Page 1 2009 FE 350 Maintenance and Service Supplement FE 350 Gasoline Vehicles Manual Number 103472709 Edition Code 0509A00000...
Page 3 Engines and Drivetrain Components, Repair and Rebuild Manual (CCI P/N 102396501). If you do not have the appropriate maintenance and service manual, you may order one from your local Club Car representative. Maintenance and service manuals available include the following: 2008/2009 Turf/Carryall Vehicle Maintenance and Service Manual Publication Part No.
Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.
Page 5: Table Of Contents
Test Procedures ............................11-16 SECTION 12 — ELECTRICAL COMPONENTS ....................12-1 Starter/Generator............................12-1 Starter/Generator Removal ........................12-1 Disassembly of the Starter/Generator to Service the Brushes ..............12-2 Brush Inspection and Replacement......................12-2 2009 FE 350 Maintenance and Service Supplement Page iii...
Page 6 Oil Level Sensor ............................12-31 Oil Level Sensor Removal ........................12-31 Oil Level Sensor Installation ........................12-31 Relay .................................12-31 Relay Removal ............................12-31 Relay Installation ............................12-32 Headlights..............................12-33 Headlight Bulb Removal..........................12-33 Headlight Bulb Installation ........................12-33 Voltage Limiter ............................12-34 Page iv 2009 FE 350 Maintenance and Service Supplement...
Page 7 Charging the Battery ..........................12-46 Battery Installation ..........................12-46 Battery Storage ............................12-47 Charging a Dead Battery.........................12-47 Ground Cables ............................12-47 SECTION 13 — S10 FE 350 ENGINE ....................... 13-1 General Information ............................. 13-1 Before Servicing ............................13-1 Engine Rotation............................13-1 Spark Plug .............................. 13-1 Cylinder Head .............................
Page 8 SECTION 14 — S27 FE 350 ENGINE ....................... 14-1 General Information ............................. 14-1 Before Servicing ............................14-1 Engine Rotation............................14-1 Spark Plug .............................. 14-1 Cylinder Head ............................. 14-3 General Information ..........................14-3 Breather Valve (Reed Valve)........................14-3 Valve Clearance Check and Adjustment....................14-3 Crankcase..............................
Page 9 Fuel Tank Installation ..........................15-27 Fuel Lines ..............................15-28 Fuel Shut-Off Valve.............................15-29 SECTION 16 — S27 FE 350 FUEL SYSTEM ....................16-1 General Information ............................. 16-1 Carburetor..............................16-1 Main Jet Elevation/Size Chart........................16-2 Changing the Main Jet ..........................16-3 Engine Control Linkage ..........................16-6 General Information ..........................
Page 10 Drive Clutch Assembly ..........................19-10 Drive Clutch Installation .......................... 19-11 Driven Clutch .............................19-12 Driven Clutch Removal ...........................19-12 Driven Clutch Disassembly........................19-12 Driven Clutch Inspection .........................19-13 Driven Clutch Assembly ..........................19-13 Driven Clutch Installation.........................19-16 SECTION i — INDEX Page viii 2009 FE 350 Maintenance and Service Supplement...
Page 11: Section 1 - Safety
SECTION 1 — SAFETY For information regarding this particular section, see the appropriate maintenance and service manual covering the vehicle being serviced. 2009 FE 350 Maintenance and Service Supplement Page 1-1...
Page 13: Section 2 - Vehicle Specifications
SECTION 2 — VEHICLE SPECIFICATIONS For information regarding this particular section, see the appropriate maintenance and service manual covering the vehicle being serviced. 2009 FE 350 Maintenance and Service Supplement Page 2-1...
Page 15: Section 3 - General Information
SECTION 3 — GENERAL INFORMATION For information regarding this particular section, see the appropriate maintenance and service manual covering the vehicle being serviced. 2009 FE 350 Maintenance and Service Supplement Page 3-1...
Page 17: Section 4 - Body And Trim
SECTION 4 — BODY AND TRIM For information regarding this particular section, see the appropriate maintenance and service manual covering the vehicle being serviced. 2009 FE 350 Maintenance and Service Supplement Page 4-1...
Page 19: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP For information regarding this particular section, see the appropriate maintenance and service manual covering the vehicle being serviced. 2009 FE 350 Maintenance and Service Supplement Page 5-1...
Page 21: Section 6 - Wheel Brake Assemblies
SECTION 6 — WHEEL BRAKE ASSEMBLIES For information regarding this particular section, see the appropriate maintenance and service manual covering the vehicle being serviced. 2009 FE 350 Maintenance and Service Supplement Page 6-1...
Page 23: Section 7 - Steering And Front Suspension
SECTION 7 — STEERING AND FRONT SUSPENSION For information regarding this particular section, see the appropriate maintenance and service manual covering the vehicle being serviced. 2009 FE 350 Maintenance and Service Supplement Page 7-1...
Page 25: Section 8 - Wheels And Tires
SECTION 8 — WHEELS AND TIRES For information regarding this particular section, see the appropriate maintenance and service manual covering the vehicle being serviced. 2009 FE 350 Maintenance and Service Supplement Page 8-1...
Page 27: Section 9 - Rear Suspension
SECTION 9 — REAR SUSPENSION For information regarding this particular section, see the appropriate maintenance and service manual covering the vehicle being serviced. 2009 FE 350 Maintenance and Service Supplement Page 9-1...
Page 29: Section 10 - Periodic Maintenance
• Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch the vehicle frame, engine, or any other metal component. WARNING CONTINUED ON NEXT PAGE 2009 FE 350 Maintenance and Service Supplement Page 10-1...
Page 30: Disabling The Vehicle
Disable the vehicle. See Disabling the Vehicle on page 10-2. Disconnect the battery cables, negative (–) cable first, as shown (Figure 10-1, Page 10-3). Disconnect the spark plug wire(s) from the spark plug(s). Page 10-2 2009 FE 350 Maintenance and Service Supplement...
Page 31: Connecting The Battery - Gasoline Vehicles
Figure 10-1 Disconnect Battery – Gasoline Vehicle PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.
Page 32: Performance Inspection
Use the following checklist, in conjunction with the Pre-Operation and Daily Safety Checklist, as a guide to inspect the vehicle and check daily for proper operation. Any problems should be corrected by a Club Car distributor/dealer or a trained technician.
Page 33: General Information
This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local authorized Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service.
Page 34: Periodic Service Schedules
Both the Periodic Service Schedules and the Periodic Lubrication Schedules must be followed to keep vehicle in optimum operating condition. Page 10-6 2009 FE 350 Maintenance and Service Supplement...
Page 35 Check for loose hardware and tighten if General vehicle necessary. Two year service by trained technician only (or every 200 hours of operation, whichever Fuel filters Replace. Dispose of used filters properly. comes first) 2009 FE 350 Maintenance and Service Supplement Page 10-7...
Page 36: Periodic Lubrication Schedules
32 oz. (.95 liters) without filter; 38 oz. (1.12 Change engine oil and oil filter hours of operation or annually, liters) with filter (Figure 10-8, Page 10-11). whichever comes first Figure 10-3 Lubrication Points – Gasoline Vehicles Page 10-8 2009 FE 350 Maintenance and Service Supplement...
Page 37: Engine Oil
Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 10, Page 10-2. Position a pan designed for oil changes under the front drain plug (Figure 10-5). 2009 FE 350 Maintenance and Service Supplement Page 10-9...
Page 38 Or, make a drip guard by folding a piece of cardboard, thin metal, or plastic under the oil filter forming a channel to direct the filter port oil into the drain pan. Dispose of used oil according to the environmental laws and regulations for your area. Page 10-10 2009 FE 350 Maintenance and Service Supplement...
Page 39 NOTE: Use only Club Car oil filters (CCI P/N 1016467) designed for this engine. 12. Tighten the oil filter by hand until tight. Do not use a band wrench or channel lock plier to tighten.
Page 40: Fueling Instructions
Remove the fuel cap located on the passenger-side panel and fill the fuel tank with fresh unleaded gasoline only (Figure 10-10, Page 10-13). See preceding CAUTION and NOTE. Replace fuel cap on tank. Ensure cap is tightened securely. Replace seat. Page 10-12 2009 FE 350 Maintenance and Service Supplement...
Page 41: Battery
1. Vent 2. Fuel Shut-off Valve 3. Fuel Vent Line 4. Fuel Tank Figure 10-9 Fuel Tank – Villager 6 and 8 Figure 10-10 Fuel Tank – Turf and Carryall BATTERY For periodic battery maintenance, see Battery on page 12-42. 2009 FE 350 Maintenance and Service Supplement Page 10-13...
Page 43: Section 11 - Troubleshooting And Electrical System
Water or dirt in the fuel system and/or Section 15 — S10 FE350 Fuel System carburetor; dirty or clogged fuel filter Section 16 — S27 FE 350 Fuel System Section 15 — S10 FE350 Fuel System Carburetor improperly adjusted Section 16 — S27 FE 350 Fuel System...
Page 44 Water or dirt in the fuel system and/or Section 15 — S10 FE350 Fuel System carburetor; dirty or clogged fuel filter Section 16 — S27 FE 350 Fuel System Fuel pump malfunction; fuel pressure to Section 15 — S10 FE350 Fuel System carburetor too low Section 16 —...
