Sending Unit Fuel Gauge/Hour Meter Installation 1. Install a new gauge/meter into hole in dash until ﬂange seats against dash (Figure 12a-25, Page 12a-25). 2. Slide the mounting bracket onto the two threaded studs on the gauge/meter and secure with two lock washers and two hex nuts.
Page 311: Ignition Coil
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ignition Coil DAMPER RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK KILL CIRCUIT WIRE FEMALE BULLET TERMINAL BLACK WIRE Figure 12a-26 RPM Limiter Assembly RPM Limiter Installation 1. Place the RPM limiter on the damper squarely so that RPM limiter ﬁts tightly against the damper. 2.
Page 312 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ignition Coil Ignition Coil Removal Removing the ignition coil requires the removal of the engine and unitized transaxle. See Unitized Transaxle Removal, Section 16a, Page 16a-9. ∆ CAUTION • Before removal and disassembly, clean the engine. 1.
Page 313 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ignition Coil SPARK PLUG 0.012 Inch (0.304 mm) Figure 12a-29 Clean Grommet Figure 12a-30 Mount Ignition Coil Using Feeler Gauge 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 314: Oil Level Sensor
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Oil Level Sensor Ignition Coil Installation, Continued: 13. When installing fan housing, make sure the top front corner of the housing is above the upper cylinder shroud. The front edge of the fan housing should be behind the lower cylinder shroud. Align the slots in the housing with the ﬂanged bolts (6) loosened earlier (Figure 12a-27, Page 12a-28).
Page 315: Headlights
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Headlights Figure 12a-31 Headlight Assembly HEADLIGHTS Read DANGER and WARNING on page 12a-1. Testing the Headlight Bulb and Socket See Test Procedure 30, Section 11a, Page 11a-49. Headlight Bulb Removal 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2.
Page 316: Headlight Diode
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Headlight Diode Headlight Bulb Installation, Continued: 4. Connect the battery cables, positive (+) cable ﬁrst, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 5. Lower the cargo bed. See WARNING "For vehicles with cargo beds..." on page 12a-2. SET SCREW Figure 12a-32 Headlight Diode Figure 12a-33 Light Switch...
Page 317: Light Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Light Switch LIGHT SWITCH Read DANGER and WARNING on page 12a-1. Testing the Light Switch See Test Procedure 28, Section 11a, Page 11a-47. Light Switch Removal 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2.
Page 318 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 classiﬁ- cation 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 18.4...
Page 319 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Battery 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. Excessive vibration shortens the life of the battery. It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts.
Page 320 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Battery Battery Removal, Continued: ∆ WARNING • Keep the battery in an upright position to prevent electrolyte leakage. Tipping the battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak out of the vent hole.
Page 321 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Battery Battery Installation Read DANGER and WARNING on page 12a-1 and DANGER on page 12a-33. 1. Place the battery into the vehicle. Make sure the battery posts are facing the engine. 2. Secure the battery to the vehicle with the clamp. Install bolt, washer and lock nut and tighten to 12 ft-lb (16.3 N·m).
Page 322: Ground Cables
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ground Cables Battery Storage, Continued: 6. The frequency of recharging required depends on the temperature of the storage area, but it is recom- mended that the battery be monitored for state of charge every month. Also, if the storage area is unheated in a cold climate and recharging is required, it is recommended that the area be heated to at least 60 °F (16 °C) prior to charging.
Page 323: Section 12B - Electrical Components: Fe350, Pedal-Start Engine
SECTION 12B – ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 324: Starter/Generator
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. •...
Page 325 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator 2.1. Tilt the bed and ensure that the prop rod is properly engaged. 3. Place the neutral lockout cam in the SERVICE position. 4. Disconnect the battery cables, negative (–) cable ﬁrst. See WARNING "To avoid unintentionally start- ing..."...
Page 326 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator Disassembly of the Starter/Generator to Service the Brushes, Continued: 2. Remove brush covers (29 and 30), screws (25) and lock washers (26), brush springs (28), and brushes (27) (Figure 12b-4, Page 12b-4). See following NOTE. NOTE: To clean and inspect the armature/commutator and the bearings, see Disassembly of the Starter/Generator to Service the Armature/Commutator on page 12b-6.
Page 327 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator ∆ CAUTION • When checking brush spring tension, do not push springs beyond the point they would normally be if there were new brushes installed. Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs. Replace springs that apply a force of less...
Page 328 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator BRUSH BEING HELD BY BRUSH SPRING Figure 12b-7 Pull Brushes Away from Center of the Commutator End Cover Disassembly of the Starter/Generator to Service the Armature/Commutator 1. If the brushes are not removed, contact between the brushes and commutator as the commutator end cover is being removed or installed could damage the brushes.
Page 329 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator Bearing Cleaning And Inspection 1. Using a clean cloth, wipe the carbon dust off the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 12b-9, Page 12b-7). 2.
Page 330 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator Field Coil Removal 1. Remove the retaining nut from each ﬁeld coil terminal and slide the insulator out of the slots in the hous- ing. Remove the four pole piece screws from the housing. Remove the four pole pieces from inside the housing.
Page 331 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator ∆ CAUTION • Never use emery cloth on the commutator. particles of emery are conductive and may short- circuit the commutator bars. Never use oil or lubricants on the commutator or brushes. 2. Using a micrometer, measure the outside diameter at four points: two points 90° to each other to the out- side of the commutator (A and A ), and two points 90°...
Page 332 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE 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 333 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator Starter/Generator Assembly 1. Place the ﬁeld coil into the housing. The two insulators that look alike ﬁt into the slots next to the F1 and F2 markings on the outside of the housing. The insulator that looks different slides into the slot next to the DF marking.
Page 334 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator Starter/Generator Installation, Continued: 2. Install two 3/8-inch hex-head pivot bolts (5) into the mounting bracket with the heads of the bolts facing towards the driver side of the vehicle. Position the starter/generator in the mounting bracket so that the bolts will go through the starter/generator before going through the bracket.
Page 335: Voltage Regulator
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Voltage Regulator 4. Disconnect the battery cables, negative (–) cable ﬁrst. See WARNING "To avoid unintentionally start- ing..." on page 12b-1. 5. Make sure the two pivoting screws (5) on the mounting bracket are ﬁnger tight. The carriage bolt (11) and hex nut (12) are to be ﬁnger tight also (Figure 12b-14, Page 12b-12).
Page 336: Key Switch
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Key Switch TO KILL LIMIT SWITCH TO BATTERY FRAME GROUND TO BULLET ELECTRICAL TO SOLENOID CONNECTOR COMPONENT BOX Figure 12b-16 Voltage Regulator Voltage Regulator Installation 1. Position the voltage regulator (9) in the electrical component box and install the mounting screw (8) (Figure 12b-16, Page 12b-14).
Page 337: Solenoid
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Solenoid 5.3. Pull forward on top of dash panel to access back side of key switch. There is sufﬁcient slack in wiring to allow for this as shown in detail C. 6. Disconnect the wire connector from the key switch. 7.
Page 338 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Solenoid Figure 12b-18 Center Dash Panel Removal Page 12b-16 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 339 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Fuse Solenoid Installation 1. Install the solenoid in the electrical component box. Use two screws to secure the solenoid to the box and tighten to 13.5 in-lb (1.5 N·m). 2. Connect all wires as indicated. 2.1.
Page 340: Kill Limit Switch
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Kill Limit Switch Fuse Installation, Continued: 2. Install the snap-on electrical box cover by ﬁrmly pressing down on all corners and install the screw, tight- ening to 18 in-lb (2 N·m). 3. Connect the battery cables, positive (+) cable ﬁrst, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305).
Page 341: Neutral Lockout Limit Switch
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Neutral Lockout Limit Switch 6. Connect the battery cables, positive (+) cable ﬁrst, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 7. Place the neutral lockout cam in the OPERATE position. 8.
Page 342: Neutral Lockout Cam
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Neutral Lockout Cam Neutral Lockout Limit Switch Installation Continued: ∆ WARNING • Do not overtighten the retaining nuts. If the nuts are overtightened, limit switches could be damaged. 2. Connect the black wire to common (COM) terminal, the green wire to the normally open (NO) terminal and the white wire to the normally closed (NC) terminal of the neutral lockout limit switch (Figure 12b-21, Page 12b-20).
Page 343: Reverse Warning Buzzer
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Reverse Warning Buzzer 3. Place the neutral lockout cam in the SERVICE position. 4. Disconnect the battery cables, negative (–) cable ﬁrst. See WARNING "To avoid unintentionally start- ing..." on page 12b-1. 5. Remove the external snap ring (14) (Figure 12b-21, Page 12b-20). 6.
Page 344: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Reverse Buzzer Limit Switch Reverse Warning Buzzer Installation, Continued: 6. Connect the battery cables, positive (+) cable ﬁrst, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). 7.
Page 345: Oil Warning Light
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Oil Warning Light Reverse Buzzer Limit Switch Installation 1. Install the reverse buzzer limit switch (4), and then install two spacers (9) against the limit switch. 2. Install the neutral lockout limit switch (5) and install two washers (6) and two nuts (2). Tighten to 5 in-lb (0.6 N·m).
