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Club Car TURF 272 2003 Maintenance Service Manual

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2003-2004

MAINTENANCE

SERVICE

MANUAL

TURF 272, CARRYALL 272,

AND CARRYALL 472

GASOLINE VEHICLES

MANUAL NUMBER 102318811

EDITION CODE 1003A00000

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Page 1 2003-2004 MAINTENANCE SERVICE MANUAL TURF 272, CARRYALL 272, AND CARRYALL 472 GASOLINE VEHICLES MANUAL NUMBER 102318811 EDITION CODE 1003A00000...
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 Identification ......................... Serial Number Identification ......................Storage ............................. Preparing The Vehicle For Extended Storage ................To Return Vehicle To Service .......................
Page 6 Rear Seat Support ........................... Rear Seat Support Removal ......................Rear Seat Support Installation ..................... Cargo Bed ............................Cargo Bed Removal ........................Cargo Bed Installation ........................4-11 Bed Stop Bumper Adjustment ...................... 4-12 Rear Fender ............................. 4-12 Rear Fender Removal ........................4-12 Rear Fender Installation .......................
Page 7 Brake Shoe Removal ........................Front Brake Shoe Removal ......................Rear Brake Shoe Removal ......................Brake Cluster Inspection and Cleaning .................... 6-10 Brake Shoe Installation ........................6-11 Front Brake Shoe Installation ....................... 6-12 Rear Brake Shoe Installation ......................6-12 Brake Drum Installation ........................6-14 Front Wheel Brake Drum Installation ....................
Page 8 Bleeding the Hydraulic Brake System ....................6-31 Purging the Hydraulic System ...................... 6-32 Filling the Hydraulic System ......................6-32 Park Brake System .......................... 6-33 Park Brake Cable Removal ......................6-33 Park Brake Cable Installation ....................... 6-34 Park Brake Handle Removal ......................6-35 Park Brake Handle Installation .....................
Page 9 SECTION 8 – WHEELS AND TIRES General Information .......................... SECTION 9 – REAR SUSPENSION Shock Absorbers ..........................Shock Absorber Removal and Inspection ..................Shock Absorber Installation ......................Multi-Leaf Springs ..........................Multi-Leaf Spring Removal ......................Multi-Leaf Spring Installation ......................Snubber ............................Snubber Removal .........................
Page 10 Electrical Circuits ..........................11a-8 Starter Circuit ..........................11a-8 Generator Circuit .......................... 11a-8 Engine Ignition Circuit ........................11a-9 Engine Kill Circuit ......................... 11a-9 Reverse Buzzer Circuit ........................ 11a-10 Low Oil Warning Circuit ........................ 11a-10 Lockout Cam Circuit ........................11a-11 Fuel Gauge and Sending Unit Circuit ................... 11a-12 Hour Meter Circuit ........................
Page 11 Fuse ..............................12a-16 Lockout Cam Limit Switch ........................ 12a-17 Lockout Cam ............................ 12a-17 Reverse Warning Buzzer ........................12a-18 Reverse Buzzer Limit Switch ......................12a-19 Oil Warning Light ..........................12a-20 Fuel Gauge/Hour Meter ........................12a-21 Fuel Level Sending Unit ........................12a-22 RPM Limiter ............................
Page 12 SECTION 13 – FE350 AND FE400 ENGINES General Information ......................... 13-1 Before Servicing ........................... 13-1 Lubrication System ........................13-1 Spark Plug ............................ 13-2 Cylinder ............................13-3 Breather Valve (Reed Valve) ....................... 13-3 Valve Clearance Check and Adjustment ..................13-3 Crankcase ............................13-3 Engine Removal ...........................
Page 13 Fuel Filters ............................14-17 Fuel Filter Removal ........................14-17 Fuel Filter Installation ........................14-18 Fuel Pump ............................14-18 General Information ........................14-18 Fuel Pump Removal ........................14-18 Fuel Pump Disassembly ....................... 14-19 Fuel Pump Cleaning and Inspection ..................... 14-22 Fuel Pump Assembly ........................14-22 Fuel Pump Installation ........................
Page 14 SECTION 17 – TORQUE CONVERTER General Information ......................... 17-1 Troubleshooting ..........................17-3 Drive Belt ............................17-3 Drive Belt Removal ........................17-3 Drive Belt Installation ........................17-4 Drive Clutch ............................17-4 Drive Clutch Removal ........................17-4 Drive Clutch Cleaning and Inspection ..................17-5 Drive Clutch Disassembly ......................
Page 15: 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 16 SAFETY General Warning ∆ WARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and CAUTION statements in this manual as well as those on the vehicle. • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair.
Page 17 SAFETY General Warning EARLIER CABLE MOUNTING HARDWARE 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 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 1-3...