Page 45 Section 14 — S27 FE 350 Engine Section 15 — S10 FE350 Fuel System Unsuitable or contaminated fuel Section 16 — S27 FE 350 Fuel System Section 13 — S10 FE 350 Engine Exhaust valve is restricted with carbon deposit Section 14 —...
Page 46 Inlet valve or seat is leaking, dirty, worn, or Section 15 — S10 FE350 Fuel System damaged Section 16 — S27 FE 350 Fuel System Section 15 — S10 FE350 Fuel System Float is damaged and filled with fuel Section 16 — S27 FE 350 Fuel System Carburetor floods.
Page 47 Section 18 — Unitized Transaxle out of adjustment Section 15 — S10 FE350 Fuel System Idle RPM setting is set too high Section 16 — S27 FE 350 Fuel System Transmission does not engage or disengage Insufficient (low) level of lubricant or wrong smoothly.
Page 48: Wiring Diagrams
WIRING DIAGRAMS FUEL GAUGE/ HOUR METER (Through mid-2007) 18_ORG( W23 ) 18 _BLU(W41) 18 _BLK(W16 ) DETAIL FUEL/HOUR METER GAUGE WD103197101B5-L Figure 11-1 Wiring Diagram for Turf 2 and Carryall 2 (Front) Page 11-6 2009 FE 350 Maintenance and Service Supplement...
Page 49 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams WD103197101B5-R Figure 11-2 Wiring Diagram for Turf 2 and Carryall 2 (Rear) 2009 FE 350 Maintenance and Service Supplement Page 11-7...
Page 50 Wiring Diagrams TROUBLESHOOTING AND ELECTRICAL SYSTEM FUEL/HOUR METER GUAGE WD1032208C7-L Figure 11-3 Wiring Diagram for Carryall 6, Villager 6, and TransPorter Vehicles (Front) Page 11-8 2009 FE 350 Maintenance and Service Supplement...
Page 51 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams WD1032208C7-R Figure 11-4 Wiring Diagram for Carryall 6, Villager 6, and TransPorter Vehicles (Rear) 2009 FE 350 Maintenance and Service Supplement Page 11-9...
Page 52 Wiring Diagrams TROUBLESHOOTING AND ELECTRICAL SYSTEM WD1032639C7-L Figure 11-5 Wiring Diagram for Turf 6 (Front) Page 11-10 2009 FE 350 Maintenance and Service Supplement...
Page 53 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams WD1032639C7-R Figure 11-6 Wiring Diagram for Turf 6 (Rear) 2009 FE 350 Maintenance and Service Supplement Page 11-11...
Page 54 Wiring Diagrams TROUBLESHOOTING AND ELECTRICAL SYSTEM WD1032209D7-L Figure 11-7 Wiring Diagram for Villager 8 (Front) Page 11-12 2009 FE 350 Maintenance and Service Supplement...
Page 55 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams WD1032209D7-R Figure 11-8 Wiring Diagram for Villager 8 (Rear) 2009 FE 350 Maintenance and Service Supplement Page 11-13...
Page 56 Wiring Diagrams TROUBLESHOOTING AND ELECTRICAL SYSTEM WD1031980B5-L Figure 11-9 Wiring Diagram for Carryall 2 Plus (Front) Page 11-14 2009 FE 350 Maintenance and Service Supplement...
Page 57 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams WD1031980B5-R Figure 11-10 Wiring Diagram for Carryall 2 Plus (Rear) 2009 FE 350 Maintenance and Service Supplement Page 11-15...
Page 58: Electrical System
15 – RPM Limiter 16 – Ignition Coil 17 – Kill Limit Switch 18 – Key Switch (Engine Kill Circuit) 19 – Engine Kill Wire 20 – Reverse Buzzer Limit Switch Page 11-16 2009 FE 350 Maintenance and Service Supplement...
Page 59 Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position. Chock the wheels. Check for loose or corroded battery terminal connections. Remove the negative (–) cable first and clean, tighten, and replace connections as necessary. 2009 FE 350 Maintenance and Service Supplement Page 11-17...
Page 60 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 11-18 2009 FE 350 Maintenance and Service Supplement...
Page 61 0 °F (-18 °C) 8.5 V 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. 2009 FE 350 Maintenance and Service Supplement Page 11-19...
Page 62 5.1. A 6-gauge black cable connects the negative (–) battery post to the frame. The frame connection should be clean and tight. Visual inspection of the connection on the frame is very difficult. The best check for Page 11-20 2009 FE 350 Maintenance and Service Supplement...
Page 63 2. Disconnect the 6-gauge black wire from the battery. Place red (+) probe on disconnected end of cable. 3. Place black (–) probe on frame. 1600-19700-10373 Figure 11-15 Battery Ground Cable Test 2009 FE 350 Maintenance and Service Supplement Page 11-21...
Page 64 Remove the center dash assembly. See Key Switch Removal, Section 12, Page 12-14. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Page 11-22 2009 FE 350 Maintenance and Service Supplement...
Page 65 1. Cover 2. Electrical Component Box 3. 6 Ga. White Wire 4. 18 Ga. Yellow 6. Blue 7. Green 8. Black White Wire 5. 18 Ga. Red Wire 6. Solenoid Figure 11-18 Key Switch Test – Accessory Terminal Figure 11-19 Solenoid Wire Removal 2009 FE 350 Maintenance and Service Supplement Page 11-23...
Page 66 10. Disconnect the 6-gauge black wire from the negative (–) post of the battery before reconnecting the wires to the solenoid. WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V Figure 11-20 Solenoid Continuity Test Figure 11-21 Solenoid Ground Test Page 11-24 2009 FE 350 Maintenance and Service Supplement...
Page 67 1. Lever Up 2. Lever Depressed 3. Tester light is OFF. Meter reads 1. 4. Tester light is ON. Meter reads approx. zero ohms. Figure 11-22 Neutral Lockout Limit Switch Test 2009 FE 350 Maintenance and Service Supplement Page 11-25...
Page 68 1000 --- FUSED 750V 1. Yellow Wire 2. 200 Ohm Setting 1. Yellow Wire 2. Jumper Wire Figure 11-23 Check Starter Terminal Continuity Figure 11-24 Jumper Wire Ground – DF to A2 Page 11-26 2009 FE 350 Maintenance and Service Supplement...
Page 69 14.7 volts and not rising, and the starter/generator is good; or if the reading is over 15.3 volts and continues to rise, replace voltage regulator. See Voltage Regulator Removal on page 12-13. 2009 FE 350 Maintenance and Service Supplement Page 11-27...
Page 70 It will be necessary to pull and hold the choke handle until the engine stops running. If the engine does not run, proceed to Test Procedure 14 – Ignition Spark on page 11-29. Page 11-28 2009 FE 350 Maintenance and Service Supplement...
Page 71 The gap should be set at 0.027 to 0.031 of an inch (0.69 to 0.79 mm). If the gap is correct, replace the spark plug with a new part and test the engine for proper operation. 2009 FE 350 Maintenance and Service Supplement Page 11-29...
Page 72 Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. 1. Brown Wire 2. Black Wire 3. Female Bullet Terminal 4. White/Black Kill Circuit Wire 5. Ignition Coil Black Wire Figure 11-28 RPM Limiter Page 11-30 2009 FE 350 Maintenance and Service Supplement...
Page 73 2.2. If the resistance is not between 0.6 - 1.7 ohms, bench test the ignition coil. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohm Setting Figure 11-29 Primary Coil Resistance – In Vehicle Test 2009 FE 350 Maintenance and Service Supplement Page 11-31...
Page 74 (Figure 11-31, Page 11-33). 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 11-32, Page 11-33). Page 11-32 2009 FE 350 Maintenance and Service Supplement...
Page 75 Proceed to the next step with the spark plug cap still removed. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 20k Ohm Setting 2. Spark Plug Cap Figure 11-33 Spark Plug Cap Test 2009 FE 350 Maintenance and Service Supplement Page 11-33...
Page 76 2.1. Place the black (–) probe of the meter on the terminal on the ignition coil (1), and place the red (+) probe on the core (2) (Figure 11-35, Page 11-35). Page 11-34 2009 FE 350 Maintenance and Service Supplement...
Page 77 3.1. Place the red (+) probe of the meter into the end of the spark plug cap (3) that normally connects to the spark plug and place the black (–) probe on the core (2) (Figure 11-36, Page 11-35). 2009 FE 350 Maintenance and Service Supplement Page 11-35...
Page 78 If the preceding tests indicate that the ignition coil resistance readings are within acceptable ranges, but the coil fails to function properly, replace the ignition coil and cap. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 11-36 2009 FE 350 Maintenance and Service Supplement...
Page 79 1. 200 Ohm Setting 2. Lever Up 1. 200 Ohm Setting 2. Lever Up Figure 11-39 Kill Limit Switch Test for Key-Start Vehicle Figure 11-38 Kill Limit Switch Test for Pedal-Start Vehicle 2009 FE 350 Maintenance and Service Supplement Page 11-37...
Page 80 There should be no continuity. If there is continuity, check for worn insulation on the white/black wire that may be allowing the engine kill wire to ground to the frame. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 11-38 2009 FE 350 Maintenance and Service Supplement...
Page 81 Then test the key switch. See Key Switch (Starter Circuit) on page 11-22. If the yellow wire and the key switch test okay, then replace the low oil warning light. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. 2009 FE 350 Maintenance and Service Supplement Page 11-39...