Page 346: Fuel Gauge/Hour Meter
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Fuel Gauge/Hour Meter Testing the Oil Warning Light See Test Procedure 22, Section 11b, Page 11b-43. Oil Warning Light Removal 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2.
Page 347: Rpm Limiter
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Fuel Level Sending Unit 7. Remove the two hex nuts (3) and lock washers (4) from the threaded studs on the back of the gauge/ meter. Remove the mounting bracket (5) from the back side of the gauge/meter and remove the gauge/ meter from the dash.
Page 348: Ignition Coil
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Ignition Coil RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK KILL CIRCUIT WIRE FEMALE BULLET TERMINAL BLACK WIRE Figure 12b-24 RPM Limiter Assembly RPM Limiter Installation 1. Place the RPM limiter damper on the front of the RPM limiter mounting bracket (Figure 12b-24, Page 12b-26).
Page 349 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Ignition Coil Ignition Coil Removal Removing the ignition coil requires the removal of the engine and unitized transaxle. See Unitized Transaxle Removal, Section 16b, Page 16b-9. ∆ CAUTION • Before removal and disassembly, clean the engine. 1.
Page 350 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Ignition Coil 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. See steps 1 through 8 for procedures to remove and install these existing parts.
Page 351: Oil Level Sensor
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Oil Level Sensor 11. Connect the 18-gauge black wire (12) to the spade terminal (13) on the coil (11) (Figure 12b-26, Page 12b-27). 12. Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch on the housing.
Page 352: Headlights
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Headlights HEADLIGHTS Read DANGER and WARNING on page 12b-1. Testing the Headlight Bulb and Socket See Test Procedure 31, Section 11b, Page 11b-49. Headlight Bulb Removal 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2.
Page 353: Voltage Limiter
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Voltage Limiter SET SCREW Figure 12b-30 Voltage Limiter Figure 12b-31 Light Switch VOLTAGE LIMITER Read DANGER and WARNING on page 12b-1. Testing the Voltage Limiter See Test Procedure 30, Section 11b, Page 11b-48. Voltage Limiter Removal 1.
Page 354: Light Switch
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Light Switch LIGHT SWITCH Read DANGER and WARNING on page 12b-1. Testing the Light Switch See Test Procedure 29, Section 11b, Page 11b-47. Light Switch Removal 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2.
Page 355 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 classiﬁ- cation 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 16.5 cm D x 18.4...
Page 356 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Battery manently inactive. Check the water level more frequently in hot weather or when the battery becomes old. See Figure 11b-28, Section 11b, Page 11b-25. 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 357: Charging The Battery
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Battery 7. Carefully lift and rotate the seat support (7) 90° counterclockwise and allow it to rest on the vehicle body as illustrated (Figure 12b-32, Page 12b-35). NOTE: It is not necessary to remove the park brake cable or differential lock cable to service or remove the battery.
Page 358 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Battery ∆ WARNING • If the battery case feels hot (approximately 125 °F (52 °C) or more), emits gases, or ﬂuid boils from vents, stop charging immediately. Failure to stop charging battery when any of these conditions are present could result in an explosion, personal injury and/or damage to the battery.
Page 359: Ground Cables
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Ground Cables 6. The frequency of recharging required depends on the temperature of the storage area, but it is recom- mended that the battery be monitored for state of charge every month. Also, if the storage area is unheated in a cold climate and recharging is required, it is recommended that the area be heated to at least 60 °F (16 °C) prior to charging.
Page 361 SECTION 13 – FE350 AND FE400 ENGINES ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 362: General Information
GENERAL INFORMATION Read DANGER and WARNING on page 13-1. All Club Car gasoline vehicles are powered by 4-cycle, overhead valve, single cylinder, air-cooled engines. The 272 model vehicles are equipped with one of two engine models: FE350 or FE400. These 4-cycle engines have an oil reservoir (crankcase) similar to automobile, truck, heavy equipment machinery and other similar equipment engines designed for reliable heavy-duty service.
Page 363: Special Engine Service Tools Available From Club Car
FE350 AND FE400 ENGINES General Information SPECIAL ENGINE SERVICE TOOLS AVAILABLE FROM CLUB CAR DESCRIPTION CCI P/N Gear yoke 1016418 Compression gauge and adapter 101641002 Valve spring compressor 101641101 Valve guide reamer 101641201 Valve guide reamer and arbor 101641202 Piston ring compressor kit...
Page 364 FE350 AND FE400 ENGINES General Information Mechanical Systems, Continued: Dirt Clean the engine thoroughly before servicing it. See following CAUTION. ∆ CAUTION • Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or other parts will work as an abrasive and shorten the life of the engine. For the same reason, before installing a new part, clean off any dust or metal ﬁlings.
Page 365: Lubrication System
FE350 AND FE400 ENGINES General Information Ball Bearing Installation When installing a ball bearing, the bearing race which has a press ﬁt should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents damage. Press on the inner race if the ball bearing is being pressed onto a shaft, or on the outer race if the ball bearing is being pressed into a housing.
Page 366: Hydraulic Lifters
FE350 AND FE400 ENGINES General Information (1) Oil Sump (2) Oil Filter Screen (4) Camshaft (6) Push Rod (3) Oil Pump Bearing (9) Hydraulic (5) Oil Filter Lifter (9) Hydraulic (8) Pressure (7) Passage Relief Valve Lifter (10) Crankshaft Main Bearing (11) Link Rod Bearig (12) Connecting...
Page 367: Spark Plug
FE350 AND FE400 ENGINES General Information the hydraulic lifters at the time of engine assembly does not, in most cases, require any special techniques beyond the normal practice for solid lifter valve trains. There are, however, two areas of concern to be aware of to assure satisfactory installation and initial engine start.
Page 368: Engine Mounting Plate
FE350 AND FE400 ENGINES Engine Mounting Plate ∆ WARNING • Remove spark plug wire to avoid accidental start up of the engine when servicing vehicle. To avoid ignition of fuel and serious personal injury or death, never try to start the engine with plug removed from engine.
Page 369: Cylinder Shroud Removal
FE350 AND FE400 ENGINES Cylinder Head CYLINDER SHROUD REMOVAL ∆ CAUTION • Before removal and disassembly, clean the engine. 1. Access the engine compartment. See WARNING "For vehicles with cargo beds..." on page 13-2. 1.1. Tilt the bed and ensure that the prop rod is properly engaged. 2.
Page 370: Rocker Arm And Push Rod Removal
FE350 AND FE400 ENGINES Cylinder Head Cylinder Shroud Removal, Continued: 10. If the engine is to be totally disassembled, drain oil and remove the oil ﬁlter. If only the cylinder head is to be disassembled, proceed without draining the oil or removing the oil ﬁlter. 11.
Page 371: Valve Removal
FE350 AND FE400 ENGINES Cylinder Head Figure 13-10 Remove Rocker Cover Figure 13-11 Remove Rocker Arms and Breather Tube and Push Rods Figure 13-12 Remove Cylinder Head Figure 13-13 Remove Head Gasket VALVE REMOVAL 1. Compress the valve spring using a valve spring compressor (5) (CCI P/N 101641101) and remove the collet halves (6) (Figure 13-14, Page 13-12).
Page 372: Breather Valve (Reed Valve)
FE350 AND FE400 ENGINES Cylinder Head PADDING Figure 13-14 Valve Removal Figure 13-15 Spring Seat Removal BREATHER VALVE (REED VALVE) General Information The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets.
Page 373: Cylinder Head Cleaning And Inspection
FE350 AND FE400 ENGINES Cylinder Head CYLINDER HEAD CLEANING AND INSPECTION 1. Clean the head with a non-ﬂammable solvent and dry thoroughly. 2. Bead blast or scrape carbon deposits from head. When scraping carbon deposits, be careful to avoid scratching or nicking the cylinder head. 3.
Page 374: Valve Seats
FE350 AND FE400 ENGINES Cylinder Head VALVE SEATS Valve Seat Inspection 1. Inspect the valve seats for damage. If the seats are warped or distorted beyond reconditioning, replace the cylinder head. 2. Using prussian blue metal die, coat the valve seat. 3.
Page 375 ∆ CAUTION • If you are unfamiliar with the following procedures, Club Car suggests that the cylinder head be taken to a professional engine machine shop for reconditioning. 1. Clean the cylinder head thoroughly. See Cylinder Head Cleaning and Inspection on page 13-13.
Page 376 FE350 AND FE400 ENGINES Cylinder Head Valve Seat Repair, Continued: Resurface valve seat with (45° exhaust port) (30° intake port) cutter. Measure seats in several places. Figure 13-25 Measuring Valve Seats Figure 13-26 Resurfacing Valve Seat NOTE: Keep the seat width as close as possible to 0.031 inch (0.8 mm). 2.7.
Page 377: Valves
FE350 AND FE400 ENGINES Cylinder Head VALVES Visual Inspection 1. Inspect the valve head seating area (1) for erosion, nicks and warping, etc. (Figure 13-28, Page 13-16). See following NOTE. NOTE: The valve seating surface angle is 30° (Intake), 45° (Exhaust) (Figure 13-29, Page 13-17). 2.
Page 378: Rocker Arm And Rocker Shaft Inspection
FE350 AND FE400 ENGINES Cylinder Head Measure each position in 2 places, 90° apart. Figure 13-30 Measure Valve Stem Bend Figure 13-31 Measure Valve Stem Diameter Valve Spring Inspection 1. Inspect the valve springs (1) for pitting, cracks, corrosion and burrs. Replace the springs if necessary (Figure 13-32, Page 13-18).
Page 379: Push Rod Inspection
FE350 AND FE400 ENGINES Cylinder Head Measure each position in two places, 90° apart. Figure 13-34 Measure Rocker Shaft O.D. Figure 13-35 Check For Push Rod Distortion PUSH ROD INSPECTION 1. Support the rod in V blocks at each end of the rod. Position a dial gauge perpendicular to the rod (Figure 13-35, Page 13-19).
Page 380: Breather Valve (Reed Valve)
FE350 AND FE400 ENGINES Cylinder Head BREATHER VALVE (REED VALVE) General Information The function of the breather is to create a vacuum in the crankcase that prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. The breather has a reed valve which limits the direction of air ﬂow caused by the piston moving up and down.
Page 381: Installation Of Remaining Engine Components
FE350 AND FE400 ENGINES Cylinder Head INSTALLATION OF REMAINING ENGINE COMPONENTS 1. Install rocker cover. 2. Install lower, upper, and head shrouds (1) along with two-ended bolt (2) (Figure 13-39, Page 13-21). NOTE: The shorter end of the two-ended bolt (2) goes through washer and upper shroud. To prevent leaks, apply a light coat of clean engine oil to the O-ring seal (7) before installation.