Page 19: Section 2 - Vehicle Specifications
SECTION 2 – VEHICLE SPECIFICATIONS GENERAL INFORMATION SPECIFICATIONS TURF/CA 272 CARRYALL 472 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 20 VEHICLE SPECIFICATIONS General Information SPECIFICATIONS TURF/CA 272 CARRYALL 472 Governed RPM FE350 engine 3800 (±30) RPM FE400 engine 3850 (±30) RPM 3850 (±30) RPM Curb clearance circle (diameter) 24 ft. 1 in. (734 cm) 31 ft. 8 in. (965 cm) Turning radius (per SAE J 695) 139.6 in.
Page 21: Section 3 - General Information
The dashboard must be removed to view this number. See following NOTE.Always have the vehicle serial number at hand when ordering parts or making inquiries (Figure 3-1, Page 3-1). SERIAL NUMBER Club Car AD0201-583947 P O BOX 204658 AUGUSTA GA 30917...
Page 22: Storage
GENERAL INFORMATION Storage STORAGE ∆ DANGER • Read General Warning, Section 1, Page 1-1. ∆ WARNING • Read General Warning, Section 1, Page 1-1. ∆ CAUTION • Read General Warning, Section 1, Page 1-1. PREPARING THE VEHICLE FOR EXTENDED STORAGE 1.
Page 23: To Return Vehicle To Service
GENERAL INFORMATION Storage 5.2. Key-Start Vehicles: 5.2.1. Turn the fuel shut-off valve to the closed (OFF) position (Figure 3-7, Page 3-4) and run the engine until it stalls. See DANGER "Do not operate gasoline vehicle..." in General Warning, Section 1, Page 1-1. 6.
Page 24 GENERAL INFORMATION Storage FUEL VENT SHUT-OFF TANK FUEL SHUT-OFF VALVE VENT VALVE TO CARBURETOR TANK FUEL PUMP (under rear seat) FUEL FILTER (under rear seat) VENT TUBE VENT TUBE Figure 3-4 Turf-CA 272 Fuel Tank Figure 3-5 Carryall 472 Fuel Tank CLOSED (OFF) POSITION (SELECTOR IS ALIGNED FULL OPEN (ON)
Page 25: Section 4 - Body And Trim
Club Car does not recommend any type of pressure washing or steam cleaning. Both can create water dam- age to electrical components and subsequent component failure. Normal resitential water pressure is ade- quate for exterior cleaning.
Page 26: Light Scratches
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 27: Dashboard Installation
BODY AND TRIM Front Body Components 8. Remove the steering wheel. See Steering Wheel Removal, Section 7, Page 7-1. 9. Remove dashboard from vehicle. DASHBOARD INSTALLATION 1. Reverse the dashboard removal process. 2. Tighten screws (5) to 11 in-lb (1.2 N·m) (Figure 4-2, Page 4-5). 3.
Page 28: Front Body Removal
BODY AND TRIM Seat FRONT BODY REMOVAL 1. Remove ﬁve caps (1) from top of dashboard (2) (Figure 4-2, Page 4-5). 2. Use a Torx #T-30 driver to remove the Torx-head screws (3) and washers (4) from top of front body (6). 3.
Page 29 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 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 4-5...
Page 30: Seat Adjustment
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 31 BODY AND TRIM Front Seat Support ∆ WARNING • Both armrests must be installed before operating the vehicle, unless the vehicle is ﬁtted with a structural cab. 3. Connect differential lock cable to differential lock handle. See step 33 of Unitized Transaxle Installa- tion, Section 16, Page 16-21.
Page 32: Rear Seat Support
BODY AND TRIM Rear Seat Support TYPICAL 4 PLACES TYPICAL 10 PLACES TYPICAL 4 PLACES Figure 4-4 Carryall 472 Rear Seat Support REAR SEAT SUPPORT Read General Warning, Section 1, Page 1-1. REAR SEAT SUPPORT REMOVAL 1. Lift rear seat cushion and remove from the vehicle. Page 4-8 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 33: Rear Seat Support Installation
BODY AND TRIM Cargo Bed 2. Remove eight 1/4-20 ﬂange nuts (21) and eight 1/4-20 x 3/4-inch carriage bolts (20) and remove arm rests (10 and 11) (Figure 4-4, Page 4-8). 3. Remove four 1/4-20 x 1 inch, phillips drive, truss-head machine screws (19) and lock washers (18) from seat back support (22) and remove seat back (16) and seat back cap (17).
Page 34 BODY AND TRIM Cargo Bed TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 4-5 Turf/CA 272 Cargo Bed Page 4-10 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 35: Cargo Bed Installation
BODY AND TRIM Cargo Bed 2. Carryall 472: 2.1. Remove two 3/8-16 nylon lock nuts (2) from left and right cargo bed hinge/bolt assemblies (Figure 4-6, Page 4-11). 2.2. 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 (1) from the hinge assemblies.