Page 82 Pedal-Start Vehicle: T1 – Black/Light Blue Stripe T2 – Black T3 – Black/Yellow Stripe Key-Start Vehicle: T1 – Gray T2 – Red T3 – Pink 1. Position 1 2. Position 2 Figure 11-41 Neutral Lockout Switch Test Page 11-40 2009 FE 350 Maintenance and Service Supplement...
Page 83 If all of the test results are good and the voltage reading is zero, there may be a broken or damaged 6-gauge white wire from the solenoid to the starter/generator. See Test Procedure 9 – Starter/Generator (Starter Function) on page 11-26. 2009 FE 350 Maintenance and Service Supplement Page 11-41...
Page 84 If the readings are correct according to the position of the float, but give an incorrect reading on the fuel gauge/hour meter, test the fuel gauge/hour meter. See Test Procedure 27 – Fuel Gauge on page 11-43. Page 11-42 2009 FE 350 Maintenance and Service Supplement...
Page 85 (+) probe on the (4) terminal of the fuel gauge/hour meter (Figure 11-45, Page 11-44). The voltage reading should be approximately 4.94 volts. If the reading is incorrect, replace the fuel gauge/hour meter. 2009 FE 350 Maintenance and Service Supplement Page 11-43...
Page 86 If the hour meter still does not function after the low oil warning light, oil pressure switch, and all of the appropriate wires have been checked for continuity, replace the fuel gauge/hour meter. Page 11-44 2009 FE 350 Maintenance and Service Supplement...
Page 87 Remove the tape and reconnect the wires to the relay. Install the electrical component box cover. Connect the 6-gauge white wire to the F2 post on the starter/generator. 10. Connect battery. See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. 2009 FE 350 Maintenance and Service Supplement Page 11-45...
Page 88 1. 20 VDC Setting 2. 20 Amp Fuse 3. Ground Terminal Block 4. Electrical Component Box 1409 1410 Figure 11-47 Starter/Generator and Neutral Lockout Figure 11-48 Battery Voltage Supply Test Circuits Relay Test Page 11-46 2009 FE 350 Maintenance and Service Supplement...
Page 89 If the there is no voltage reading, check continuity of the 10-gauge red wire from the fuse block to the solenoid. Check continuity of the 10-gauge black wire from the terminal block to the frame ground. 2009 FE 350 Maintenance and Service Supplement Page 11-47...
Page 90 See Headlight Switch Removal, Section 12, Page 12-35. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. Ground Terminal Block 1421 Figure 11-49 Light Switch Test Page 11-48 2009 FE 350 Maintenance and Service Supplement...
Page 91 1. 20 VDC Setting 2. Light Switch 3. Blue Wire 4. Yellow Wire 5. Voltage Limiter 6. Black Wires 7. Ground Terminal Block 8. Frame Ground 1420 Figure 11-50 Voltage Limiter Circuit Test 2009 FE 350 Maintenance and Service Supplement Page 11-49...
Page 92 (+) probe onto the positive battery terminal. If the multimeter reading is approximately 12 volts, the black wire has continuity. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-51 Check Voltage to Headlight Socket Page 11-50 2009 FE 350 Maintenance and Service Supplement...
Page 93 7.4. If the relay has failed closed, replace the relay. See Relay Removal, Section 12, Page 12-31. 1411 Figure 11-52 Brake Light Relay Test Bypass the brake light relay. 8.1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 10, Page 10-2. 2009 FE 350 Maintenance and Service Supplement Page 11-51...
Page 94 11. If the brake lights do not operate with the relay bypassed, there is most-likely a problem in the brake light circuit other than the brake light relay. Restore the wiring to the original configuration (not bypassed), and proceed to step 13 for additional test procedures. Page 11-52 2009 FE 350 Maintenance and Service Supplement...
Page 95 139 and 171 ohms. If the reading is incorrect, replace the relay. See Relay Removal, Section 12, Page 12-31. 13.3.Restore the wiring to the original configuration (not bypassed). 2009 FE 350 Maintenance and Service Supplement Page 11-53...
Page 96 – Check the continuity of the red wire from the fuse block to the large post of the solenoid. – Check the continuity of the accessory fuse (located in the fuse block). Page 11-54 2009 FE 350 Maintenance and Service Supplement...
Page 97 The reading should be approximately 12 volts. If the reading is incorrect, check bulb socket and wire continuity. WAVETEK 1000 2000 200k 200nA 1000 --- 750V FUSED 1419 Figure 11-56 Taillight Socket Voltage Test 2009 FE 350 Maintenance and Service Supplement Page 11-55...
Page 98 If wire continuity is correct and the switch continuity readings are still incorrect, replace the switch. See Brake Pedal Limit Switch Removal, Section 12, Page 12-40. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 11-56 2009 FE 350 Maintenance and Service Supplement...
Page 99 Press the horn button. The reading should be approximately 12 volts. If the readings are incorrect, check the continuity of the wires, the horn button, and fuse. If the readings are correct, replace the horn. 2009 FE 350 Maintenance and Service Supplement Page 11-57...
Page 100 The reading should show no continuity. With the horn button pressed, the reading should show continuity. If the readings are incorrect, replace the horn button. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 11-58 2009 FE 350 Maintenance and Service Supplement...
Page 101: Section 12 - Electrical Components
Support the starter/generator so that when the pivot bolts are removed the starter/generator will not fall to the ground. Remove the two pivot nuts (7) and bolts (5) from the mounting bracket. Remove the starter/generator. 2009 FE 350 Maintenance and Service Supplement Page 12-1...
Page 102: Disassembly Of The Starter/Generator To Service The Brushes
Service the Armature/Commutator on page 12-4. Figure 12-2 Commutator End Cover Figure 12-3 Brush Covers and Brushes BRUSH INSPECTION AND REPLACEMENT Visually inspect brushes. Replace brushes that are cracked or severely chipped. Page 12-2 2009 FE 350 Maintenance and Service Supplement...
Page 103: Brush Spring Inspection And Replacement
Connect the brush wires to the holders using four lock washers (26) and four screws (25), making sure the crossover leads are connected also. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12-3, Page 12-2). 2009 FE 350 Maintenance and Service Supplement Page 12-3...
Page 104: Disassembly Of The Starter/Generator To Service The Armature/Commutator
To separate armature (33) from output end cover (36), remove nut (41), lock washer (40), pulley (39), shaft key (34), spacer (37), and bearing retainer screws (43) (Figure 12-7, Page 12-5). Page 12-4 2009 FE 350 Maintenance and Service Supplement...
Page 105: Bearing Cleaning And Inspection
(CCI P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft. Support the armature so that it will not drop when the bearing is removed (Figure 12-9, Page 12-6). 2009 FE 350 Maintenance and Service Supplement Page 12-5...
Page 106: Field Coil Removal
• Flared armature windings • Worn, burned, or glazed commutator • Loose or raised commutator bars • Bruised or damaged armature core laminations • Worn armature bearing or shaft • Dirty or oily commutator Page 12-6 2009 FE 350 Maintenance and Service Supplement...
Page 107: Commutator Cleaning And Inspection
Using a micrometer, measure the outside diameter at two points along the commutator. If the commutator outside diameter is less than 1.535 inches (39 mm), replace the armature and bearings (Figure 12-11, Page 12-8). 2009 FE 350 Maintenance and Service Supplement Page 12-7...
Page 108: Armature Ground Test
The reading should be no continuity. If the reading is incorrect, replace the armature and the two bearings (Figure 12-12, Page 12-8). WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 12-12 Armature Ground Test Page 12-8 2009 FE 350 Maintenance and Service Supplement...
Page 109: Visual Inspection Of Field Coils
• To prevent damage to the retainer, use care while pressing new bearing onto the output end of the shaft. • Press against the inner race of the new bearing until it is fully seated. 2009 FE 350 Maintenance and Service Supplement Page 12-9...
Page 110: Starter/Generator Installation
A2 terminal on the starter/generator. Install a flat washer, lock washer and nut onto each terminal, and tighten the nut to 48 in-lb (5.4 N·m). Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 12-10 2009 FE 350 Maintenance and Service Supplement...
Page 111 ELECTRICAL COMPONENTS Starter/Generator Figure 12-13 Starter/Generator Installation Belt Tension Gauge 2. End View Figure 12-14 Belt Tension Gauge 2009 FE 350 Maintenance and Service Supplement Page 12-11...
Page 112: Belt Tension Adjustment
(5) and hex nuts (7) to 23 ft-lb (31.2 N·m) (Figure 12-13, Page 12-11). See following CAUTION. CAUTION • Remove pry bar before starting engine. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 12-12 2009 FE 350 Maintenance and Service Supplement...
Page 113: Voltage Regulator
– Pedal-Start vehicles: Connect the voltage regulator red wire (1) at the large post on the solenoid, the yellow wire (4) at the bullet connector, and the black wire (7) at the battery frame ground (Figure 12-15, Page 12-13). 2009 FE 350 Maintenance and Service Supplement Page 12-13...
Page 114: Key Switch
Do not allow wires to touch. See following NOTE. NOTE: Take care to prevent key switch terminals and wires from touching the metal frame around the dash. 2.6. Slide center dash panel up the steering column. Page 12-14 2009 FE 350 Maintenance and Service Supplement...