Page 382: Crankcase
FE350 AND FE400 ENGINES Crankcase CRANKCASE Read DANGER and WARNING on page 13-1. ENGINE REMOVAL To perform repairs on crankcase components, the engine must be removed from the vehicle. ∆ CAUTION • Before removal and disassembly, clean the engine. 1. Remove the powertrain. See Unitized Transaxle Removal, Section 16a, Page 16a-9. See following NOTE.
Page 383 FE350 AND FE400 ENGINES Crankcase TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 13-41 Engine Mounting Plate - with MC012C-AS00 Transaxle 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 13-23...
Page 384 FE350 AND FE400 ENGINES Crankcase Oil Level Sensor Removal 1. If not already removed, remove crankcase cover. See Crankcase Cover Removal on page 13-22. 2. Disconnect the oil level sensor wire (2) from the cord connection (1) (Figure 13-44, Page 13-24). 3.
Page 385: Camshaft And Hydraulic Lifters
FE350 AND FE400 ENGINES Crankcase CAMSHAFT AND HYDRAULIC LIFTERS Camshaft and Hydraulic Lifter Removal 1. Keep the timing marks (A) aligned during removal (Figure 13-45, Page 13-24). 2. With cylinder head removed, pull the hydraulic lifters out of their bores to the top of the cylinder. See Cyl- inder Head Removal on page 13-10.
Page 386: Piston And Connecting Rod
FE350 AND FE400 ENGINES Piston and Connecting Rod Camshaft and Hydraulic Lifters, Continued: 8. Key-Start Engines: 8.1. Check the automatic compression release valve (ACR) arms to make sure they move freely and are not binding. Clean the arms if needed. Make sure the take-up spring is properly installed. Replace the spring if it is broken.
Page 387 FE350 AND FE400 ENGINES Piston and Connecting Rod Piston and Connecting Rod Removal 1. Turn crankshaft to expose the two connecting rod cap bolts (1) (Figure 13-50, Page 13-27). 2. Loosen the cap bolts and take them out together with the connecting rod cap (2). 3.
Page 388 FE350 AND FE400 ENGINES Piston and Connecting Rod Piston Ring Inspection 1. Insert the ring squarely into the cylinder bore to a point approximately 1 inch (25 mm) down from the top the cylinder. See following NOTE. NOTE: Use the top of the piston to push the ring into the bore to be sure it is square. 2.
Page 389: Cylinder Block
FE350 AND FE400 ENGINES Cylinder Block Measure each position in 2 places, 90° apart. Measure each position in 2 places, 90° apart. Figure 13-54 Measure Piston Pin O.D. Figure 13-55 Measure Piston Pin Hole I.D. 6. If the inside diameter exceeds 1.479 inches (37.567 mm), replace the connecting rod. See following NOTE.
Page 390 FE350 AND FE400 ENGINES Cylinder Block Cylinder Block, Continued: 2. Make the ﬁrst measurement parallel with the crankshaft and the second at right angles to the crankshaft at three different locations in the bore. The ﬁrst measurement location is 0.4 inch (10 mm) from the top of the cylinder.
Page 391: Ignition Coil And Flywheel
FE350 AND FE400 ENGINES Ignition Coil and Flywheel NOTE: Important: The cylinder wall ﬁnish should have a 40° to 60° cross-hatch pattern (Figure 13-59, Page 13-30). Do not use solvents or gasoline to clean cylinder after honing. Solvents and gasoline allow the grindings to remain in the honed surface and will not provide a surface suited for ring seating.
Page 392 FE350 AND FE400 ENGINES Ignition Coil and Flywheel Loosen. Remove. Remove. Figure 13-60 Flywheel Housing Figure 13-61 Ignition Coil Ignition Coil Installation 1. Installation is the reverse of removal. 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 13-63, Page 13-32).
Page 393: Oil Pump
FE350 AND FE400 ENGINES Oil Pump TYPICAL 6 PLACES Figure 13-64 Oil Pump Removal Figure 13-65 Measure Rotor Clearance OIL PUMP Read DANGER and WARNING on page 13-1. Oil Pump Cover Removal 1. Remove the six screws (1-6) and remove the oil pump cover (7) (Figure 13-64, Page 13-33). 2.
Page 394: Oil Pressure Relief Valve
FE350 AND FE400 ENGINES Oil Pump Measure two Measure two places, 90° apart. places, 90° apart. Figure 13-66 Measure Pump Shaft Bearing Surface Figure 13-67 Measure Outer Rotor O.D. Figure 13-68 Measure Outer Rotor Thickness OIL PRESSURE RELIEF VALVE Oil Pressure Relief Valve Removal 1.
Page 395 FE350 AND FE400 ENGINES Oil Pump PUMP Figure 13-69 Oil Pressure Relief Valve Figure 13-70 Measure Free Length of Spring Oil Pump Installation ∆ CAUTION • Do not allow any dust or other foreign matter into the oil pump. 1. Installation is the reverse of removal. 2.
Page 396: Crankshaft And Counterbalance
FE350 AND FE400 ENGINES Crankshaft and Counterbalance CRANKSHAFT AND COUNTERBALANCE Read DANGER and WARNING on page 13-1. Crankshaft and Counterbalance Removal 1. Remove the four nuts (1) and pull out the counterbalance guide shaft (2) and the O-ring (3) (Figure 13-72, Page 13-36). 2.
Page 397 FE350 AND FE400 ENGINES Crankshaft and Counterbalance GEAR YOKE HELICAL GEAR (CCI P/N 1016418) SPUR GEAR PRESS RAM GEAR YOKE SIDE BLOCKS SIDE BLOCKS (2) PRESS TABLE PRESS TABLE Figure 13-74 Place Assembly in Press Figure 13-75 Remove Helical and Spur Gears Link Rod Inspection 1.
Page 398: Counterbalance Weight
FE350 AND FE400 ENGINES Crankshaft and Counterbalance Measure in two places, 90° apart. TYPICAL 4 PLACES Figure 13-76 Inspect Link Rod Figure 13-77 Measure Link Rod Small Bore I.D. Measure each position in 2 places, 90° apart. Figure 13-78 Measure Link Rod Large Bore I.D COUNTERBALANCE WEIGHT NOTE: The wrist pins are tightly pressed into the weight and normally require no maintenance.
Page 399 FE350 AND FE400 ENGINES Crankshaft and Counterbalance Measure each position in 2 places, 90° apart. Measure each position in two places, 90° apart. Figure 13-79 Measure Counterbalance Bearing Figure 13-80 Measure O.D. of Counterbalance Surface I.D. Guide Shaft Counterbalance Guide Shaft Inspection 1.
Page 400 FE350 AND FE400 ENGINES Crankshaft and Counterbalance Groove machined into Measure each position the outside diameter in 2 places, 90° apart. of the counterweight UNITIZED (CLOCKWISE) CRANKSHAFT Figure 13-81 Crankshaft Inspection Figure 13-82 Measure Crankshaft Journals Measure each position Measure each position in 2 places, 90°...
Page 401: Oil Screen
2. Place the crankcase cover (1) on a bench with its outside up (gasket surface against bench) (Figure 13-88, Page 13-41). 3. Using a bearing driver (2) (part of Club Car Bearing Driver Kit, CCI P/N 1016416), drive out the ball bear- ing (3) as shown.
Page 402: Oil Seals
FE350 AND FE400 ENGINES Crankshaft and Counterbalance Ball Bearing Inspection 1. Clean the ball bearing thoroughly in high ﬂash-point solvent and dry it. NOTE: Never use compressed air to dry bearing. Use of compressed air will result in premature bearing failure.
Page 403 FE350 AND FE400 ENGINES Crankshaft and Counterbalance 1. Inspect the camshaft surfaces, one in the crankcase (3) (Figure 13-90, Page 13-42) and the other in the crankcase cover (1) (Figure 13-91, Page 13-43). Using an inside micrometer or telescoping gauge, measure the inside diameter of each bearing surface.
Page 404 FE350 AND FE400 ENGINES Crankshaft and Counterbalance Crankshaft Installation, Continued: NOTE: Make sure the chamfered inside diameters of the spur gear and helical gear are oriented down- ward on the crankshaft as shown (Figure 13-93, Page 13-44). Make sure the link rods rotate smoothly after the gears are pressed on. 4.
Page 405: Crankshaft Axial Play Adjustment
FE350 AND FE400 ENGINES Crankshaft Axial Play Adjustment CRANK SHAFT CENTER LINE 30°-45° Figure 13-95 Piston/Connecting Rod Alignment Figure 13-96 Piston Ring Gap Alignment CRANKSHAFT AXIAL PLAY ADJUSTMENT Read DANGER and WARNING on page 13-1. 1. With the gasket installed on the crankcase, measure from the gasket surface (1) to the helical gear sur- face (2).
Page 406 FE350 AND FE400 ENGINES Crankshaft Axial Play Adjustment Camshaft Installation ∆ CAUTION • When installing the camshaft, make sure that the tang (1) on the oil pump rotor seats in the slot (2) in end of the camshaft (Figure 13-100, Page 13-47). If the oil pump tang is not seated in the slot in the camshaft, serious engine damage will result.
Page 407 FE350 AND FE400 ENGINES Crankshaft Axial Play Adjustment Figure 13-100 Proper Seating of Tang into Figure 13-101 Align Timing Marks between Camshaft Camshaft Slot and Crankshaft Camshaft Axial Play Adjustment 1. With the gasket (1) installed on the crankcase, measure from the gasket surface to the camgear surface (2).
Page 408: Crankcase Cover Installation
FE350 AND FE400 ENGINES Crankshaft Axial Play Adjustment 13.35 13.45 13.55 Measurement (A) Measurements in MM Figure 13-104 Camshaft Shim Table CRANKCASE COVER INSTALLATION ∆ CAUTION • Before assembly, make sure parts are clean. • Do not reuse the gasket. Install a new one. •...
Page 409: Engine Assembly
FE350 AND FE400 ENGINES Engine Assembly Figure 13-105 Crankcase Cover Installation Figure 13-106 Fan and Flywheel Assembly ENGINE ASSEMBLY Read DANGER and WARNING on page 13-1. ∆ CAUTION • Before assembly, make sure parts are clean. 1. Install cylinder head. See Cylinder Head Installation on page 13-19. 2.
Page 410 FE350 AND FE400 ENGINES Engine Assembly Engine Assembly, Continued: 7. Place engine onto engine mounting plate and tighten the mounting hardware (1, 2 and 5) to 21 ft-lb (28.4 N·m). Tighten nuts (6) to 17 ft-lb (23.1 N·m) (Figure 13-41, Page 13-23). 8.
Page 411: Service Specifications
FE350 AND FE400 ENGINES Service Specifications SERVICE SPECIFICATIONS SERVICE LIMIT SERVICE LIMIT ITEM FE350 ENGINE FE400 ENGINE Breather reed valve (valve tip air gap) 0.008 in. (0.2 mm) max. Camshaft axial play 0.0137 in. (0.35 mm) 0.024 in. (0.06 mm) Camshaft bearing 0.9080 in.
Page 412: Specifications For Resizing Cylinder Bore
FE350 AND FE400 ENGINES Service Specifications SERVICE LIMIT SERVICE LIMIT ITEM FE350 ENGINE FE400 ENGINE Push rod (rod bend) 0.0196 in. (0.50mm) max. Relief valve spring (free length) 0.748 in. (19.0 mm) min. Rocker arm bearing 0.4754 in. (12.074 mm) inner diameter max. Rocker shaft 0.4704 in.
Page 413: Adjustment And Settings
FE350 AND FE400 ENGINES Service Specifications ADJUSTMENT AND SETTINGS SERVICE LIMIT SERVICE LIMIT ITEM FE350 ENGINE FE400 ENGINE Spark plug gap (standard) 0.027 to 0.031 in. (0.69 to 0.79 mm) Ignition coil air gap (standard) 0.012 in. (0.304 mm) Oil pressure (min.) at fast idle speed 45.5 psi (3.14 Bars) Oil ﬁlter: bypass-valve opening pressure 11.4 to 17.0 psi (.78 to 1.18 Bars)
Page 415: Section 14 - Fuel System
SECTION 14 – FUEL SYSTEM ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 416: General Information
FUEL SYSTEM General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic ﬂoor jack) with 1000 lb.
Page 417: Slow Speed System
FUEL SYSTEM How the Carburetor Works If the engine exhibits symptoms of overly rich or lean fuel mix after all maintenance and adjustments are cor- rectly performed, the main jet should be replaced. A smaller numbered jet gives a leaner mixture and a larger numbered jet gives a richer mixture.
Page 418: Float System
FUEL SYSTEM How the Carburetor Works BYPASS HOLES TOP VIEW MAIN AIR JET MAIN NOZZLE THROTTLE VALVE MIXTURE INTAKE CYLINDER CARBURETOR BORE MAIN AIR PASSAGE TO ENGINE PILOT AIR JET PILOT OUTLET PILOT AIR SCREW PILOT JET FUEL FUEL FUEL AIR / FUEL MIXTURE SIDE VIEW MAIN AIR PASSAGE...
Page 419: Carburetor