Page 36: Bed Stop Bumper Adjustment
BODY AND TRIM Rear Fender BED STOP BUMPER ADJUSTMENT 1. Turf/Carryall 272: 1.1. Adjust the two front bumpers (16) by loosening the 1/4-20 nylon lock nuts (17) and position so that when the cargo bed is lowered, both bumpers are centered on the bed frame weldments (Figure 4-5, Page 4-10).
Page 37: Tailskirt Installation
BODY AND TRIM Trailer Hitch TAILSKIRT INSTALLATION 1. Installation is the reverse of removal. Tighten screws (7) to 55 in-lb (6.2 N·m). TRAILER HITCH Read General Warning, Section 1, Page 1-1. TRAILER HITCH REMOVAL 1. Turf/Carryall 272: 1.1. Remove the tailskirt. See Tailskirt Removal on page 4-12. 1.2.
Page 38 BODY AND TRIM Receiver Hitch TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 4-7 Turf/Carryall 272 Rear Fender, Tailskirt, and Trailer Hitch Page 4-14 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 39 BODY AND TRIM Receiver Hitch TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 4-8 Carryall 472 Rear Fender, Tailskirt, and Receiver Hitch 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 4-15...
Page 40: Floor Mat
BODY AND TRIM Floor Mat FLOOR MAT Read General Warning, Section 1, Page 1-1. FLOOR MAT REMOVAL 1. Turf/Carryall 272: 1.1. Remove the brake and accelerator pedals. See Accelerator Pedal Removal, Section 5, Page 5-5. Also see Brake Pedal Removal, Section 5, Page 5-1. 1.2.
Page 41: Section 5 - Accelerator And Brake Pedal Assemblies
SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. BRAKE PEDAL See General Warning, Section 1, Page 1-1. BRAKE PEDAL REMOVAL 1.
Page 42 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES PioneerSE Plug Figure 5-1 Brake Pedal Assembly Page 5-2 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 43: Brake Pedal Adjustment
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal Adjustment BRAKE PEDAL ADJUSTMENT See General Warning, Section 1, Page 1-1. 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Remove the key. Chock the wheels. 2. Remove the brake rod clevis pin (8) and bow tie locking pin (21) from the brake push rod (16) and bell crank (11) (Figure 5-1, Page 5-2).
Page 44 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal Adjustment Brake Pedal Adjustment, Continued: 6. Adjust the brake stop bumper (22) up to increase the distance between the pedal and the ﬂoorboard. or down to increase (Figure 5-4, Page 5-3). Proper brake pedal height is 6-5/8 inches ± 1/4 inch (16.8 cm ±...
Page 45: Accelerator Pedal
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal ACCELERATOR PEDAL See General Warning, Section 1, Page 1-1. ACCELERATOR PEDAL REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Remove the key. Chock the wheels. See following WARNING. ∆...
Page 46: Accelerator Pedal Adjustment
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment Accelerator Pedal Installation, Continued: 3. Tighten bolts (22) to 75 in-lb (8.5 N·m). 4. Install spacer (24), aligning the splined parts, and tighten the nylon lock nut (26) to 18 ft-lb (24.5 N·m). 5.
Page 47 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment 1/2 IN. SOCKET 1/2 IN. WRENCH Correct pedal position is 5-3/4 in. ± 1/4 in. (14.6 cm ± 6 mm) from floormat to back of accelerator pedal Figure 5-7 Accelerator Pedal Height Figure 5-8 Accelerator Pedal Adjustment ACCELERATOR PEDAL ADJUSTMENT TOOL...
Page 48 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment Accelerator Pedal Adjustment Continued: RETAINING PARALLEL NUTS WITH TOP VIEW OF THE ELECTRICAL COMPONENT Figure 5-10 Accelerator Cable and Electrical Box 8. Connect the accelerator rod at the accelerator pedal (Figure 5-11, Page 5-9). 8.1.
Page 49 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment FLOORBOARD REMOVED FOR CLARITY Figure 5-11 Accelerator Pedal Assembly 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 5-9...
Page 51: Section 6 - Mc012C-As00 Transaxle: Hydraulic And Park Brake Systems
SECTION 6 – MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. BRAKE SYSTEM INSPECTION See General Warning, Section 1, Page 1-1. The hydraulic brake system and park brake system should be inspected immediately after any service to either of the brake systems.
Page 52 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 6-1 Front Hydraulic Brake Cluster Assembly Brake Line and Hose Inspection •...
Page 53: Brake System Troubleshooting
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting Brake Drum and Shoe Inspection • Remove and inspect each brake drum. The drum should not be cracked, warped or have excessive scores or heat checks. • Inspect the brake shoes. Shoes should not be distorted, cracked or have broken welds. •...