Page 115: Key Switch Installation
Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. 2009 FE 350 Maintenance and Service Supplement Page 12-15...
Page 116: Solenoid Removal
18-gauge blue wire from the voltage regulator, the 18-gauge orange wire from the (COIL) terminal on the relay, and the diode, directional end, to the other small post on the solenoid. Turf 6 vehicles: Page 12-16 2009 FE 350 Maintenance and Service Supplement...
Page 117 Install the snap-on electrical box cover by pressing down firmly on all corners and install the screw, tightening to 18 in-lb (2 N·m). Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. 2009 FE 350 Maintenance and Service Supplement Page 12-17...
Page 118: Fuse Removal
Install the snap-on electrical box cover by pressing down firmly on all corners and install the screw, tightening to 18 in-lb (2 N·m). Connect battery. See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 12-18 2009 FE 350 Maintenance and Service Supplement...
Page 119: Kill Limit Switch
Place the accelerator limit switch (11) on the mounting screws located in the electrical component box. Secure the switches using two washers (10) and two nuts (9). Tighten to 5 in-lb (0.6 N·m). See following CAUTION. 2009 FE 350 Maintenance and Service Supplement Page 12-19...
Page 120: Neutral Lockout Limit Switch
Use a wrench and a pair of needle-nosed pliers to remove the two nuts and washers and remove the limit switch (Figure 12-21, Page 12-20). Figure 12-20 Neutral Lockout (left), Reverse Buzzer Figure 12-21 Removal of Limit Switches (center) and Starter Solenoid (right) Limit Switches Page 12-20 2009 FE 350 Maintenance and Service Supplement...
Page 121: Neutral Lockout Limit Switch Installation
Disconnect the wires from the reverse warning buzzer (2). Do not allow wires to touch (Figure 12-22, Page 12-22). Remove the mounting screws (3) securing the buzzer to the center dash. 2009 FE 350 Maintenance and Service Supplement Page 12-21...
Page 122: Front Reverse Warning Buzzer Installation
Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. As seen from front driver side of vehicle with body removed. 1423 Figure 12-22 Front Reverse Warning Buzzer Figure 12-23 Rear Reverse Warning Buzzer Page 12-22 2009 FE 350 Maintenance and Service Supplement...
Page 123: Rear Reverse Warning Buzzer Removal
Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Install the bed or seat. See Section 5 – Body and Trim in the appropriate maintenance and service manual. 2009 FE 350 Maintenance and Service Supplement Page 12-23...
Page 124: Reverse Buzzer Limit Switch
– Turn the key switch to the ON position. Shift the Forward/Reverse handle to the REVERSE position. The buzzer should sound. Test drive the vehicle in both forward and reverse to check for proper operation. Page 12-24 2009 FE 350 Maintenance and Service Supplement...
Page 125: Low Oil Warning Light
Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Figure 12-24 Low Oil Warning Light Figure 12-25 Fuel Gauge/Hour Meter Installation 2009 FE 350 Maintenance and Service Supplement Page 12-25...
Page 126: Fuel Gauge/Hour Meter
Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. FUEL LEVEL SENDING UNIT See General Warning on page 10-1. Page 12-26 2009 FE 350 Maintenance and Service Supplement...
Page 127: Rpm Limiter
Disconnect the black wire (5) at the other bullet connector (6) near the RPM limiter. Remove the flange head bolts (7) from the RPM limiter band (8) and remove the RPM limiter and damper (9) (Figure 12-26, Page 12-27). Figure 12-26 RPM Limiter Assembly 2009 FE 350 Maintenance and Service Supplement Page 12-27...
Page 128: Rpm Limiter Installation
(4) from the housing (Figure 12-30, Page 12-30). Disconnect the 18-gauge black wire (12) from the spade terminal on the ignition coil (11) and remove the coil by removing two bolts (10) (Figure 12-29, Page 12-29). Page 12-28 2009 FE 350 Maintenance and Service Supplement...
Page 129: Ignition Coil Installation
Remove the rubber gasket (1) on the plug cap (2) by rolling back the gasket onto the spark plug wire (Figure 12-30, Page 12-30). Remove the cap (2) from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire. 2009 FE 350 Maintenance and Service Supplement Page 12-29...
Page 130 16. Install the fan shroud with four pan-head bolts (5). Tighten to 50 in-lb (5.7 N·m) (Figure 12-28, Page 12-29). 17. Secure the wire harness to the stiffener with a wire tie. Place the wire tie through the lower hole at the back of the stiffener (Figure 12-27, Page 12-29). Page 12-30 2009 FE 350 Maintenance and Service Supplement...
Page 131: Oil Level Sensor
Remove the mounting bolt (9), washer (10), lock washer (12), and nut (13) from the relay (38). Lift the relay and mounting bracket (11) out of the electrical component box (21). 2009 FE 350 Maintenance and Service Supplement Page 12-31...
Page 132: Relay Installation
Install snap-on electrical component box cover. Firmly press down all corners before installing screw to 18 in-lb (2 N·m). Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 12-32 2009 FE 350 Maintenance and Service Supplement...
Page 133: Headlights
From the front of vehicle, reach under cowl and insert wire harness/halogen bulb assembly (4 and 6), into the headlight lens (7). Turn the wire harness/halogen bulb assembly (4 and 6) counterclockwise one-quarter turn. Connect battery. See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. 2009 FE 350 Maintenance and Service Supplement Page 12-33...
Page 134: Voltage Limiter
Install the dash panel in reverse order of removal. See Key Switch Removal on page 12-14. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Figure 12-34 Voltage Limiter Figure 12-35 Light Switch Page 12-34 2009 FE 350 Maintenance and Service Supplement...
Page 135 TESTING THE TAILLIGHT BULB AND SOCKET See Test Procedure 36 – Voltage At Taillight Socket on page 11-55. TAILLIGHT BULB REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline Vehicles, Section 10, Page 10-2. 2009 FE 350 Maintenance and Service Supplement Page 12-35...
Page 136 Mount the taillight to the rear fender with two screws (Figure 12-37, Page 12-36). Connect battery. See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Ensure that taillights and brake lights are functioning correctly. Page 12-36 2009 FE 350 Maintenance and Service Supplement...
Page 137 Remove the brake light relay from the vehicle. A. COM Terminal B. COM Terminal 1427 1428 Figure 12-38 Brake Light Relay – Pedal-Start Vehicle Style Figure 12-39 Brake Light Relay – Pedal-Start Vehicle Style 2009 FE 350 Maintenance and Service Supplement Page 12-37...
Page 138 Install the center dash panel in the reverse order of removal. Be sure the key switch terminals cannot touch the frame and that the panel is properly seated and snapped in place. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 12-38 2009 FE 350 Maintenance and Service Supplement...
Page 139 Tighten the screws to 10 in-lb (1.1 N·m). Install pad to brake pedal, tightening the screws until the pad is secure. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. 2009 FE 350 Maintenance and Service Supplement Page 12-39...
Page 140 Secure the switch to the bracket with lock nuts (4) and hex-head machine screws (5) (Figure 12-44, Page 12-40). Tighten the mounting hardware to 10 in-lb (1.1 N·m). Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 12-40 2009 FE 350 Maintenance and Service Supplement...
Page 141 NOTE: Shoulder on nut fits into hole in mounting bracket. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. 1434 1435 Figure 12-45 Horn Assembly Figure 12-46 Horn Switch Assembly 2009 FE 350 Maintenance and Service Supplement Page 12-41...
Page 142 • Tools, wires, and metal objects can cause sparks when shorted across a battery. • Follow all instructions carefully when working with batteries. • Charge battery in a well-ventilated area only. DANGER CONTINUED ON NEXT PAGE Page 12-42 2009 FE 350 Maintenance and Service Supplement...
Page 143 1 gallon (3.8 L) of water). Rinse with water. Do not allow solution to enter battery through the vent cap holes. See Self-Discharge on page 12-44. Maintain proper water level. See Water Level on page 12-44. 2009 FE 350 Maintenance and Service Supplement Page 12-43...
Page 144 The acid that is lost reduces the capacity of the battery and cannot be replaced. Page 12-44 2009 FE 350 Maintenance and Service Supplement...
Page 145 Self-discharge, can form poisonous gas at negative Copper Increased self-discharge, lower oncharge voltage Nickel None Allowed Intense lowering of on-charge voltage Platinum None Allowed Violent self-discharge, lower on-charge voltage Selenium Positive shedding Zinc Slight self-discharge at negative 2009 FE 350 Maintenance and Service Supplement Page 12-45...
Page 146 Secure the battery to the vehicle with the clamp and install bolt, washer and locknut and tighten to 80 in-lb (9.3 N·m). A loose battery clamp may allow the battery to become damaged from vibration or jarring. Page 12-46 2009 FE 350 Maintenance and Service Supplement...
Page 147 WARNING. WARNING • Do not jump-start a dead battery using another battery and jumper cables. GROUND CABLES TESTING THE GROUND CABLES See Test Procedure 3 – Ground Cables on page 11-20. 2009 FE 350 Maintenance and Service Supplement Page 12-47...
Page 149 SECTION 13 — S10 FE 350 ENGINE DANGER • See General Warning on page 10-1. WARNING • See General Warning on page 10-1. GENERAL INFORMATION See General Warning on page 10-1. This gasoline vehicle is powered by a 4-cycle, overhead valve, single cylinder, air-cooled engine. The 4-cycle engine has an oil reservoir (crankcase) similar to automobiles, trucks, aircraft, heavy equipment, machinery and other applications designed for reliable heavy-duty service.