FUEL SYSTEM Carburetor Fuel is supplied to the carburetor ﬂoat chamber by an external impulse pump that draws fuel from the fuel tank and through the fuel ﬁlters (Figure 14-4, Page 14-5). The fuel then passes through the inlet valve (5) and into the ﬂoat bowl.
Page 420: Main Jet Elevation/Size Chart
FUEL SYSTEM Carburetor MAIN JET ELEVATION/SIZE CHART FE350 ENGINE FE400 ENGINE ALTITUDE ALTITUDE MAIN JET SIZE MAIN JET SIZE 0-3000 ft. 0-3280 ft. (0-914.4 m) (0-1000 m) 3000-5000 ft. 3280-6562 ft. (914.4-1524 m) (1000-2000 m) 5000-8000 ft. 6562 ft. and over (1524-2438.4 m) (2000 m and over) 8000-10,000 ft.
Page 421 FUEL SYSTEM Carburetor 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 14-8, Page 14-9). See following NOTE. NOTE: Make sure the fuel bowl gasket (9) remains properly seated in the carburetor body when the fuel bowl is removed (Figure 14-8, Page 14-9).
Page 422 FUEL SYSTEM Carburetor Changing the Main Jet, Continued: TYPICAL 2 PLACES Figure 14-7 Carburetor Installation Page 14-8 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 423 FUEL SYSTEM Carburetor STEPS 2 AND 3 Drain carburetor over a catch basin by turning bowl drain screw (11) counterclockwise 2 to 3 turns. STEP 4 Mark carburetor and corresponding position of fuel bowl. CAUTION: DO NOT REMOVE VALVE/SPRING FROM FLOAT. TO DO SO WILL DAMAGE SPRING. If spring looks like this...
Page 424: Engine Control Linkage
FUEL SYSTEM Engine Control Linkage Changing the Main Jet, Continued: NOTE: Make sure the intake hose is not twisted during installation. 21. Turn fuel shut-off valve (on gas tank) to the ON position (Figure 14-23, Page 14-32, and Figure 14-24, Page 14-33).
Page 425 FUEL SYSTEM Engine Control Linkage Figure 14-9 Accelerator Rod Accelerator Rod Installation and Adjustment 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2. Before installing the accelerator rod, adjust accelerator pedal position. See Accelerator Pedal Adjust- ment, Section 5, Page 5-7.
Page 426: Governor Cable
FUEL SYSTEM Engine Control Linkage Accelerator Rod Installation and Adjustment, Continued: 8.2. Key-Start vehicles: 8.2.1. While pressing the accelerator pedal, the carburetor throttle should begin to move when the pedal is depressed approximately 8° to 12°. 9. While holding the accelerator ball joint with pliers, tighten the jam nuts against the ball joints, accelerator ball joint ﬁrst, at each end of the accelerator rod.
Page 427 FUEL SYSTEM Engine Control Linkage 2.1. Tilt the bed and ensure that the prop rod is properly engaged. 3. Disconnect the battery, negative (–) cable ﬁrst. See WARNING "To avoid unintentionally starting..." on page 14-1. 4. Remove the electrical component box cover and loosen the cable housing retaining nuts (Figure 14-10, Page 14-13).
Page 428: Closed Throttle Or Idle Adjustment
FUEL SYSTEM Engine Control Linkage Accelerator Cable Installation, Continued: 7. Install the electrical component box cover, and tighten the retaining screw to 18 in-lb (2.0 N·m). 8. Connect the battery cables, positive (+) cable ﬁrst, and tighten terminals to 20 ft-lb (27 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305).
Page 429 FUEL SYSTEM Engine Control Linkage TYPICAL 2 PLACES REFERENCE EXHAUST SECTION Figure 14-12 Governor and Accelerator Cables 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 14-15...
Page 430: Choke And Air Intake System
FUEL SYSTEM Choke and Air Intake System Engine RPM Adjustment, Continued: IDLE SCREW Figure 14-13 Idle Screw 6. Be sure both retaining nuts are locked against the electrical box and then check the RPM again. If the RPM needs to be adjusted, repeat step 5. 7.
Page 431: Choke Cable Removal
FUEL SYSTEM Choke and Air Intake System CHOKE CABLE REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2. Access the engine compartment. See WARNING "For vehicles with cargo beds..." on page 14-2. 2.1.
Page 432: Intake Duct Repair
FUEL SYSTEM Choke and Air Intake System Figure 14-14 Compound Steering Joint 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 (12.7 mm) in diameter, it may be repairable with an Air Duct Repair Kit (CCI P/N 101971001).
Page 433: Intake Duct Installation
FUEL SYSTEM Choke and Air Intake System 8. Remove the four bolts and lock nuts (2) from the rack and pinion assembly mount and gently disconnect the steering joint from steering column shaft at the bolt (1) location (Figure 14-14, Page 14-18). Gently allow both the rack and pinion assembly and the steering column shaft to drop down, remaining sus- pended between both rod ball joint ends.
Page 434: Air Filter
FUEL SYSTEM Choke and Air Intake System Intake Duct Installation, Continued: 4. Install the shield to the frame with the adhesive strip and pop rivet (30). 5. Install air box. See Air Box Installation on page 14-17. 6. Lower the cargo bed. See WARNING "For vehicles with cargo beds..." on page 14-2. 7.
Page 435: 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 436: Fuel Filter Installation
FUEL SYSTEM Fuel Pump Fuel Filter Removal, Continued: 8. Remove the secondary ﬁlter (22) (Figure 14-18, Page 14-27). 8.1. Remove the clamps (16) and fuel lines (3 and 4) from the ﬁlter and plug the fuel lines (3 and 4) (Figure 14-18, Page 14-27).
Page 437 FUEL SYSTEM Fuel Pump REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 14-15 Air Intake and Choke Assemblies 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 14-23...
Page 438: Fuel Pump Removal
9. Remove the back cover (36), the fuel diaphragm (34) and gasket (35) (Figure 14-16, Page 14-25). FUEL PUMP DISASSEMBLY NOTE: A fuel pump rebuild kit is available from Club Car (CCI P/N 1014524). This kit includes all gaskets, diaphragms, and valves.
Page 439: Fuel Pump Cleaning And Inspection
FUEL SYSTEM Fuel Pump PUMPING CHAMBER VENT FUEL FUEL OUTLET OUTLET VENT FRONT COVER FUEL INLET FUEL INLET VALVE ASSEMBLY DIRECTION OF FUEL FLOW IMPULSE LINE BACK COVER Figure 14-16 Fuel Pump Figure 14-17 Fuel Pump Orientation FUEL PUMP CLEANING AND INSPECTION 1.
Page 440: Fuel Pump Installation
FUEL SYSTEM Fuel Tank FUEL PUMP INSTALLATION 1. Connect the fuel line (2) that comes from the fuel ﬁlter (17) to the fuel pump (18). Install a new clamp (16) (Figure 14-18, Page 14-27). See same ﬁgure for proper routing of fuel lines. NOTE: Be sure to connect the fuel line (2), that comes from the primary fuel ﬁlter (17), to the inlet nipple on the pump.
Page 441 FUEL SYSTEM Fuel Tank SEE ABOVE GAS TANK FUEL PICKUP TUBE TYPICAL 2 PLACES FUEL LINE FUEL LINE ROUTING ROUTING LENGTH LENGTH Solid Color Solid Color Clear Clear Fuel tank to primary fuel filter Fuel tank to primary fuel filter 14.0 in.
Page 442: General Information
FUEL SYSTEM Fuel Tank GENERAL INFORMATION The vehicle is equipped with a high impact plastic, seven gallon (26.5 liter) fuel tank. FUEL TANK REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2.
Page 443: Fuel Tank Disposal
FUEL SYSTEM Fuel Tank ∆ DANGER • Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. ∆ WARNING • Never attempt to siphon fuel using a hose that does not have a built-in suction device. •...
Page 444: Fuel Tank Installation
FUEL SYSTEM Fuel Tank ORANGE WIRE FRAME TANK CONNECTION CONNECTION Figure 14-20 Fuel Level Sending Unit FUEL TANK INSTALLATION 1. With the retaining straps correctly positioned, install the fuel tank in the vehicle (Figure 14-18, Page 14-27). 2. Secure the tank with the retaining straps (13 and 10) (Figure 14-18, Page 14-27). 2.1.
Page 445: Fuel Lines
FUEL SYSTEM Fuel Lines ∆ DANGER • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation. • After installing the fuel tank and adding gasoline, carefully check all fuel lines and connections for leaks.
Page 446: Fuel Shut-Off Valve
FUEL SYSTEM Fuel Shut-Off Valve Fuel Lines Continued:Fuel Lines, Continued: Fuel line no. 1 runs directly from the fuel tank to the primary fuel ﬁlter (17). The primary fuel ﬁlter (17) has an arrow indicating fuel ﬂow direction (Figure 14-18, Page 14-27). Fuel line no.
Page 447 FUEL SYSTEM Fuel Shut-Off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 14-24 Incorrect Fuel Shut-off Valve 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 14-33...
Page 449: Section 15 - Exhaust System
SECTION 15 – EXHAUST SYSTEM ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 450: General Information
EXHAUST SYSTEM General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic ﬂoor jack) with 1000 lb.
Page 451: Muffler Installation
EXHAUST SYSTEM Muffler MUFFLER INSTALLATION NOTE: The following procedure is the same for both FE350 and FE400 engines. Any time the mufﬂer is removed from the vehicle, install a new mufﬂer clamp (6) (CCI P/N 1017689) and mufﬂer gasket (12) (Figure 15-1, Page 15-3 or Figure 15-2, Page 15-4). The gasket (12) is different for each of the two engines: FE350 and FE400.
Page 452 EXHAUST SYSTEM Muffler Mufﬂer Installation, Continued: 6. Tighten the manifold hex nuts (10) to 11 ft-lb (14.9 N·m).Tighten the mufﬂer bracket hex cap screw (7) to 14 ft-lb (18.9 N·m). 7. Tighten the mufﬂer clamp bracket mounting bolts (5) to 75 in-lb (8.5 N·m). 8.
Page 453 EXHAUST SYSTEM Muffler 11.2. Key-Start vehicles: 11.2.1.Start the engine and check for exhaust leaks and proper engine operation. See following DANGER ∆ DANGER • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an exclosed area without proper ventilation. 12.
Page 455: Section 16A - Mc012C-As00 Unitized Transaxle With Differential Lock
SECTION 16A – MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 456: Transaxle Models And Identification
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. •...
Page 457: Lubrication
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Transaxle Models and Identification RUBBER DUST IDENTIFICATION IDENTIFICATION DECAL DECAL Figure 16a-1 MC010C-BS00 Transaxle Figure 16a-2 MC012C-AS00 Transaxle Shifter Lever A shifter lever, connected to a shifter arm on the unitized transaxle, is used to change the gears to one of three shift positions: FORWARD (F), NEUTRAL (N), or REVERSE (R) (Figure 16a-3, Page 16a-3).
Page 458 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Transaxle Models and Identification Differential Lock Lever The MC012C-AS00 unitized transaxle has a differential lock, controlled by a differential lock lever. The lever is located between the driver and passenger seats (Figure 16a-5, Page 16a-4). Figure 16a-5 Differential Lock Lever Neutral Lockout •...
Page 459: Axle Shaft
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Unitized Transaxle Service The unitized transaxle is extremely durable and should require very little service under normal operating con- ditions. The only service required on the unitized transaxle is to maintain proper lubricant level. See Periodic Lubrication Schedule, Section 10, Page 10-5.
Page 460 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Axle Shaft, Bearing, and Oil Seal Removal, Continued: Figure 16a-6 Axle Retaining Ring Pliers Figure 16a-7 Rolling Head Prybar 6. To remove the wheel bolt ﬂange on the MC012C transaxle (Figure 16a-6, Page 16a-6): 6.1.
Page 461: Axle Bearing Removal
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft AXLE BEARING REMOVAL 1. Slip the bearing (88) off of the machined journal and over the outside splined end of the axle (Figure 16a-9, Page 16a-8). AXLE SHAFT, BEARING, AND OIL SEAL INSTALLATION 1.