Page 54 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Low pedal – Pedal may go to the ﬂoor, Replace the worn hose. See Hydraulic continued Weak (bulging) brake hose Line and Hose Replacement on page 6-23.
Page 55 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle pulls to one side, continued Replace hub, axle seal or wheel cylinder Grease or brake ﬂuid on the brake shoe and replace the brake shoes. See Brake linings Shoe Removal on page 6-8.
Page 56: Brake Drum Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Removal TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Rear brakes drag Binding park brake cables Adjust or replace cables and adjust. Adjust shoes and repair the brake shoe Improper brake adjustment adjusters if necessary.
Page 57 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Removal Figure 6-2 Front Spindle and Brake Drum Assembly 5. To remove tight brake drums: 5.1. On the back of each brake cluster assembly, locate the heads of the two brake shoe adjusters. 5.2.
Page 58: Rear Wheel Brake Drum Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Removal REAR WHEEL BRAKE DRUM REMOVAL ∆ WARNING • Use only approved replacement brake drums designed for your vehicle. For MC012C-AS00 transaxles, use CCI P/N 102264701. 1. Place chocks at the front wheels, release the park brake, loosen the rear wheel lug nuts and lift the rear of the vehicle with a chain hoist or ﬂoor jack.
Page 59 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Removal NOTE: It is recommended that the wheel bolt ﬂange (22) be removed prior to brake shoe removal (Figure 6-5, Page 6-9). 2. Remove rubber boot (26), cotter pin (25), locking cap (27) and large ﬂat washer (23) (Figure 6-5, Page 6-9).
Page 60: Brake Cluster Inspection And Cleaning
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 6-6, and Rear Wheel Brake Drum Removal on page 6-8.
Page 61: Brake Shoe Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation 9.2. Remove the lever and strut (14) from the brake cluster assembly (Figure 6-19, Page 6-21). 9.3. Disassemble the lever and strut by removing the C-clip and pin (Figure 6-8, Page 6-10). 9.4.
Page 62: Front Brake Shoe Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation NOTE: This vehicle uses a pair of identical brake shoes in each front and rear brake cluster. Each shoe must be positioned so that the adjuster pin is inserted into the slot of the brake shoe (Figure 6-11, Page 6-12).
Page 63 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Installation Lever is present on rear brake clusters only. TOP SLOTS BOTTOM SLOTS Figure 6-12 Brake Shoe Installation Figure 6-13 Slide Brake Shoes 4. Position the bottom tip of the remaining shoe into the mounting block and the top tip into the slot in the wheel cylinder piston.
Page 64: Brake Drum Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation Rear Brake Shoe Installation, Continued: NOTE: Push the rubber boot onto the washer so that the washer edge ﬁts into the boot-lip groove. 9. Install rear wheel brake drum. See Rear Wheel Brake Drum Installation on page 6-16. 10.
Page 65 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation 9. If the brake drum is difﬁcult to push over the brake shoes, use the following procedure: 9.1. Locate the bolt heads of the two brake shoe adjusters on the back of the brake cluster plates. 9.2.
Page 66: Rear Wheel Brake Drum Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Drum Installation Rotate adjuster bolts Rotate adjuster bolts to loosen brake shoes. to tighten brake shoes. Hex-Head Bolt Wrench Torx-Head Bolt Wrench Torx Torx Figure 6-14 Loosen or Tighten Brake Adjusters REAR WHEEL BRAKE DRUM INSTALLATION NOTE: Prior to installing the brake drum, inspect the brake lines, hoses, drums and brake cluster assem- blies.
Page 67: Brake Cluster Assembly Replacement
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement 5. Install the wheel and ﬁnger-tighten the lug nuts (21) (Figure 6-19, Page 6-21). 6. Repeat steps 1 through 5 for the opposite rear wheel as required. 7. Lower the vehicle and ﬁnish tightening the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m). 8.
Page 68: Rear Brake Cluster Assembly Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement Front Brake Cluster Assembly Installation, Continued: ∆ 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.
Page 69: Rear Brake Cluster Assembly Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement PLASTIC WIRE TIE FLEX BRAKE HOSE Figure 6-18 Rear Brake Hose With Plastic Bag REAR BRAKE CLUSTER ASSEMBLY INSTALLATION 1. Install the back plate to the axle tube ﬂange with new four Torx-head bolts (16), washers (17) and lock nuts (18).
Page 70: Front Wheel Cylinder Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Wheel Cylinder Replacement Front Wheel Cylinder Removal, Continued: 3. Remove the banjo bolt (16) and two copper washers (17) (Figure 6-1, Page 6-2). 4. 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 6-15, Page 6-17).