Page 150 Use a wire type gauge. Bend the outside or ground electrode so only a slight drag on the gauge is felt when passing it between the electrode. Never make an adjustment by bending the center electrode. Set gap (A) to 0.027-0.031 inches (0.69-0.79 mm) (Figure 13-1, Page 13-2). Page 13-2 2009 FE 350 Maintenance and Service Supplement...
Page 151 The air passes through a tube and vents to the intake manifold. See Engines and Transaxles Manual for inspection and repair. CRANKCASE See General Warning on page 10-1. 2009 FE 350 Maintenance and Service Supplement Page 13-3...
Page 152 NOTE: If the crankcase cover sticks, tap lightly with a plastic mallet on alternate sides near the dowel pins (5) (Figure 13-3, Page 13-4). Remove the crankcase cover gasket completely. It may stick to the flanged surface of the crankcase. Figure 13-2 Oil Level Sensor Wire Figure 13-3 Crankcase Cover Page 13-4 2009 FE 350 Maintenance and Service Supplement...
Page 153 If the oil level sensor was removed from the bracket, install sensor (6) into bracket (5) and secure with three screws (7) (Figure 13-5, Page 13-6). Tighten to 17 in-lb (1.9 N·m). 2009 FE 350 Maintenance and Service Supplement Page 13-5...
Page 154 130 in-lb (14 N·m). Then, repeating the sequence, tighten them to 250 in-lb (28.2 N·m) (Figure 13-6, Page 13-7). Connect the yellow jumper wire (11) to the cord connector (12) (Figure 13-2, Page 13-4). Page 13-6 2009 FE 350 Maintenance and Service Supplement...
Page 155 Hold the flywheel (4), not the fan (7), with a strap wrench (5) and, using a 25 mm socket, remove the flywheel nut (and flat washer) by turning it counterclockwise (Figure 13-9, Page 13-8). See following CAUTION. 2009 FE 350 Maintenance and Service Supplement Page 13-7...
Page 156 • Be careful not to damage the fan blades. Use a strap wrench to hold flywheel. Do not place screwdriver or pry bar between fan blades. Install the fan housing and tighten the screws to 90 in-lbs (10 N·m). Page 13-8 2009 FE 350 Maintenance and Service Supplement...
Page 157 Install oil drain plug in the crankcase and tighten to 20 ft-lb (27.1 N·m). Apply a light film of oil on the seal of a new oil filter and install the filter on the crankcase. Fill the crankcase to the proper level with the correct 2009 FE 350 Maintenance and Service Supplement Page 13-9...
Page 158 90 in-lb (10 N·m) Fan shroud screws 25 in-lb (2.8 N·m) 130 in-lb (15 N·m) Bolts marked with “4” (when used with nuts) 50 in-lb (5.9 N·m) 30 in-lb (3.4 N·m) Page 13-10 2009 FE 350 Maintenance and Service Supplement...
Page 159 0.027 to 0.031 in. (0.69 to 0.79 mm) Ignition coil air gap (standard) 0.012 in. (0.304 mm) Compression pressure (min.) 156 psi (1076 kPa) 3050 (±30) RPM for Key-Start Vehicles Engine RPM 2900 (±30) RPM for Pedal-Start Vehicles 2009 FE 350 Maintenance and Service Supplement Page 13-11...
Page 161 SECTION 14 — S27 FE 350 ENGINE DANGER • See General Warning on page 10-1. WARNING • See General Warning on page 10-1. GENERAL INFORMATION See General Warning on page 10-1. This vehicle is powered by a 4-cycle, overhead valve, single cylinder, air-cooled engine. The S27 engine is identified by labelling on the blower housing and has mechanical lifters as opposed to a hydraulically-lifted valve train.
Page 162 “gauling” and thread seizing for future replacements. Install the spark plug by threading it in until finger tight, then tighten the spark plug to 20 ft-lb (27 N·m). Page 14-2 2009 FE 350 Maintenance and Service Supplement...
Page 163 (0.127 mm) for both intake and exhaust (Figure 14-2, Page 14-4) While keeping the adjuster from turning with the screw holder (5) (CCI P/N 1016413), tighten the lock nut (3) to 90 in-lb (10 N·m). Recheck the clearance on both valves. 2009 FE 350 Maintenance and Service Supplement Page 14-3...
Page 164 Remove drive clutch. See Drive Clutch Removal on page 19-4 and preceding NOTE. Remove muffler. See Muffler Removal on page 17-1. Remove engine mounting hardware (items 1, 2, 5 and 6) (Figure 14-6, Page 14-6). Lift engine from the mounting plate. Page 14-4 2009 FE 350 Maintenance and Service Supplement...
Page 165 NOTE: If the crankcase cover sticks, tap lightly with a plastic mallet on alternate sides near the dowel pins (5) (Figure 14-5, Page 14-5). Remove the crankcase cover gasket completely. It may stick to the flanged surface of the crankcase. Figure 14-4 Oil Level Sensor Wire Figure 14-5 Crankcase Cover 2009 FE 350 Maintenance and Service Supplement Page 14-5...
Page 166 If the oil level sensor was removed from the bracket, install sensor (6) into bracket (5) and secure with three screws (7) (Figure 14-7, Page 14-7). Tighten to 17 in-lb (1.9 N·m). Page 14-6 2009 FE 350 Maintenance and Service Supplement...
Page 167 130 in-lb (14 N·m). Then, repeating the sequence, tighten them to 250 in-lb (28.2 N·m) (Figure 14-8, Page 14-8). Connect the yellow jumper wire (11) to the cord connector (12) (Figure 14-4, Page 14-5). 2009 FE 350 Maintenance and Service Supplement Page 14-7...
Page 168 Hold the flywheel (4), not the fan (7), with a strap wrench (5) and, using a 25 mm socket, remove the flywheel nut (and flat washer) by turning it counterclockwise (Figure 14-11, Page 14-9). See following CAUTION. Page 14-8 2009 FE 350 Maintenance and Service Supplement...
Page 169 • Be careful not to damage the fan blades. Use a strap wrench to hold flywheel. Do not place screwdriver or pry bar between fan blades. Install the fan housing and tighten the screws to 90 in-lbs (10 N·m). 2009 FE 350 Maintenance and Service Supplement Page 14-9...
Page 170 Install oil drain plug in the crankcase and tighten to 20 ft-lb (27.1 N·m). Apply a light film of oil on the seal of a new oil filter and install the filter on the crankcase. Fill the crankcase to the proper level with the correct Page 14-10 2009 FE 350 Maintenance and Service Supplement...
Page 171 90 in-lb (10 N·m) Fan shroud screws 25 in-lb (2.8 N·m) 130 in-lb (15 N·m) Bolts marked with “4” (when used with nuts) 50 in-lb (5.9 N·m) 30 in-lb (3.4 N·m) 2009 FE 350 Maintenance and Service Supplement Page 14-11...
Page 172 0.027 to 0.031 in. (0.69 to 0.79 mm) Ignition coil air gap (standard) 0.012 in. (0.304 mm) Compression pressure (min.) 128 psi (883 kPa) 3050 (±30) RPM for Key-Start Vehicles Engine RPM 2900 (±30) RPM for Pedal-Start Vehicles Page 14-12 2009 FE 350 Maintenance and Service Supplement...
Page 173 For elevations above 3000 feet, main jets other than standard operate more effectively. The following chart lists the elevation ratings for various jet sizes. No adjustment is required for the pilot jet. If the vehicle idles roughly, turn the pilot air screw out until the vehicle idles smoothly. 2009 FE 350 Maintenance and Service Supplement Page 15-1...
Page 174 Carburetor S10 FE350 FUEL SYSTEM Figure 15-1 Carburetor Mounting Page 15-2 2009 FE 350 Maintenance and Service Supplement...
Page 175 Mark the body of the carburetor and the carburetor fuel bowl with an indelible ink marker so that, after removal, the bowl can be installed again in the same position (Figure 15-3, Page 15-4). 2009 FE 350 Maintenance and Service Supplement Page 15-3...
Page 176 NOTE: Make sure the fuel nozzle (7) does not fall out of the carburetor body after removal of the main jet. This is best accomplished by positioning the carburetor upside down during main jet removal (Figure 15-4, Page 15-4). Figure 15-4 Carburetor Components Page 15-4 2009 FE 350 Maintenance and Service Supplement...
Page 177 13.3.Install the carburetor retaining nuts (19) and tighten them to 50 in-lb (5.7 N·m). 14. Connect fuel supply line (26) and tighten screw clamp to 9 in-lb (1.0 N·m) (Figure 15-1, Page 15-2). 2009 FE 350 Maintenance and Service Supplement Page 15-5...
Page 178 Place jack stands under the round frame cross tube to support the vehicle. See preceding DANGER. See also WARNING “Lift only one end of the vehicle...” in General Warning on page 10-1. Page 15-6 2009 FE 350 Maintenance and Service Supplement...
Page 179 • Inspect the limit switch inside the electrical box. If the limit switch lever is bent, replace the switch. NOTE: Use the inside hole location, or hole closest to the bell crank shaft as shown (Figure 15-8, Page 15-8). 2009 FE 350 Maintenance and Service Supplement Page 15-7...