Page 462 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft TYPICAL 8 PLACES REFERENCE REFERENCE DRIVER SIDE PASSENGER SIDE CASE CASE TYPICAL 7 PLACES Figure 16a-9 Differential Gear Case/Axle Tubes Page 16a-8 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 463: Unitized Transaxle Removal
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Axle Shaft, Bearing, and Oil Seal Installation, Continued: 5.7. Install the rubber boot (26) onto the large washer (23) (Figure 16a-6, Page 16a-6). NOTE: Push the rubber boot onto the washer so that the washer edge ﬁts into the boot-lip groove. 5.8.
Page 464 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: CLAMP Figure 16a-10 Carburetor Vent Tube 5.7. Disconnect the engine ground wire from the oil ﬁller tube mounting bracket (Figure 16a-17, Page 16a-12). 5.8. Loosen nuts securing shifter cable to shifter cable mounting bracket. Then disconnect the shifter cable rod end from the shifter arm on the unitized transaxle and remove the cable from the cable mounting bracket (Figure 16a-18, Page 16a-12).
Page 465 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Rotate the cable connector toward the driver side of the vehicle to disconnect the cable from the differential lock lever. Figure 16a-13 Differential Lock Cable Bracket 1. Apply pressure to locking tabs of the cable. 2.
Page 466 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: TOP VIEW Loosen retaining nuts to remove Remove fuel line. accelerator cable from electric box. Figure 16a-15 Fuel Line Figure 16a-16 Accelerator Cable ENGINE GROUND TOP VIEW RETAINING NUT SPRING RELEASE NUTS...
Page 467 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal 5.14. Disconnect the engine kill switch wire (18-gauge white/black) from the bullet connector at the lower right front of the engine (Figure 16a-24, Page 16a-14). 5.15. Cut away the wire ties securing the kill switch wire at the lower right front of the engine (below the exhaust header), the wire harness at the governor cable bracket, and the wire harness to the plate beneath the mufﬂer.
Page 468 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: WHITE/BLACK WIRE BLACK WIRE Figure 16a-24 Engine Kill Switch Wire Figure 16a-25 Shock Absorbers 9. Lower the hydraulic jack, allowing the vehicle I-beam frame to rest on the jack stands but allow the jack to remain under, and in contact with, the transaxle case guard (Figure 16a-27, Page 16a-15).
Page 469 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal PROPER POSITIONING PROPER POSITIONING OF FLOOR JACK OF JACK STANDS APPROX. 17-1/2" (44.5 cm) Figure 16a-26 Raise Vehicle Figure 16a-27 Position Jack Stands REMOVE BOLTS, THEN ROTATE SHACKLES UP AND AWAY FROM SPRINGS.
Page 470 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: SNUBBER SNUBBER BRACKET Figure 16a-30 Snubber Figure 16a-31 Remove Powertrain 18. Loosen, but do not remove, the governor arm retaining bolt. Remove the governor arm from the shaft (Figure 16a-35, Page 16a-17).
Page 471 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal GOVERNOR ARM RETAINING BOLT RETAINING BOLT Leave cable connected. Leave cable connected. Figure 16a-34 Driven Clutch Figure 16a-35 Governor Arm BRACKET Figure 16a-36 Governor Cable Bracket Figure 16a-37 Accelerator Cable Bracket TRANSAXLE MOUNTING BOLT AND NUT (TYPICAL 4 PLACES)
Page 472: Unitized Transaxle Disassembly
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Disassembly UNITIZED TRANSAXLE DISASSEMBLY Read DANGER and WARNING on page 16a-1. NOTE: The following information provides instructions for disassembling the unitized transaxle; however, the transaxle case can be separated and gears accessed without removing the axles or axle tubes from the case.
Page 473 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Disassembly 13. Use a seal puller (CCI P/N 1012809) or rolling head prybar to remove the input shaft oil seal from the case (Figure 16a-44, Page 16a-21). 14. Remove the oil ﬂow guide from the case (Figure 16a-45, Page 16a-21). 15.
Page 474: Component Disassembly
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly Unitized Transaxle Disassembly, Continued: DIFFERENTIAL GEAR CASE ASSEMBLY Figure 16a-41 Loosen Gears Figure 16a-42 Remove Differential Gear Case 16. Remove the breather (32) from the case (Figure 16a-40, Page 16a-19). 17. Remove the governor assembly from the case. 17.1.
Page 475 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly Remove synchronizer gear assembly and shifter fork together as a unit. INTERMEDIATE GEAR ASSEMBLY IDLER SHAFT ASSEMBLY Figure 16a-43 Remove Intermediate Gear Figure 16a-44 Input Shaft Oil Seal SHIFTER SHAFT SLOT OIL FLOW GUIDE Figure 16a-45 Oil Flow Guide Figure 16a-46 Pivot Arm Oil Seal 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 476: Governor Gear Disassembly
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly GOVERNOR GEAR DISASSEMBLY NOTE: It will be necessary to disassemble the governor gear assembly in order to reinstall it into the tran- saxle case. 1. Secure the governor gear assembly in a vise as shown. Wrap shaft in a cloth to prevent damage (Figure 16a-50, Page 16a-24).
Page 477 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly REFERENCE PASSENGER SIDE CASE REFERENCE DRIVER SIDE CASE Figure 16a-48 Unitized Transaxle with Differential Lock 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 16a-23...
Page 478 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly Differential Gear Case Disassembly, Continued: Figure 16a-49 Remove Governor Gear Figure 16a-50 Pry Gear from Shaft 2. Pull the cover (76) and thrust plate (75) from the differential gear carrier case (Figure 16a-48, Page 16a-23).
Page 479: Shifter Fork Disassembly
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly ∆ CAUTION • Do not tighten the bearing puller wedge attachment against the shaft. This could damage the shaft. PRESS ARBOR WEDGE ATTACHMENT Figure 16a-52 Differential Pin Figure 16a-53 Remove Bearing SHIFTER FORK DISASSEMBLY 1.
Page 480: Intermediate Gear Disassembly
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly Synchronizer Gear Disassembly, Continued: ∆ CAUTION • Do not tighten the bearing puller wedge attachment against the shaft. This could damage the shaft. 4. Pull the spring washer (42), thrust washer (56), input gear assembly (55), two needle bearings (46), thrust plate (44), and synchronizer ring (48) from the input shaft (Figure 16a-48, Page 16a-23).
Page 481: Idler Shaft Disassembly
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly PRESS PRESS RAM ARBOR ARBOR WEDGE ATTACHMENT Figure 16a-56 Remove Bearing Figure 16a-57 Remove Bearing IDLER SHAFT DISASSEMBLY 1. Place a bearing puller wedge attachment (CCI P/N 1012812) between the bearing (67) (Figure 16a-48, Page 16a-23) and the small gear on the idler shaft (66) (Figure 16a-48, Page 16a-23), then press the bearing off the shaft as shown (Figure 16a-57, Page 16a-27).
Page 482: Unitized Transaxle Component Inspection
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Component Inspection UNITIZED TRANSAXLE COMPONENT INSPECTION Read DANGER and WARNING on page 16a-1. 1. Clean all of the component parts of the transaxle in a high ﬂash-point solvent and then dry them. Inspect all components for excessive wear or damage.
Page 483: Intermediate Gear Assembly
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly INTERMEDIATE GEAR ASSEMBLY 1. If the gear (61) was removed from the shaft, install the key (60) into the slot and then position the gear on the shaft with keyway properly aligned with key. Press gear into place on the key (Figure 16a-48, Page 16a-23).
Page 484 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly Synchronizer Gear Assembly, Continued: 7. Install the input gear assembly (55), with the smooth collar toward the synchronizer ring as shown (Figure 16a-48, Page 16a-23). The input gear should seat in the synchronizer ring. 8.
Page 485: Shifter Fork Assembly
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly 11. Install the narrow bearing (47), wide bearing (46), and input gear (45) onto the shaft. The smooth collar of the input gear should be oriented toward the synchronizer ring as shown (Figure 16a-48, Page 16a-23).
Page 486 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly Differential Gear Case Assembly, Continued: 6. Position the output ring gear (71) (Figure 16a-48, Page 16a-23) on the carrier case, visually aligning the dowel hole in the carrier case with the dowel pin in the ring gear. Using a plastic or rubber mallet, tap the ring gear into place on the dowel pin as shown (Figure 16a-71, Page 16a-33).
Page 487: Governor Gear Assembly
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly DOWEL PIN TIGHTENING SEQUENCE DOWEL HOLE Figure 16a-71 Ring Gear Figure 16a-72 Retaining Bolts GOVERNOR GEAR ASSEMBLY The governor gear is not assembled before installing it in the unitized transaxle case. The governor gear shaft is installed into the case and then the rest of the governor gear assembly is installed on the shaft.
Page 488: Unitized Transaxle Assembly
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly O-RING GROOVE RETAINING SCREW GROOVE Figure 16a-73 Differential Lock Shaft Figure 16a-74 Differential Lock Housing Assembly UNITIZED TRANSAXLE ASSEMBLY Read DANGER and WARNING on page 16a-1. NOTE: Although the following drawings show the transaxle being assembled in an upright position, laying the transaxle on its left (driver) side will simplify the assembly process.
Page 489 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly SHAFT TOOL Press oil seal into right side case. Figure 16a-75 Install Seals Figure 16a-76 Governor Gear Shaft SLEEVE GOVERNOR GEAR WASHER Figure 16a-77 Position Governor Gear Figure 16a-78 Install Governor Gear 6.
Page 490 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly Unitized Transaxle Assembly, Continued: 7.2. Install the idler gear assembly into case as shown. Do not seat the assembly in the bore, but insert far enough that it will not fall out. No gears mesh at this time (Figure 16a-82, Page 16a-37). 7.3.
Page 491 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly Figure 16a-81 Differential Gear Assembly Figure 16a-82 Idler Gear Assembly Cutaway view of shifter SLOT fork and synchronizer gear assembly being inserted as a unit into casing. Figure 16a-83 Oil Guide Figure 16a-84 Synchronizer Ring Gear 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 16a-37...
Page 492 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly As you insert the synchronizer gear Several gears mesh assembly (complete with shifter fork) as you insert the into the casing, several gears intermediate gear must mesh together. assembly. Spur gear and governor gear mesh.
Page 493 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly Unitized Transaxle Assembly, Continued: 8. Make sure the mating surfaces of the left and right sides of the case are clean and free of oil, grease, or residue of any kind, and they are not scratched or damaged in any way. 9.