Page 71: Brake Shoe Adjuster Replacement
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Adjuster Replacement REFERENCE BRAKE HOSE BLEEDER VALVE TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL TYPICAL 4 PLACES 2 PLACES Figure 6-19 Rear Hydraulic Brake Cluster Assembly BRAKE SHOE ADJUSTER REPLACEMENT See General Warning, Section 1, Page 1-1.
Page 72: Front Brake Shoe Adjuster Removal
MC012C-AS00 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 6-6. 2. Remove front brake shoes. See Front Brake Shoe Removal on page 6-8. 3.
Page 73: Hydraulic Line And Hose Replacement
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement 2. Apply a light coat of grease to the Bellville washer (5) and install the washer onto the bolt (4) and against the inside surface of the back plate (1). 3.
Page 74: Front Brake Hose Assembly Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement Front Brake Line Installation, Continued: 4. Tighten the ﬂare nut (4) to the master cylinder to 11 ft-lb (14.9 N·m). 5. Tighten the ﬂare nut (4) to the T-manifold block (1) to 11 ft-lb (14.9 N·m). 6.
Page 75: Rear Brake Line Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement 1.5. Use a 3/8-inch ﬂare nut wrench to remove the same brake line (10 or 11) from the rear brake hose at the I-beam of the vehicle frame. 1.6.
Page 76 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement Rear Brake Hose Removal, Continued: 4. Use a 3/8-inch ﬂare nut wrench to remove the brake hose from the wheel cylinder (Figure 6-17, Page 6-18). 5. Use a 3/8-inch ﬂare nut wrench to remove the rear brake line (10 or 11) from the rear brake hose at the I-beam of the vehicle frame (Figure 6-20, Page 6-26 or Figure 6-21, Page 6-27).
Page 77 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement TYPICAL BOTH SIDES TYPICAL 2 PLACES REFERENCE REFERENCE FRONT SUSPENSION MASTER CYLINDER REFERENCE FRONT BRAKE ASSEMBLY TYPICAL BOTH SIDES REFERENCE REAR BRAKE ASSEMBLY Figure 6-21 Carryall 472 Four-Wheel Hydraulic Brake System 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 6-27...
Page 78: Rear Brake Hose Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement REAR BRAKE HOSE INSTALLATION 1. Install brake hose (9) through the oval-shaped hole in the vehicle I-beam, and install the horseshoe clip (12) that secures the brake hose to the I-beam frame (Figure 6-20, Page 6-26 or Figure 6-21, Page 6-27).
Page 79: Master Cylinder Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement 1. Chock the wheels and release the park brake and access the master cylinder. 2. Place a pan below the vehicle to collect the brake ﬂuid. 3. Remove the two wires from the master cylinder pressure switch (4) (Figure 6-22, Page 6-30). 4.
Page 80 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement Turf-Carryall PLUG TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 6-22 Master Cylinder Page 6-30 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 81: Bleeding The Hydraulic Brake System
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System BLEEDING THE HYDRAULIC BRAKE SYSTEM See General Warning, Section 1, Page 1-1. The hydraulic system must be free of air. Air enters the hydraulic system whenever the system is opened and will result in a "spongy"...
Page 82: Purging The Hydraulic System
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System PURGING THE HYDRAULIC SYSTEM In some cases it may be necessary to completely drain the front, rear or entire hydraulic brake system of brake ﬂuid. To completely purge the hydraulic system, perform the following procedure. 1.
Page 83: Park Brake System
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Full Level Safe Level Level Figure 6-24 Master Cylinder Reservoir PARK BRAKE SYSTEM See General Warning, Section 1, Page 1-1. PARK BRAKE CABLE REMOVAL Equalizer Cable Removal 1. Chock the wheels and release the park brake. 2.
Page 84: Park Brake Cable Installation
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System PARK BRAKE CABLE INSTALLATION Park Brake Pulley Installation 1. Align the equalizer cable pulley assembly (13) with the mounting holes in the frame (Figure 6-27, Page 6-37). 2. Install the four 10-24 x 3/4-inch socket-head screws (14), ﬂat washers (17) and lock nuts (18) and tighten to 54 in-lb (6.1 N·m).
Page 85: Park Brake Handle Removal
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System 5. Pull the end of the brake cable (8) up and into a keyhole opening in the park brake equalizer bracket (10). 6. Adjust the park brake. See Park Brake Adjustment on page 6-35. 7.
Page 86 MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Park Brake Adjustment, Continued: 5. 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 6-27, Page 6-37). 6.
Page 87 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 6-27 Park Brake System 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 6-37...
Page 89: Section 7 - Steering And Front Suspension
SECTION 7 – STEERING AND FRONT SUSPENSION ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. STEERING WHEEL See General Warning, Section 1, Page 1-1. STEERING WHEEL REMOVAL 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the wheels. 2.