Page 180 Disconnect the governor cable (2) from the governor lever arm (15) (Figure 15-9, Page 15-9). Remove the governor cable (2) from the governor cable engine bracket (11), and governor cable support bracket (10) (Figure 15-9, Page 15-9). Remove the cable (2) from the vehicle. Page 15-8 2009 FE 350 Maintenance and Service Supplement...
Page 181 While holding the arm and shaft in the fully counterclockwise position, tighten the governor arm lever nut to 36 in-lb (4.0 N·m). Check engine RPM adjustment. See Engine RPM Adjustment on page 15-11. Figure 15-9 Governor and Accelerator Cables 2009 FE 350 Maintenance and Service Supplement Page 15-9...
Page 182 Key-Start vehicles: When the engine running and the Forward/Reverse control in NEUTRAL, attach a tachometer (CCI P/N 1016112) to the spark plug wire and adjust the idle screw on the carburetor until the tachometer reads 1200 to 1250 RPM (Figure 15-10, Page 15-11). Page 15-10 2009 FE 350 Maintenance and Service Supplement...
Page 183 – Carryall 2 Plus (with portable refreshment center): 3050 ±30 RPM – Carryall 6: 3050 ±30 RPM – Villager 6 and 8: 3050 ±30 RPM – TransPorter vehicles: 3050 ±30 RPM 2009 FE 350 Maintenance and Service Supplement Page 15-11...
Page 184 Insert choke cable through hole in body until choke lever assembly seats against body. Install three screws (19), washers (20), and lock nuts (21) as shown and tighten to 18 in-lb (2.0 N·m) (Figure 15-12, Page 15-16 or Figure 15-13, Page 15-17). Page 15-12 2009 FE 350 Maintenance and Service Supplement...
Page 185 Remove the front body. See Body and Trim section in the appropriate Maintenance and Service Manual. Remove the front left wheel. See Wheels and Tires section in the appropriate Maintenance and Service Manual. Remove the steering joint assembly (Figure 15-11, Page 15-14). 2009 FE 350 Maintenance and Service Supplement Page 15-13...
Page 186 3.1. Remove any old double-sided tape that may still be adhered to the air duct shield or frame. 3.2. Place a new strip of double-sided tape on the air duct shield. Do not remove backing from exposed side of tape. Page 15-14 2009 FE 350 Maintenance and Service Supplement...
Page 187 Install the bolt and lock washer on the upper universal joint and tighten to 15 ft-lb (20 N·m). Install front left wheel. Tighten the wheel rim mounting nuts to 55 ft-lb (75 N·m). Install front body. Check for proper operation. 2009 FE 350 Maintenance and Service Supplement Page 15-15...
Page 188 Choke and Air Intake System S10 FE350 FUEL SYSTEM Figure 15-12 Air Intake and Choke Assemblies – Turf 2, Carryall 2 and Carryall 2 Plus Page 15-16 2009 FE 350 Maintenance and Service Supplement...
Page 189 Figure 15-13 Air Intake and Choke Assemblies – Turf 6, Carryall 6, TransPorter, and Villager Turf 6, Carryall 6, TransPorter and Villager Remove front seat and insert air duct through the hole in the floorboard under the seat. 2009 FE 350 Maintenance and Service Supplement Page 15-17...
Page 190 • 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 191 MAINTENANCE position. See following DANGER. Start the engine and check for fuel leaks. See following DANGER. DANGER • Repair all fuel leaks before operating the vehicle. Place the neutral lockout switch in the OPERATE position. 2009 FE 350 Maintenance and Service Supplement Page 15-19...
Page 192 17.0 in. (43.2 cm) Vent tube (Carburetor) 22.0 in. (55.9 cm) Vent tube (Fuel Tank) 17.0 in. (43.2 cm) Impulse line 17.0 in. (43.2 cm) Total: 46.0 in. (116.8 cm) 39.0 in. (99.1 cm) Page 15-20 2009 FE 350 Maintenance and Service Supplement...
Page 193 17.0 in. (43.2 cm) Impulse line 14.0 in. (35.6 cm) 17.0 in. (43.2 cm) Total: 51.0 in. (129.4 cm) 39.0 in. (99.1 cm) 48.0 in. (122 cm) 39.0 in. (99.1 cm) 2009 FE 350 Maintenance and Service Supplement Page 15-21...
Page 194 NOTE: A fuel pump rebuild kit is available from your distributor/dealer (CCI P/N 1014524). This kit includes all gaskets, diaphragms, and valves. Match mark the fuel pump and cover before disassembly. Page 15-22 2009 FE 350 Maintenance and Service Supplement...
Page 195 FUEL PUMP ASSEMBLY Install the fuel gasket (35) and diaphragm (34) on the back cover (36) (Figure 15-16, Page 15-23). Install the valve assembly in the pumping chamber (30). See following CAUTION. 2009 FE 350 Maintenance and Service Supplement Page 15-23...
Page 196 Start the engine and check for fuel leaks. If the fuel pump leaks, a rebuild kit must be installed to replace all gaskets and diaphragms. See following DANGER. DANGER • Repair all fuel leaks before operating the vehicle. 10. Place the neutral lockout switch in the OPERATE position. Page 15-24 2009 FE 350 Maintenance and Service Supplement...
Page 197 Service only in a well-ventilated area. WARNING • Do not attempt to siphon fuel using a hose that does not have a built-in suction device. • Do not attempt to siphon fuel using your mouth. 2009 FE 350 Maintenance and Service Supplement Page 15-25...
Page 198 • Dispose of wastewater and fuel tank in accordance with local, state, and federal laws and ordinances. FUEL TANK STORAGE Remove the cap from the tank and thoroughly rinse it with water. Page 15-26 2009 FE 350 Maintenance and Service Supplement...
Page 199 15.1.Check all of the fuel line clamps at the carburetor, fuel filters, fuel pump, and fuel tank for leaks. 15.2.Inspect each fuel line to ensure that the lines are not cracked, cut, or worn. 2009 FE 350 Maintenance and Service Supplement Page 15-27...
Page 200 Fuel line no. 3 runs directly from the fuel outlet of the fuel pump to the carburetor. Small spring steel band clamps are used on all hose connections except at the carburetor. A screw band clamp (21) should be used at the carburetor. Page 15-28 2009 FE 350 Maintenance and Service Supplement...
Page 201 Figure 15-21 Fuel Shut-off Valve – 49-State Fuel Tank Figure 15-22 Fuel Shut-off Valve – California Fuel Tank 2009 FE 350 Maintenance and Service Supplement Page 15-29...
Page 203 SECTION 16 — S27 FE 350 FUEL SYSTEM DANGER • See General Warning on page 10-1. WARNING • See General Warning on page 10-1. GENERAL INFORMATION The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The carburetor atomizes the fuel, mixes it with air, and feeds the combustible mixture into the cylinder.
Page 204 Figure 16-1 Carburetor Mounting MAIN JET ELEVATION/SIZE CHART ALTITUDE FE350 ENGINE MAIN JET SIZE 0-3200 ft. (0-975 m) 3200-6500 ft. (975-1981 m) 6500-9800 ft. (1981-2987 m) 9800 ft. and above (2987 m and above) Page 16-2 2009 FE 350 Maintenance and Service Supplement...
Page 205 (Figure 16-4, Page 16-4). See following NOTE. NOTE: Make sure the fuel bowl gasket (9) remains properly seated in the carburetor body when the fuel bowl is removed. 2009 FE 350 Maintenance and Service Supplement Page 16-3...
Page 206 Examine the float valve/spring assembly to make sure the spring is installed correctly (Figure 16-5, Page 16-5). 10. Install the fuel bowl. Make sure that it is positioned properly by aligning the marks applied in step 4. See following CAUTION. Page 16-4 2009 FE 350 Maintenance and Service Supplement...
Page 207 18. Turn fuel shut-off valve on top of fuel tank to the ON position (Figure 16-21, Page 16-29 or Figure 16-22, Page 16-29). 19. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. 20. Test drive the vehicle. 2009 FE 350 Maintenance and Service Supplement Page 16-5...
Page 208 Remove the accelerator rod by disconnecting the ball joint (1) from the ball stud (2) on the accelerator pedal (Figure 16-6, Page 16-7) and from the bell crank at the electrical box (Figure 16-8, Page 16-8). Page 16-6 2009 FE 350 Maintenance and Service Supplement...
Page 209 • Inspect the limit switch inside the electrical box. If the limit switch lever is bent, replace the switch. NOTE: Use the inside hole location, or hole closest to the bell crank shaft as shown (Figure 16-8, Page 16-8). 2009 FE 350 Maintenance and Service Supplement Page 16-7...
Page 210 (10). Remove the cable (2) from the vehicle. Governor Cable Installation and Adjustment Install the cable onto the governor cable support bracket (10) and the engine bracket (11) (Figure 16-9, Page 16-9). Page 16-8 2009 FE 350 Maintenance and Service Supplement...
Page 211 While holding the arm and shaft in the fully counterclockwise position, tighten the governor arm lever nut to 36 in-lb (4.0 N·m). Check engine RPM adjustment. See Engine RPM Adjustment on page 16-11. Figure 16-9 Governor and Accelerator Cables ACCELERATOR CABLE Accelerator Cable Removal Access the engine compartment. 2009 FE 350 Maintenance and Service Supplement Page 16-9...