Page 494 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly Unitized Transaxle Assembly, Continued: Figure 16a-89 Casing Torque Sequence Dowell pin will help hold differential locking assembly to transaxle casting until axle bolts are inserted. Figure 16a-90 Seal Axle Tube Surface Page 16a-40 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 495 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly 12.7. Install the left (driver side) axle shaft (90) in the left axle tube (92) (Figure 16a-9, Page 16a-8). Using 90° angle (0.090 tip) snap ring pliers, install the retaining ring as shown (Figure 16a-92, Page 16a-41).
Page 496: Unitized Transaxle Installation
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Assembly, Continued: NOTE: Push the rubber boot onto the washer so that the washer edge ﬁts into the boot-tip groove. 14. Install rear wheel brake drum. 15. Repeat steps 13 and 14 for the passenger side rear axle and wheel bolt ﬂange. UNITIZED TRANSAXLE INSTALLATION Read DANGER and WARNING on page 16a-1.
Page 497 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation BRACKET Figure 16a-95 Accelerator Cable Bracket 10. While holding the arm and shaft in the fully counterclockwise position, tighten the governor arm lever nut to 35 in-lb (4.0 N·m) (Figure 16a-97, Page 16a-44). 11.
Page 498 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 1. Install the governor arm 4. Tighten the on the governor shaft. retaining nut. 2. Turn shaft counterclockwise. 3. Pull governor arm rearward. Figure 16a-96 Governor Cable Bracket Figure 16a-97 Governor Arm SNUBBER SNUBBER...
Page 499 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation 23. Install three wire ties to secure the engine kill wire to the accelerator cable where they both route together on the passenger side of the engine. 24. Connect the oil level sensor wire (18-gauge yellow) to the jumper wire (Figure 16a-104, Page 16a-47). Figure 16a-100 Leaf Springs Figure 16a-101 Leaf Springs and Shackles WHITE/BLACK...
Page 500 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: Figure 16a-103 Shock Absorber 25. Connect the 6-gauge white wire to the F2 post, the 6-gauge black ground wire to the A2 post and tighten to 48 in-lb (5.4 N·m). Connect the 16-gauge yellow wire to the DF post on the starter/generator and tighten to 30 in-lb (3.4 N·m) (Figure 16a-105, Page 16a-47).
Page 501 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation STARTER/ GENERATOR YELLOW WHITE YELLOW OIL SENDING UNIT JUMPER WIRE GROUND Figure 16a-104 Oil Level Sensor Jumper Wire Figure 16a-105 Starter/Generator TOP VIEW SPRING RELEASE NUTS Figure 16a-106 Connect Shifter Cable Figure 16a-107 Engine Ground TOP VIEW CLAMP...
Page 502 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 30. Connect the impulse line to the fuel pump and secure it with the hose clamp (Figure 16a-110, Page 16a-48). 31. Connect air intake hose to carburetor and secure hose clamp (Figure 16a-111, Page 16a-48). 32.
Page 503 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation CLAMP Figure 16a-112 Carburetor Vent Tube Step 1 Step 2 Step 3 Figure 16a-113 Differential Cable End Installation Push cable into the bracket. Figure 16a-114 Differential Cable Installation 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 16a-49...
Page 504: Forward/Reverse Shifter Cable
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Forward/Reverse Shifter Cable TOP VIEW SHIFTER SHIFTER F N R LEVER Figure 16a-115 Forward/Reverse Positions FORWARD/REVERSE SHIFTER CABLE Read DANGER and WARNING on page 16a-1. If the Forward/Reverse shifter cable is damaged in any way, it must be replaced. FORWARD/REVERSE SHIFTER CABLE REMOVAL NOTE: Before removing cable, note cable routing and positions of wire ties or other devices securing the cable to the vehicle.
Page 505: Forward/Reverse Shifter Cable Adjustment
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Forward/Reverse Shifter Cable ∆ WARNING • If wires are removed or replaced, make sure wiring and/or wiring harness is properly routed and secured to vehicle frame. Failure to properly route and secure wiring could result in vehicle malfunction, property damage or personal injury.
Page 506: Differential Lock System
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System Forward/Reverse Shifter Cable Adjustment, Continued: ∆ CAUTION • 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. For major adjustments, the cable retaining nuts (5) must be loosened and adjusted.
Page 507: Differential Lock Cable Installation
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System 4. While maintaining pressure on the locking tabs, pull the differential lock cable toward the rear of the vehi- cle to disconnect the cable from the bracket (Figure 16a-13, Page 16a-11). 5.
Page 508 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System 1. Rotate the cable connector toward the passenger side of the vehicle to connect the cable to the differential lock lever. 2. Push plastic cable retainer toward the front of the vehicle to secure the cable to the bracket.
Page 509: Section 16B - Mc010C-Bs00 Unitized Transaxle With Differential Lock
SECTION 16B – MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 510: Transaxle Models
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. •...
Page 511: Lubrication
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Transaxle Models RUBBER DUST IDENTIFICATION IDENTIFICATION DECAL DECAL Figure 16b-1 MC010C-BS00 Figure 16b-2 MC012C-AS00 Shifter Lever A shifter lever, connected to a shifter arm on the unitized transaxle, is used to change the gears to one of three shift positions: FORWARD (F), NEUTRAL (N), or REVERSE (R) (Figure 16b-3, Page 16b-3).
Page 512 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Transaxle Models Differential Lock Lever The MC010C-BS00 unitized transaxle has a differential lock, controlled by a differential lock lever. The lever is located between the driver and passenger seats (Figure 16b-5, Page 16b-4). Figure 16b-5 Differential Lock Lever Neutral Lockout •...
Page 513: Axle Shaft
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Unitized Transaxle Service The unitized transaxle is extremely durable and should require very little service under normal operating con- ditions. The only service required on the unitized transaxle is to maintain proper lubricant level. See Periodic Lubrication Schedule, Section 10, Page 10-5.
Page 514: Axle Bearing
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Axle Shaft and Oil Seal Removal, Continued: ∆ CAUTION • Do not scar or damage the inside surfaces of the tube when removing the oil seal. A damaged tube might have to be replaced. Figure 16b-6 Retaining Ring Figure 16b-7 Rolling Head Prybar Insert prybar under...
Page 515 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft TYPICAL 8 PLACES REFERENCE DRIVER SIDE CASE REFERENCE PASSENGER SIDE CASE TYPICAL 7 PLACES Figure 16b-9 Differential Gear Case/Axle Tubes 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 16b-7...
Page 516 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Axle Bearing Removal, Continued: 2. Press the bearing (86) and collar (87) off together of either axle (82 or 83) (Figure 16b-9, Page 16b-7).See also Figure 16b-10, Page 16b-8. See following NOTE. NOTE: It may be necessary to heat the collar to remove it.
Page 517: Axle Shaft And Oil Seal Installation
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal AXLE SHAFT AND OIL SEAL INSTALLATION 1. Clean bearing and seal seats inside axle tube (90 or 91) hubs (Figure 16b-9, Page 16b-7). 2. Place a new seal (89) (Figure 16b-9, Page 16b-7) in axle tube with seal lip facing inside of the axle tube. Use an axle seal tool (CCI P/N 1014162) to press it in until it seats ﬁrmly in position (Figure 16b-11, Page 16b-8).
Page 518 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: CLAMP Figure 16b-12 Carburetor Vent Tube CLAMP IMPULSE LINE Figure 16b-13 Air Intake Hose Figure 16b-14 Impulse Line 5.5. Remove the differential lock cable. 5.5.1. Place differential lock handle in the disengaged direction. 5.5.2.
Page 519 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal 1. Apply pressure to locking tabs of the cable. 2. Pull cable sheath toward rear of vehicle to disconnect from the bracket. Figure 16b-15 Differential Lock Cable Bracket 5.8. Loosen nuts securing shifter cable to shifter cable mounting bracket. Then disconnect the shifter cable rod end from the shifter arm on the unitized transaxle and remove the cable from the cable mounting bracket (Figure 16b-20, Page 16b-12).
Page 520 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: Rotate the cable connector toward the driver side of the vehicle to disconnect the cable from the differential lock lever. Figure 16b-16 Differential Lock Cable Removal TOP VIEW Loosen retaining nuts to remove Remove fuel line.
Page 521 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal 6. Remove the lower shock mounting hardware from both rear shocks (Figure 16b-24, Page 16b-13). 7. Disconnect the brake hoses and park brake cables. 7.1. Remove the park brake cable clip (1), hair spring cotter pin (2) and clevis pin (3) (Figure 16b-25, Page 16b-14).
Page 522 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: CABLE SUPPORT BRACKET Figure 16b-25 Park Brake Cable Figure 16b-26 Brake Hose 7.2. Remove the cable from the cable support bracket (Figure 16b-25, Page 16b-14). 7.3. Remove the upper shock mounting hardware from the rear shock absorber and remove the shock absorber.
Page 523 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal 11. Remove the bolts that secure the leaf springs to the shackles (Figure 16b-29, Page 16b-15). 12. With the hydraulic jack, slowly lower the powertrain until both of the rear tires are resting on the ﬂoor. Figure 16b-28 Spring Retainer Bolts Figure 16b-29 Rear Shackles 13.
Page 524 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: SNUBBER SNUBBER BRACKET Figure 16b-32 Snubber Figure 16b-33 Remove Powertrain 14. Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle (Figure 16b-33, Page 16b-16).
Page 525 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal GOVERNOR ARM RETAINING BOLT RETAINING BOLT Leave cable connected. Leave cable connected. Figure 16b-36 Driven Clutch Figure 16b-37 Governor Arm 18. Loosen, but do not remove, the governor arm retaining bolt. Remove the governor arm from the shaft (Figure 16b-37, Page 16b-17).
Page 526: Unitized Transaxle Disassembly
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Disassembly TRANSAXLE MOUNTING BOLT AND NUT (TYPICAL 4 PLACES) WOODEN BLOCKS TRANSAXLE MOUNTING NUTS (TYPICAL 2 PLACES) Figure 16b-40 Differential Lock Arm and Bracket Figure 16b-41 Transaxle Mounting UNITIZED TRANSAXLE DISASSEMBLY Read DANGER and WARNING on page 16b-1. NOTE: The following information provides instructions for disassembling the unitized transaxle;...
Page 527 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Disassembly TYPICAL 15 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 16b-42 Transaxle Gear Casing and Brackets 10. Turn the case section containing the gearing on edge as shown (Figure 16b-43, Page 16b-20). While holding it in this position, gently rock all the gear assemblies to slightly loosen them in their seating.