Page 90 STEERING AND FRONT SUSPENSION Steering Wheel TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-3 Steering Column Page 7-2 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 91: Steering Wheel Installation
STEERING AND FRONT SUSPENSION Steering Column STEERING WHEEL INSTALLATION NOTE: To minimize corrosion, apply a small amount of oil or anti-seize compound to steering shaft splines and taper before installing the steering wheel. 1. Install the steering wheel (25) on the splines of the steering shaft (11). Align the match marks placed on the wheel and steering column shaft in step 5, Steering Wheel Removal on page 7-1.
Page 92: Steering Column Assembly
STEERING AND FRONT SUSPENSION Steering Column Figure 7-4 Steering Joint Assembly STEERING COLUMN ASSEMBLY 1. Insert bearing seat (10) into both ends of steering tube (14). Place a block of wood on bearing seat and tap lightly on block until bearing seat (10) is fully seated in steering tube (14) (Figure 7-5, Page 7-5 and Figure 7-6, Page 7-5).
Page 93: Rack And Pinion
STEERING AND FRONT SUSPENSION Rack and Pinion COLUMN RETAINING TOOL (CCI P/N 1014259) STEP 1 STEP 1 BEARING BEARING PRESS TOOL PRESS TOOL 5.1-5.4 cm (CCI P/N 1014264) (CCI P/N 1014264) 2 in.-2 1/8 in. STEP 2 WEDGE SEATING WEDGE SEATING INTO THE INNER INTO THE INNER RACES OF BEARING...
Page 94 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Removal, Continued: 3. Remove the lug nuts from the front wheels. 4. Remove the cotter pins (18) and ball joint retaining nuts (24) (Figure 7-19, Page 7-10). 5. Remove the ball joints (23) from the spindle assemblies. Figure 7-7 Rack and Pinion Bolts 6.
Page 95: Rack And Pinion Disassembly
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION DISASSEMBLY 1. Remove the two ball joints and inspect for excessive wear (Figure 7-9, Page 7-7). 2. Remove both drag links (Figure 7-10, Page 7-7). Figure 7-9 Ball Joint Figure 7-10 Drag Link 3.
Page 96 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly, Continued: 6. Remove the universal joint assembly from the pinion by removing the bolt and then sliding off the uni- versal joint (Figure 7-12, Page 7-8). 7. Remove the dust seal (Figure 7-13, Page 7-8). 8.
Page 97 STEERING AND FRONT SUSPENSION Rack and Pinion 10. If the ball bearing (15) (Figure 7-19, Page 7-10) has been damaged, remove the c-type stop ring (16) (Figure 7-14, Page 7-8) and press the bearing off (Figure 7-16, Page 7-9). 11. Inspect the ball joints (9) for wear. If one or both of the ball joints (9) are excessively worn, remove and replace the ball joint from the rack (Figure 7-19, Page 7-10).
Page 98 STEERING AND FRONT SUSPENSION Rack and Pinion TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-19 Steering Gear Page 7-10 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 99: Rack And Pinion Assembly
STEERING AND FRONT SUSPENSION Rack and Pinion 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 7-19, Page 7-10). CAUTION •...
Page 100: Rack And Pinion Installation
STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Assembly, Continued: 11. Insert a 3/8-inch, 1/4-drive, deep-well socket into the steering column end of the universal joint (2) and tighten the bolts (1) to 15 ft-lb (20.3 N·m) (Figure 7-22, Page 7-12). 12.
Page 101: Front Suspension
STEERING AND FRONT SUSPENSION Front Suspension 4. Install remaining bolt and lock washer on the upper universal joint and tighten it to 15 ft-lb (20 N·m). 5. Check all universal joint bolts for proper torque of 15 ft-lb (20 N·m). 6.
Page 102: Front Suspension Components
STEERING AND FRONT SUSPENSION Front Suspension Components Toe-in Adjustment, Continued: 4. Measure the distance between the marks on the forward-facing surfaces of the tires (Figure 7-24, Page 7-13). See following NOTE. NOTE: The front measurement must be less than the rear measurement. 5.
Page 103: Kingpin And Steering Spindle Installation
STEERING AND FRONT SUSPENSION Front Suspension Components ∆ WARNING • Strain on the brake hose or the brake hose ﬁttings can result in damage to the hose or ﬁttings, causing a leak in the hydraulic system, diminished brake performance, or brake failure. Figure 7-27 Rest Brake Cluster on A-arm 5.
Page 104: A-Arm Removal
STEERING AND FRONT SUSPENSION Front Suspension Components Kingpin and Steering Spindle Installation, Continued: 9. Install a new cotter pin (18) and bend it to secure it to the ball joint. 10. Use a grease gun and apply grease to the grease ﬁtting (17) in the A-arm (13) (Figure 7-28, Page 7-17). See Lubrication on page 7-13.