Page 212 (CCI P/N 1016112) to the spark plug wire and adjust the idle screw on the carburetor until the tachometer reads 1200 to 1250 RPM (Figure 16-10, Page 16-10). Figure 16-10 Idle Screw Page 16-10 2009 FE 350 Maintenance and Service Supplement...
Page 213 If more adjustment is required than the cable housing will allow, make sure the spring on the other end of the accelerator cable is properly positioned. Excessive belt and torque converter wear can also prevent proper RPM adjustment. Check them for excessive wear. See Section 19 — Torque Converter . 2009 FE 350 Maintenance and Service Supplement Page 16-11...
Page 214 Attach choke cable to choke lever (6) on air box. Install screw (17) to secure cable to air box and tighten to 18 in-lb (2.0 N·m) (Figure 16-11, Page 16-13 and Figure 16-12, Page 16-14). Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 16-12 2009 FE 350 Maintenance and Service Supplement...
Page 215 S27 FE 350 FUEL SYSTEM Choke and Air Intake System Figure 16-11 Air Intake and Choke Assemblies – Turf 2, Carryall 2 and Carryall 2 Plus 2009 FE 350 Maintenance and Service Supplement Page 16-13...
Page 216 Choke and Air Intake System S27 FE 350 FUEL SYSTEM 1394 Figure 16-12 Air Intake and Choke Assemblies – Turf 6, Carryall 6, TransPorter, and Villager Page 16-14 2009 FE 350 Maintenance and Service Supplement...
Page 217 Remove the front left wheel. See Wheels and Tires Section in the appropriate maintenance and service manual. Remove the steering joint assembly (Figure 16-13, Page 16-15). TYPICAL 3 PLACES Figure 16-13 Compound Steering Joint 2009 FE 350 Maintenance and Service Supplement Page 16-15...
Page 218 Install front body. See Body and Trim Section in the appropriate maintenance and service manual. Check for proper operation. Turf 6, Carryall 6, TransPorter and Villager Remove front seat and insert air duct through the hole in the floorboard under the seat. Page 16-16 2009 FE 350 Maintenance and Service Supplement...
Page 219 • 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 220 MAINTENANCE position. Start the engine and check for fuel leaks. See following DANGER. DANGER • Repair all fuel leaks before operating the vehicle. Place the neutral lockout switch in the OPERATE position. Page 16-18 2009 FE 350 Maintenance and Service Supplement...
Page 221 17.0 in. (43.2 cm) Vent tube (Carburetor) 22.0 in. (55.9 cm) Vent tube (Fuel Tank) 17.0 in. (43.2 cm) Impulse line 17.0 in. (43.2 cm) Total: 46.0 in. (116.8 cm) 39.0 in. (99.1 cm) 2009 FE 350 Maintenance and Service Supplement Page 16-19...
Page 222 Fuel Filters S27 FE 350 FUEL SYSTEM 1310 Figure 16-15 Fuel and Vent Lines – Side Fill Tank Page 16-20 2009 FE 350 Maintenance and Service Supplement...
Page 223 Remove hardware attaching the fuel pump (24) and lift the fuel pump out of the engine compartment (Figure 16-14, Page 16-19 and Figure 16-15, Page 16-20). Remove the clamp (20) and impulse line (7) from fuel pump. 2009 FE 350 Maintenance and Service Supplement Page 16-21...
Page 224 If leaking occurs, all new gaskets and diaphragms must be installed. NOTE: A fuel pump rebuild kit is available from Club Car (CCI P/N 1014524). This kit includes all gaskets, diaphragms, and valves.
Page 225 NOTE: Be sure to connect the fuel line (2), that comes from the fuel filter (17), to the inlet nipple on the pump. Direction of fuel flow is indicated by the arrows on the fuel pump (Figure 16-14, Page 16-19 and Figure 16-15, Page 16-20). See also (Figure 16-17, Page 16-23). 2009 FE 350 Maintenance and Service Supplement Page 16-23...
Page 226 Start the engine and check for fuel leaks. If the fuel pump leaks, a rebuild kit must be installed to replace all gaskets and diaphragms. See following DANGER. DANGER • Repair all fuel leaks before operating the vehicle. 10. Place the neutral lockout switch in the OPERATE position. Page 16-24 2009 FE 350 Maintenance and Service Supplement...
Page 227 Service only in a well-ventilated area. WARNING • Do not attempt to siphon fuel using a hose that does not have a built-in suction device. • Do not attempt to siphon fuel using your mouth. 2009 FE 350 Maintenance and Service Supplement Page 16-25...
Page 228 In a well-ventilated area, set the tank upside down so that the water can drain out of it. To make sure that the tank dries completely, allow the tank to sit for 24 hours. Page 16-26 2009 FE 350 Maintenance and Service Supplement...
Page 229 15.1.Check all of the fuel line clamps at the carburetor, fuel filters, fuel pump, and fuel tank for leaks. 15.2.Inspect each fuel line to ensure that the lines are not cracked, cut, or worn. 2009 FE 350 Maintenance and Service Supplement Page 16-27...
Page 230 Fuel line no. 3 runs directly from the fuel outlet of the fuel pump to the carburetor. Small spring steel band clamps are used on all hose connections except at the carburetor. A screw band clamp (21) should be used at the carburetor. Page 16-28 2009 FE 350 Maintenance and Service Supplement...
Page 231 Figure 16-21 Fuel Shut-off Valve – 49-State Fuel Tank Figure 16-22 Fuel Shut-off Valve – California Fuel Tank 2009 FE 350 Maintenance and Service Supplement Page 16-29...
Page 233 Key-Start Vehicles: Place the Forward/Reverse handle in the NEUTRAL position and chock the wheels. 10. Pedal-Start Vehicles: Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout switch in the MAINTENANCE position. 2009 FE 350 Maintenance and Service Supplement Page 17-1...
Page 234 11. Start the engine and check for exhaust leaks and proper engine operation. See following 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. Figure 17-1 Exhaust System Page 17-2 2009 FE 350 Maintenance and Service Supplement...
Page 235 FORWARD, REVERSE, or NEUTRAL for certain maintenance and/or repair functions. However, if the Forward/Reverse handle is in either the FORWARD or REVERSE position and the accelerator pedal is pressed, the engine will stop running. See following WARNING and NOTE. 2009 FE 350 Maintenance and Service Supplement Page 18-1...
Page 236 Under normal operating conditions, adjustment to the system should not be required. C l u b C a r Figure 18-2 Shifter Positions (Top View) Figure 18-3 Lubricant Level (should be level with bottom of hole) and Drain Plug Page 18-2 2009 FE 350 Maintenance and Service Supplement...
Page 237 Use 90° internal snap ring pliers (0.090-in. tip) to remove internal retaining ring (1) from axle tube (Figure 18-4, Page 18-4). Carefully pull the axle shaft (2) straight out of the axle tube (Figure 18-4, Page 18-4). 2009 FE 350 Maintenance and Service Supplement Page 18-3...
Page 238 Use external retaining ring pliers (0.047-inch tip) to remove the retaining ring (74). Place a bearing puller wedge attachment (CCI P/N 1012812) on the axle shaft between the wheel mounting flange and the bearing (Figure 18-7, Page 18-5). See also Figure 18-8, Page 18-7.See following CAUTION. Page 18-4 2009 FE 350 Maintenance and Service Supplement...
Page 239 Figure 18-7 Differential Gear Case and Axle Tubes Axle Bearing Installation Ensure that the retaining ring (70) is loosely placed on the axle shaft. See preceding NOTE. 2009 FE 350 Maintenance and Service Supplement Page 18-5...
Page 240 Install the bearing retaining ring (70) in the axle tube (Figure 18-7, Page 18-5). See also Figure 18-4, Page 18-4. Place a 1/4 to 3/8-inch (6-10 mm) diameter rod against the retaining ring and tap lightly at four to five locations to ensure it is properly seated. See following WARNING. Page 18-6 2009 FE 350 Maintenance and Service Supplement...
Page 241 Figure 18-8 Press Bearing and Collar From Shaft Using Figure 18-9 Axle Seal and Seal Tool Bearing Puller Wedge Attachment 2009 FE 350 Maintenance and Service Supplement Page 18-7...
Page 242 4.4. Loosen the hose clamp and then disconnect the fuel line from the carburetor. To prevent spilling fuel, the disconnected end of the line can be plugged with a 1/4-inch bolt (Figure 18-13, Page 18-8). Figure 18-12 Impulse Line Figure 18-13 Fuel Line Page 18-8 2009 FE 350 Maintenance and Service Supplement...
Page 243 4.11. Cut away the wire ties securing the engine kill 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. 2009 FE 350 Maintenance and Service Supplement Page 18-9...
Page 244 If equipped with a stabilizer bar, remove the two bolts securing the stabilizer bar to the stabilizer bar links. See Rear Suspension Section. Position a floor jack under the vehicle frame crossmember or trailer hitch mount (Figure 18-22, Page 18-11). Page 18-10 2009 FE 350 Maintenance and Service Supplement...
Page 245 (Figure 18-23, Page 18-11). 10. Remove the bolts securing the leaf springs to their front mounts (Figure 18-24, Page 18-11). Figure 18-23 Rear Shackles Figure 18-24 Spring Retainer Bolts 2009 FE 350 Maintenance and Service Supplement Page 18-11...