Page 528 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Disassembly Unitized Transaxle Disassembly, Continued: DIFFERENTIAL GEAR CASE ASSEMBLY Figure 16b-43 Loosen Gears Figure 16b-44 Remove Differential Gear Case 14. Use a seal puller (CCI P/N 1012809) or rolling head prybar to remove the input shaft oil seal from the case (Figure 16b-46, Page 16b-20).
Page 529: Component Disassembly
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly 16.2. Remove ﬂat washer (17) from the shifter shaft on the outside of the case as shown, then remove the shifter shaft by pushing it through the case toward the interior of transaxle. 16.3.
Page 530: Governor Gear Disassembly
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly Differential Gear Lock Housing Disassembly, Continued: Figure 16b-49 Differential Lock Housing Disassembly GOVERNOR GEAR DISASSEMBLY NOTE: It will be necessary to disassemble the governor gear assembly in order to reinstall it into the tran- saxle case.
Page 531 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly REFERENCE PASSENGER SIDE CASE REFERENCE DRIVER SIDE CASE Figure 16b-50 Unitized Transaxle with Differential Lock 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 16b-23...
Page 532 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly Differential Gear Case Disassembly, Continued: Figure 16b-51 Remove Governor Gear Figure 16b-52 Pry Gear from Shaft 2. Pull the cover (78) and thrust plate (77) from the differential gear carrier case (Figure 16b-50, Page 16b-23).
Page 533: Shifter Fork Disassembly
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly 7. If the bearings (70 and 71) are to be removed, place a bearing puller wedge attachment (CCI P/N 1012812) between the bearing (71) and gear case (75) (Figure 16b-50, Page 16b-23) and press the bearing off as shown (Figure 16b-55, Page 16b-25).
Page 534: Intermediate Gear Disassembly
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly Synchronizer Gear Disassembly, Continued: 3. Place a bearing puller wedge attachment (CCI P/N 1012812) between the bearing (57) and input gear assembly (55) (Figure 16b-50, Page 16b-23), then press the bearing off the input shaft as shown (Figure 16b-57, Page 16b-26).
Page 535: Idler Shaft Disassembly
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly 2. Place the bearing puller wedge attachment under the bearing (62) and press the bearing from the shaft (Figure 16b-50, Page 16b-23). See following CAUTION. 3. Press the gear (61) from the shaft (59), then remove the key (60) (Figure 16b-50, Page 16b-23). PRESS PRESS RAM ARBOR...
Page 536: Unitized Transaxle Component Inspection
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Component Inspection UNITIZED TRANSAXLE COMPONENT INSPECTION Read DANGER and WARNING on page 16b-1. 1. Clean all of the component parts of the transaxle in a high ﬂash-point solvent and then dry them. Inspect all components for excessive wear or damage.
Page 537: Intermediate Gear Assembly
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly INTERMEDIATE GEAR ASSEMBLY 1. If the gear (61) was removed from the shaft, install the key (60) into the slot and then position the gear on the shaft with keyway properly aligned with key. Press gear into place on the key (Figure 16b-50, Page 16b-23).
Page 538 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly Synchronizer Gear Assembly, Continued: 7. Install the input gear assembly (55), with the smooth collar toward the synchronizer ring as shown (Figure 16b-50, Page 16b-23). The input gear should seat in the synchronizer ring. 8.
Page 539: Shifter Fork Assembly
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly 11. Install the narrow bearing (47), wide bearing (46), and input gear (45) onto the shaft. The smooth collar of the input gear should be oriented toward the synchronizer ring as shown (Figure 16b-50, Page 16b-23).
Page 540 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly DIFFERENTIAL GEAR CARRIER CASE Figure 16b-69 Differential Gear Figure 16b-70 Idler Gear Figure 16b-71 Second Idler Gear Figure 16b-72 Carrier Case Page 16b-32 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 541: Governor Gear Assembly
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly DOWEL PIN TIGHTENING SEQUENCE DOWEL HOLE Figure 16b-73 Ring Gear Figure 16b-74 Retaining Bolts GOVERNOR GEAR ASSEMBLY The governor gear is not assembled before installing it in the unitized transaxle case. The governor gear shaft is installed into the case and then the rest of the governor gear assembly is installed on the shaft.
Page 542: Unitized Transaxle Assembly
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly O-RING GROOVE RETAINING SCREW GROOVE Figure 16b-75 Differential Lock Shaft Figure 16b-76 Differential Lock Housing Assembly UNITIZED TRANSAXLE ASSEMBLY Read DANGER and WARNING on page 16b-1. NOTE: Although the following drawings show the transaxle being assembled in an upright position, laying the transaxle on its left (driver) side will simplify the assembly process.
Page 543 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly SHAFT TOOL Press oil seal into right side case. Figure 16b-77 Install Seals Figure 16b-78 Governor Gear Shaft SLEEVE GOVERNOR GEAR WASHER Figure 16b-79 Position Governor Gear Figure 16b-80 Install Governor Gear 6.
Page 544 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly Unitized Transaxle Assembly, Continued: 7.3. Install the oil guide with the bafﬂe toward the case wall as shown (Figure 16b-85, Page 16b-37). Make sure the two tabs on the guide are positioned in the slots in the case. INTERIOR WASHER RETAINING RING...
Page 545 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly Cutaway view of shifter SLOT fork and synchronizer gear assembly being inserted as a unit into casing. Figure 16b-85 Oil Guide Figure 16b-86 Synchronizer Ring Gear 7.4. Position the shifter fork assembly on the synchronizer gear assembly as shown, and install them together, bearing end ﬁrst, into the bore containing the oil guide (Figure 16b-86, Page 16b-37).
Page 546 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly Unitized Transaxle Assembly, Continued: 9. Apply a continuous bead of Three Bond No. 1215 (CCI P/N 101928701) sealant to the mating surface, around the complete proﬁle of the right (passenger side) case (Figure 16b-90, Page 16b-39). See fol- lowing CAUTION.
Page 547 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly EDGES FLUSH The edges of the input drive gear and large intermediate gear should be flush. MATING SURFACES The outside edges of the idler, intermediate, and differential bearings are on the same plane. The synchronizer bearing protrudes slightly.
Page 548 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly Unitized Transaxle Assembly, Continued: ∆ WARNING • Be sure 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 549: Unitized Transaxle Installation
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation 12.7. Install the left (driver side) axle shaft (82) in the left axle tube (90) (Figure 16b-9, Page 16b-7). Using 90° angle (0.090 tip) snap ring pliers, install the retaining ring as shown (Figure 16b-94, Page 16b-41).
Page 550 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: TRANSAXLE MOUNTING BOLT AND NUT (TYPICAL 4 PLACES) WOODEN BLOCKS TRANSAXLE MOUNTING NUTS (TYPICAL 2 PLACES) Figure 16b-95 Transaxle Mounting 8. Install the governor cable bracket on transaxle case. Tighten the mounting screws to 134 in-lb (15.1 N·m) (Figure 16b-98, Page 16b-43).
Page 551 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation 1. Install the governor arm 4. Tighten the on the governor shaft. retaining nut. 2. Turn shaft counterclockwise. 3. Pull governor arm rearward. Figure 16b-98 Governor Cable Bracket Figure 16b-99 Governor Arm 15.
Page 552 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: SNUBBER SNUBBER BRACKET Figure 16b-100 Driven Clutch Figure 16b-101 Snubber Figure 16b-102 Leaf Springs Figure 16b-103 Leaf Springs and Shackles Page 16b-44 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 553 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Figure 16b-104 Shock Absorber WHITE/BLACK WIRE BLACK WIRE Figure 16b-105 Ignition Kill Wire 25. Connect the 6-gauge white wire to the F2 post, the 6-gauge black ground wire to the A2 post and tighten to 48 in-lb (5.4 N·m).
Page 554 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 26.5. Position the shifter cable in the shifter cable mounting bracket on the transaxle and tighten the mounting nuts to 22 ft-lb (29.8 N·m). Connect shifter cable rod end to the shifter arm (Figure 16b-108, Page 16b-46).
Page 555 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation TOP VIEW CLAMP ACCELERATOR CABLE Figure 16b-110 Connect Cable to Cam Figure 16b-111 Connect Fuel Line 31. Connect air intake hose to carburetor and secure hose clamp (Figure 16b-113, Page 16b-47). 32.
Page 556 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 36. Check that all wiring is secured properly. See following WARNING. ∆ WARNING • If wires are removed or replaced make sure wiring and wiring harness is properly routed and secured to vehicle frame.
Page 557: Forward/Reverse Shifter Cable
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Forward/Reverse Shifter Cable Push cable into the bracket. Figure 16b-116 Differential Cable Installation TOP VIEW SHIFTER SHIFTER F N R LEVER Figure 16b-117 Forward/Reverse Positions FORWARD/REVERSE SHIFTER CABLE Read DANGER and WARNING on page 16b-1. If the Forward/Reverse shifter cable is damaged in any way, it must be replaced.
Page 558: Forward/Reverse Shifter Cable Installation
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Forward/Reverse Shifter Cable Forward/Reverse Shifter Cable Removal, Continued: 3. Loosen the retaining nuts (5) on both ends of the cable and remove the wire tie. 4. Remove cable from the vehicle. REFERENCE TRANSMISSION SHIFTER LEVER REFERENCE TRANSMISSION CABLE SUPPORT...
Page 559: Forward/Reverse Shifter Cable Adjustment
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System ∆ WARNING • If wires are removed or replaced, make sure wiring and/or wiring harness is properly routed and secured to vehicle frame. Failure to properly route and secure wiring could result in vehicle malfunction, property damage or personal injury.
Page 560: Differential Lock Cable Removal
MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System DIFFERENTIAL LOCK CABLE REMOVAL 1. Place the differential lock handle in the disengaged position. 2. Remove wire tie (6) securing the cable to the vertical support (Figure 16b-119, Page 16b-53). 3. Using a pair of pliers, apply pressure to the locking tabs of the cable end (1) where it attaches to the dif- ferential lock handle mounting bracket (Figure 16b-15, Page 16b-11).
Page 561 MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System 1. Rotate the cable connector toward the passenger side of the vehicle to connect the cable to the differential lock lever. 2. Push plastic cable retainer toward the front of the vehicle to secure the cable to the bracket.
Page 563: Section 17 - Torque Converter
SECTION 17 – TORQUE CONVERTER ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 564: General Information
TORQUE CONVERTER General Information ∆ WARNING • Any modiﬁcation or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory speciﬁcations, could result in severe personal injury or death. • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic ﬂoor jack) with 1000 lb.