Page 105 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 106: Shock Absorber Removal
STEERING AND FRONT SUSPENSION Front Suspension Components A-Arm Installation, Continued: 12. Install the brake cluster. See Front Brake Cluster Assembly Installation, Section 6, Page 6-17. 13. Install the wheel and tighten the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m). 14.
Page 107: Front Wheel Bearings And Hubs
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS See General Warning, Section 1, Page 1-1. FRONT WHEEL FREE PLAY INSPECTION 1. Chock rear wheels, loosen the front wheel lug nuts and lift the front of the vehicle with a chain hoist or ﬂoor jack.
Page 109: Section 8 - Wheels And Tires
SECTION 8 – WHEELS AND TIRES ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION • Keep tires properly inﬂated as follows: Front: 7-11 psi (.48-.76 Bars) All Terrain Tread Rear: 14-18 psi (.97-1.24 Bars) Front: 12-16 psi (.83-1.10 Bars)
Page 111: Section 9 - Rear Suspension
SECTION 9 – REAR SUSPENSION ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. SHOCK ABSORBERS See General Warning, Section 1, Page 1-1. SHOCK ABSORBER REMOVAL AND INSPECTION 1. Check shock absorbers (1) for damage or ﬂuid leakage around the housing and replace if necessary (Figure 9-1, Page 9-2).
Page 112 REAR SUSPENSION Multi-Leaf Springs TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE AXLE SADDLE Figure 9-1 Rear Suspension for MC012C-AS00 Transaxle Page 9-2 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 113: Multi-Leaf Spring Installation
REAR SUSPENSION Multi-Leaf Springs Multi-Leaf Spring Removal, Continued: 4. Position jack stands under the two side stringers as shown (Figure 9-3, Page 9-3). Lower the ﬂoor jack to let the jack stands support the vehicle. See WARNING "Lift only one end..." in General Warning, Section 1, Page 1-2.
Page 114: Snubber
REAR SUSPENSION Snubber Multi-Leaf Spring Installation, Continued: 3. Align opposite end of leaf spring with spring shackles (19). Insert bolt (16) through shackles and leaf spring eye. Attach lock nut (17) and tighten to 15 ft-lb (20.3 N·m). Lower transaxle onto leaf spring (18) (Figure 9-1, Page 9-2).
Page 115: Section 10 - Periodic Maintenance
SECTION 10 – PERIODIC MAINTENANCE ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. PERIODIC SERVICE SCHEDULE ∆ WARNING • Service, repairs, and adjustments must be made per instructions in this maintenance and service manual.
Page 116: Periodic Lubrication Schedule
PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Annual service by Check for leaks around gaskets, ﬁll plugs, etc. Engine trained technician only Inspect, clean and gap spark plug; replace if necessary. (every 100 hours of operation) Check air ﬁlter element;...
Page 117: Master Cylinder
PERIODIC MAINTENANCE Master Cylinder FLOORBOARD Figure 10-1 Turf/Carryall 272 and Carryall 472 Lubrication Points MASTER CYLINDER The master cylinder is located under the passenger seat toward the center of the vehicle (Figure 10-2, Page 10-3). Raise or remove the seat to check the brake ﬂuid level. When checking the brake ﬂuid, also inspect the following: •...
Page 118: Brake Fluid
PERIODIC MAINTENANCE Engine Oil BRAKE FLUID Brake ﬂuid level should be within 1/4-inch (6 mm) from top of reservoir (Figure 10-2, Page 10-3). Also, brake ﬂuid should be clean with no residue in bottom of reservoir or other evidence of contamination. See following WARNING.
Page 119: Engine Oil And Filter Change
PERIODIC MAINTENANCE Engine Oil ENGINE OIL AND FILTER CHANGE Engine oil and oil ﬁlter should be changed after the ﬁrst 100 hours of operation, then every 200 hours of oper- ation. 1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Chock the front wheels.
Page 120 Corning® BR2-Plus or equivalent), or new engine oil to the rubber seal of the ﬁlter before installation. This will help seal the ﬁlter to the oil mounting bracket (Figure 10-8, Page 10-6). See following NOTE. NOTE: Use only Club Car oil ﬁlters (CCI P/N 1016467) designed for this engine. Coat Rubber Seal...
Page 121: Oil Viscosity
PERIODIC MAINTENANCE Fueling Instructions 12. Tighten the oil ﬁlter by hand until tight. Do not use a band wrench or channel lock pliar to tighten. 13. Lower the vehicle and remove the ﬂoor jack from under the rear of the vehicle. 14.
Page 122: Battery
PERIODIC MAINTENANCE Battery Fueling Instructions, Continued: NOTE: Whenever possible, avoid using oxygenated fuels and fuels that are blended with alcohol. Vehicles to be stored for extended periods should be prepared for storage as instructed in Section 3 of this manual. 1.