Page 246 16. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor (Figure 18-29, Page 18-13). See following NOTE. NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from the engine. Page 18-12 2009 FE 350 Maintenance and Service Supplement...
Page 247 Figure 18-32 Governor Arm 20. Remove screws (1) securing the governor cable bracket to transaxle (Figure 18-33, Page 18-14). 21. Remove screws (1) securing the accelerator cable bracket to transaxle (Figure 18-34, Page 18-14). 2009 FE 350 Maintenance and Service Supplement Page 18-13...
Page 248 22.1.Remove four transaxle mounting bolts (one at each corner of the transaxle mounting plate) (Figure 18-35, Page 18-14). 22.2.Remove two middle transaxle mounting nuts from the engine block studs. 23. Remove leaf springs, stabilizer bar, wheels and brake assemblies from the transaxle. Figure 18-35 Transaxle Mounting Page 18-14 2009 FE 350 Maintenance and Service Supplement...
Page 249 13. Remove the blocks from under the engine and roll the powertrain into position under the vehicle. Then lift the front of the powertrain and place the snubber into the snubber bracket in the vehicle frame (Figure 18-39, Page 18-16). 2009 FE 350 Maintenance and Service Supplement Page 18-15...
Page 250 18. Connect brake cables. See Brakes section in the appropriate Maintenance and Service Manual. 19. Connect the engine kill switch wire (18-gauge white/black) to the bullet connector at the lower right front of the engine (Figure 18-43, Page 18-17). Page 18-16 2009 FE 350 Maintenance and Service Supplement...
Page 251 (29.8 N·m). Connect shifter cable rod end to the shifter arm (Figure 18-46, Page 18-18). 24. Attach the ground wire to the mounting screw on the oil filler tube mounting bracket and tighten to 50 in-lb (5.7 N·m) (Figure 18-47, Page 18-18). 2009 FE 350 Maintenance and Service Supplement Page 18-17...
Page 252 27. Connect the impulse line to the fuel pump and secure it with the hose clamp (Figure 18-50, Page 18-19). 28. Connect air intake hose to carburetor and secure hose clamp (Figure 18-51, Page 18-19). Page 18-18 2009 FE 350 Maintenance and Service Supplement...
Page 253 Failure to properly route and secure wiring could result in vehicle malfunction, property damage or personal injury. 33. Adjust the engine RPM setting. See Engine RPM Adjustment on page 15-11. 2009 FE 350 Maintenance and Service Supplement Page 18-19...
Page 254 Install the cable end socket (1) on the Forward/Reverse shifter assembly stud (2) (Figure 18-53, Page 18-21). If originally equipped, secure cable jacket to frame rail with wire tie(s). Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. Page 18-20 2009 FE 350 Maintenance and Service Supplement...
Page 255 UNITIZED TRANSAXLE Forward/Reverse Shifter Cable Figure 18-53 Forward/Reverse Shifter Cable 2009 FE 350 Maintenance and Service Supplement Page 18-21...
Page 256 Forward/Reverse handle (9) (Figure 18-53, Page 18-21) in the NEUTRAL position, the shifter arm of the transaxle will also be in the NEUTRAL position (Figure 18-54, Page 18-22). Tighten nuts at the transaxle to 22 ft-lb (29.8 N·m). Page 18-22 2009 FE 350 Maintenance and Service Supplement...
Page 257 RPM before the drive belt reaches the top of the driven clutch, there is a torque converter problem. If the torque converter is not operating properly, perform the following steps: 2009 FE 350 Maintenance and Service Supplement Page 19-1...
Page 258 1. Drive Clutch Hub Puller 2. Driven Clutch Cam Puller 3. Driven Clutch Cam Press Tool 4. Drive Clutch Holder Tool 5. Driven Clutch Puller Plug 6. Cam Installation Tool 7. Drive Clutch Puller Figure 19-1 Torque Converter Tool Kit Page 19-2 2009 FE 350 Maintenance and Service Supplement...
Page 259 With the belt started onto the driven clutch, rotate the driven clutch counterclockwise and roll the belt over the driven clutch sheaves and onto the clutch. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 10, Page 10-3. 2009 FE 350 Maintenance and Service Supplement Page 19-3...
Page 260 This will allow the weight of the centerline of the drive clutch to drop below the frame I-beam for access to the bolt securing the drive clutch. See following WARNING. Page 19-4 2009 FE 350 Maintenance and Service Supplement...
Page 261 Inspect the belt contact surfaces of the clutch sheaves for wear. If any area of a sheave contact surface has wear of 0.060 inch (1.52 mm) or more, the clutch should be replaced. 2009 FE 350 Maintenance and Service Supplement Page 19-5...
Page 262 Drive Clutch TORQUE CONVERTER Figure 19-5 Drive Clutch Assembly Page 19-6 2009 FE 350 Maintenance and Service Supplement...
Page 263 Remove the thrust washer (11) from the moveable face (14) (Figure 19-5, Page 19-6). Remove the drive buttons (3) by removing the screws (1), flat washers (2), and drive button take-up springs (4) as shown(Figure 19-8, Page 19-8). 2009 FE 350 Maintenance and Service Supplement Page 19-7...
Page 264 (3) (Figure 19-10, Page 19-8). 5.3. Remove the plastic washers, weights (2 and 3) and wave washer (1) from the pin (4). Retain all parts. Figure 19-10 Primary and Secondary Weights, Wave Washer and Pin Page 19-8 2009 FE 350 Maintenance and Service Supplement...
Page 265 Inspect the pins on the primary weights (2). There should be no measurable wear. Replace them if they are worn, scratched, or damaged. Inspect the drive belt pulley sheaves for excessive wear or damage. If the sheaves are excessively worn or damaged, replace the entire fixed face drive assembly. 2009 FE 350 Maintenance and Service Supplement Page 19-9...
Page 266 13.1. Install each spring on right-hand side of the three button mounting posts (when looking into the interior of the clutch drive hub, and with the rib at a twelve o’clock position) as shown (Figure 19-14, Page 19-11). Page 19-10 2009 FE 350 Maintenance and Service Supplement...
Page 267 12, Page 12-12. Tighten the starter/generator mounting hardware to 23 ft-lb (31.2 N·m) and the adjusting hardware to 13 ft-lb (17.6 N·m). Install the drive belt as instructed. See Drive Belt Installation on page 19-3. Drive the vehicle and check for proper operation. 2009 FE 350 Maintenance and Service Supplement Page 19-11...
Page 268 (1) (CCI P/N 1014508) to remove the cam (3) from the fixed face shaft (Figure 19-17, Page 19-14). Remove the spring (5) (Figure 19-17, Page 19-14). Retain the key (3). Slide the moveable face (7) off the fixed face shaft (8). Page 19-12 2009 FE 350 Maintenance and Service Supplement...
Page 269 Slide the moveable face assembly (7) onto the fixed face shaft (8). Place the end of the spring (5) into the hole in the moveable face assembly. Install the key (3) into the keyway of the fixed face assembly (8) shaft. 2009 FE 350 Maintenance and Service Supplement Page 19-13...
Page 270 Rotate the cam until the keyway is aligned with the key (3) on the fixed face assembly, and then start the cam onto the shaft approximately 1/4 to 3/8 inch (6.3 to 9.5 mm). 5.1. Press Assembly Process: Page 19-14 2009 FE 350 Maintenance and Service Supplement...
Page 271 (Figure 19-18, Page 19-15). 5.2.5. Place the cam press hub (6) onto the cam installation bolt and thread it down onto the cam hub, centering the press hub onto the cam hub. 2009 FE 350 Maintenance and Service Supplement Page 19-15...
Page 272 Tighten the bolt (11) to 18 ft-lb (24.4 N·m). Install the drive belt as instructed. See Drive Belt Installation on page 19-3. Drive the vehicle and check for proper operation. Page 19-16 2009 FE 350 Maintenance and Service Supplement...
Page 273 16-3 elevation/size chart ........15-3, 16-2 choke flywheel choke and air intake system ....15-12, 16-12 removal ............13-7, 14-8 choke button forward/reverse installation ..........15-12, 16-12 cable removal ..........15-12, 16-12 2009 FE 350 Maintenance and Service Supplement Page i-1...
Page 274 ............12-33 testing .............11-48 headlight switch low oil warning light installation ............12-35 installation ............12-25 removal ............12-35 removal ............12-25 headlights testing .............11-39 see also lighting circuit........11-50 Page i-2 2009 FE 350 Maintenance and Service Supplement...
Page 275 11-6 battery voltage supply........11-47 service tools brake light relay..........11-51 torque converter kit..........19-1 brake pedal limit switch........11-56 unitized transaxle ..........18-3 fuel level sending unit ........11-42 2009 FE 350 Maintenance and Service Supplement Page i-3...
Page 276 11-26–11-27 taillight bulb socket ...........11-56 taillight socket voltage at .............11-55 voltage limiter...........11-49 voltage regulator ..........11-27 wire continuity ..........11-27 testing armature ground test (starter/genera- tor) ..............12-8 spark plug..........13-2, 14-2 Page i-4 2009 FE 350 Maintenance and Service Supplement...
Page 278 Fair Poor 1. Ease of Understanding 2. Ease of Finding Information 3. Clarity of Illustrations Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2009 FE 350 Maintenance and Service Supplement...

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