Page 565 TORQUE CONVERTER General Information TORQUE CONVERTER TOOL KIT (CCI P/N 1014510) DRIVEN CLUTCH CAM PRESS TOOL (CCI P/N 101809101) DRIVE CLUTCH HUB PULLER DRIVEN CLUTCH CAM PULLER (CCI P/N 1014497) (CCI P/N 1014508) DRIVEN CLUTCH PULLER PLUG (CCI P/N 1014507) DRIVE CLUTCH HOLDER TOOL (CCI P/N 1015524) DRIVE...
Page 566: Drive Belt
The interaction of these components are essential to the troubleshooting process. If the engine and governor 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 con- verter problem.
Page 567: Drive Belt Installation
TORQUE CONVERTER Drive Clutch 4. Disconnect the spark plug wire from the spark plug. See WARNING "To avoid unintentionally start- ing..." on page 17-1. 5. Pedal-Start Vehicles: Place the Forward/Reverse handle in the NEUTRAL position and the neutral lock- out cam in the SERVICE position. 6.
Page 568: Drive Clutch Cleaning And Inspection
• Do not hit or tap the clutch with a hammer. Do not pry the clutch. These actions will damage the clutch. DRIVE CLUTCH CLEANING AND INSPECTION 1. Use a dry, lint-free cloth to clean clutch parts. See following CAUTION. Use Club Car clutch holder while tightening or loosening drive VEHICLE BODY clutch retaining bolt.
Page 569: Drive Clutch Disassembly
TORQUE CONVERTER Drive Clutch ∆ CAUTION • Do not lubricate the drive clutch. Lubricants attract dirt and dust, which interfere with proper clutch operation. • Use only a dry cloth to lightly wipe the shaft (7) of the ﬁxed face assembly (Figure 17-7, Page 17-9).
Page 570 TORQUE CONVERTER Drive Clutch Drive Clutch Disassembly, Continued: DRIVE CLUTCH HUB PULLER TOOL (CCI P/N 1014497) Mark the clutch cover and its corresponding position on the moveable casting. Figure 17-5 Mark Clutch Cover Figure 17-6 Remove Clutch Drive Hub 5. To remove the clutch weights: 5.1.
Page 571 TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES (ONE SPRING PER CLUTCH) Figure 17-7 Drive Clutch Assembly 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 17-9...
Page 572: Inspection Of Drive Clutch Parts
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 RIBS WEIGHT SLOTS IN HUB CASTING Figure 17-8 Drive Button Mounting Figure 17-9 Weight Position INSPECTION OF DRIVE CLUTCH PARTS 1.
Page 573: Drive Clutch Assembly
TORQUE CONVERTER Drive Clutch Use a scribe to remove PRESS RAM spiral back-up rings from both sides of fixed face assembly. IDLER BEARING BEARING PULLER FIXED FACE ASSEMBLY Figure 17-10 Remove Idler Bearing Figure 17-11 Spiral Back-up Rings DRIVE CLUTCH ASSEMBLY 1.
Page 574 TORQUE CONVERTER Drive Clutch Drive Clutch Assembly, Continued: 6.1. Rotate the moveable face assembly clockwise while installing it onto the shaft. 6.2. Install the retaining ring (3) (Figure 17-7, Page 17-9). 7. Install the primary weights on the mounting pins (Figure 17-12, Page 17-11). 8.
Page 575: Drive Clutch Installation
TORQUE CONVERTER Drive Clutch 18. Install the hub assembly (1) on the moveable face assembly and align the match marks made before dis- assembling the clutch. Press the hub assembly on by hand (Figure 17-7, Page 17-9). 19. Replace the plastic ring (22) hole protector (Figure 17-7, Page 17-9). DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED Figure 17-15 Correct Orientation of Drive Button Take-up Spring...
Page 576: Driven Clutch
TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH Read DANGER and WARNING on page 17-1. DRIVEN CLUTCH REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2. Access the engine compartment. See WARNING "For vehicles with cargo beds..." on page 17-2. 2.1.
Page 577 TORQUE CONVERTER Driven Clutch TYPICAL 3 PLACES Figure 17-16 Driven Clutch Assembly 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page 17-15...
Page 578: Driven Clutch Assembly
TORQUE CONVERTER Driven Clutch Place puller plug in bore of cam (A). Then clamp driven clutch cam puller onto three flat surfaces of the cam. Using external snap ring pliers, remove DRIVEN CLUTCH retaining ring. CAM PULLER PULLER PLUG Figure 17-17 Remove Retaining Ring Figure 17-18 Driven Clutch Disassembly DRIVEN CLUTCH ASSEMBLY ®...
Page 579 TORQUE CONVERTER Driven Clutch 5.1.4. While holding onto the cam, tap the end of the ﬁxed face shaft lightly with a plastic mallet until the cam seats against the retaining ring. See following CAUTION. ∆ CAUTION • Do not use a metal hammer to tap the ﬁxed face hub. A metal hammer will damage the shaft. CAM PRESS TOOL Figure 17-19 Cam Press Tool Figure 17-20 Cam Installation Tool...
Page 580: Driven Clutch Installation
TORQUE CONVERTER Driven Clutch Driven Clutch Assembly Continued: ∆ CAUTION • Do not use a metaDriven Clutch Assembly, Continued:l hammer to tap the ﬁxed face hub. A metal hammer will damage the shaft. NOTE: The cam has an interference ﬁt with the keyed shaft and should remain in position when the cam installation tool is removed, providing for the assembly of the retaining ring.
Page 581 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. bed, cargo see cargo bed accelerator belt, drive cable see drive belt installation ..........14-13 body, front removal ............. 14-12 components ............
Page 582 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. line, front closed throttle or idle adjustment ....14-14 installation ........6a-28, 6b-29 float system ............14-4 removal ..........6a-28, 6b-27 jet, main ............14-6 line, rear elevation/size chart ........14-6 installation ........6a-30, 6b-30...
Page 583 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. oil seal removal ............12a-32 installation ..........13-42 testing ............11a-48 removal ............. 13-42 drive belt removal ............13-22 inspection ............
Page 584 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. service specifications ........13-51 installation ............14-30 engine oil ............. 10-6 removal ............14-28 exhaust system .........14-5, 15-2 storage ............14-29 see also muffler fuel/hour gauge fuel gauge circuit ..........11a-14 testing ............11a-46...
Page 585 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. hydraulic lifters ..........13-6 starter/generator inspection ............13-25 armature ........... 12a-8 installation ............. 13-46 bearing ............12a-7 removal ............13-25 brush spring ..........
Page 586 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. troubleshooting ..........11a-20 oil pump lockout cam circuit cover removal ..........13-33 function ............11a-13 inspection ............13-33 low oil warning circuit installation ............13-35 function ............
Page 587 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. installation ............7-12 slow speed system ..........14-3 snubber removal ............. 7-7 reverse buzzer see suspension, rear installation ........... 12a-22 solenoid limit switch installation ...........
Page 588 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. steering test procedure battery ..........11a-22, 11a-44 rack and pinion diode ............11a-31 assembly ............. 7-11 disassembly ..........7-8 engine kill circuit ......11a-34, 11a-42 fuel gauge ............11a-46 installation ...........
Page 589 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. troubleshooting ..........17-4 trailer hitch WARNING installation ............4-14 definition of ............1-1 removal ............4-14 wheel transaxle installation ............8-3 see unitized transaxle (MC010C-BS00) removal .............
Page 591 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. bed, cargo see cargo bed accelerator belt, drive cable see drive belt installation ..........14-13 body, front removal ............. 14-12 components ............
Page 592 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. line, front closed throttle or idle adjustment ....14-14 installation ........6a-28, 6b-29 float system ............14-4 removal ..........6a-28, 6b-27 jet, main ............14-6 line, rear elevation/size chart ........14-6 installation ........6a-30, 6b-30...
Page 593 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. oil seal cleaning and inspection ......17-6, 17-10 installation ..........13-42 disassembly ............ 17-7 removal ............. 13-42 general information ......... 17-2 removal ............
Page 594 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. fender, rear hour gauge circuit testing ............11b-46 installation ............4-12 installation ............12b-25 removal ............4-11 operation ............12b-24 field coil removal ............12b-24 see starter/generator fueling instructions ..........10-7...
Page 595 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. testing ............11b-36 intake duct inspection installation ............. 14-19 brake cluster ........... 6a-5, 6b-5 removal ............14-18 inspection and cleaning ....6a-12, 6b-12 intermediate gear brake drum and shoe ......
Page 596 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. master cylinder oil viscosity ............10-7 oil, engine ............10-6 inspection ........6a-4, 6b-4, 10-6 installation ...........6a-33, 6b-32 removal ..........6a-32, 6b-32 park brake muffler adjustment ..........6a-39, 6b-39...
Page 597 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. limit switch testing ............11b-29 installation ..........12b-23 spark plug ..........13-7, 14-5 removal ........... 12b-22 cleaning, inspection and repair ....... 13-7 testing .............
Page 598 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. disassembly ............7-6 ground cables ..........11b-27 installation ............7-7 headlight ............11b-49 removal .............. 7-5 headlight switch ...........11b-47 steering wheel hour gauge ...........11b-46 installation ............
Page 599 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. transaxle wheel see unitized transaxle (MC010C-BS00) installation ............8-3 see unitized transaxle (MC012C-AS00) removal ............. 8-2 troubleshooting see also tire see also testing wheel cylinder brake system ..........
Page 601 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual...
Page 604 Transportation and Utility Vehicles Club Car, Inc. P.O. Box 204658 Augusta, GA 30917-4658...

This manual is also suitable for:

Carryall 272

Club Car TURF 272 Maintenance Manual

Section 1 - Safety

Section 2 - Vehicle Specifications

Section 3 - General Information

Section 4 - Body and Trim

Section 5 - Accelerator and Brake Pedal Assemblies

Section 6A - Mc012C-As00 Transaxle: Hydraulic and Park Brake Sys

Tems

Section 6B - Mc010C-Bs00 Transaxle: Hydraulic and Park Brake Sys

Tems

Section 7 - Steering and Front Suspension

Section 8 - Wheels and Tires

Section 9 - Rear Suspension

Section 10 - Periodic Maintenance

Section 11A - Troubleshooting and Electrical System: Fe400, Key-Start Engine

Section 11B - Troubleshooting and Electrical System: Fe350, Pedal-Start Engine

Section 12A - Electrical Components: Fe400, Key-Start Engine

Quick Links

Troubleshooting

Related Manuals for Club Car TURF 272

Summary of Contents for Club Car TURF 272