Page 123 PERIODIC MAINTENANCE Battery The battery in a Club Car vehicle is a 12-volt, low-maintenance battery that requires infrequent watering (Figure 10-14, Page 10-9). 1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 125: Section 11A - Troubleshooting And Electrical System: Fe400, Key-Start Engine
SECTION 11A – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. 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.
Page 126 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine turns but fails to start. Fuel tank is empty Section 14 – Fuel System Fuel line or ﬁlters clogged Section 14 – Fuel System Fouled spark plug Section 13 –...
Page 127 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Spark plug fouls repeatedly, continued. Section 11a – Troubleshooting and Ignition coil failed Electrical System: FE400, Key-Start Engine, Test Procedures 14, 15, and 16 Rings are heavily worn, low cylinder See the Engines and Transaxles manual pressure...
Page 128 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Starter/Generator does not charge Starter/generator belt is loose or slipping Belt Tension Adjustment on page 12a-10 battery, continued. Section 11a – Troubleshooting and Voltage regulator failed Electrical System: FE400, Key-Start Engine, Test Procedure 12 Section 11a –...
Page 129: 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 130: Wiring Diagram
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagram WIRING DIAGRAM PASSENGER SIDE HEADLIGHT DRIVER SIDE SONIC HEADLIGHT WELD SONIC WELD SONIC WELD LIGHT SWITCH Figure 11a-2 Wiring Diagram for FE400 Key-Start Vehicles (Front) Page 11a-6 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 131 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Wiring Diagram SONIC WELD SONIC WELD SONIC WELD SONIC WELD Figure 11a-3 Wiring Diagram for FE400 Key-Start Vehicles (Rear) 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 11a-7...
Page 132: 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-8). See following NOTE. NOTE: The starter circuit is completely independent of the ignition circuit.
Page 133: 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-9). See Test Pro- cedure 16 –...
Page 134: 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. The reverse buzzer circuit consists of a front mounted reverse buzzer, reverse buzzer limit switch, fuse, fuse block and connecting wires (Figure 11a-8, Page 11a-10).
Page 135: Lockout Cam Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Electrical Circuits Figure 11a-9 Low Oil Warning Circuit LOCKOUT CAM CIRCUIT This key-start vehicle is equipped with a lockout cam that allows the engine to be started and reved only when the Forward/Reverse handle is in the NEUTRAL position. The lockout cam (yellow) is located on the back of the Forward/Reverse handle, inside the engine compartment.
Page 136: 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 137: Hour Meter Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Electrical Circuits 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-13). 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-13).
Page 138: Test Procedures
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURES INDEX OF TEST PROCEDURES 1. Battery 2. Fuse 3. Ground Cables 4. Key Switch (Starter Circuit) 5. Key Switch (Accessory Terminal) 6. Solenoid 7. Lockout Cam Limit Switch 8. Starter/Generator (Starter Function) 9.
Page 139 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 1 – BATTERY See General Warning, Section 1, Page 1-1. ∆ DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working around a battery.
Page 140 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 1 – Battery, Continued: 7. Record the reading. 8. Return the electrolyte to the cell from which it was taken. Replace vent cap. 9. Repeat steps 2 through 8 on all cells. BATTERY PLATES 1.250...
Page 141 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures NOTE: A fully charged battery that is in good condition should have a speciﬁc gravity of at least 1.225 in all cells, and the difference in the speciﬁc gravity of any two cells should be less than 50 points. Open circuit voltage should be at least 12.4 volts.
Page 142 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 3 – GROUND CABLES See General Warning, Section 1, Page 1-1. 1. Turn the key swithc OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2.
Page 143 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 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 144 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 5 – KEY SWITCH (ACCESSORY TERMINAL) See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 145 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 9. Place the Forward/Reverse handle in NEUTRAL. With the key in the OFF position, the reading on the multimeter should be no continuity. Turn the key switch to the START position and listen for the solenoid click.
Page 146 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 7 – Lockout Cam Limit Switch, Continued: 4. Set the multimeter to 200 Ω (ohms). Place the red (+) probe of the multimeter on the common (COM) ter- minal of the limit switch. Place the black (–) probe on the normally open (NO) terminal of the switch. With- out the lever depressed, the reading should be no continuity.
Page 147 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 6. 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 148 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 10 – DIODE (GENERATOR CIRCUIT) See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 149 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 5. Reverse the multimeter probes and note the reading. With the black (–) probe of the multimeter to the red lead of the diode and the red (+) probe of the multimeter to the white lead, the meter should read approx- imately 450 mV, however, a range of 400-500 mV is acceptable (Figure 11a-30, Page 11a-25).
Page 150 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 11 – Starter/Generator (Generator Function), Continued: 4. Using a multimeter set to 20 volts DC, place the red (+) probe on the positive (+) cable of the battery, and place the black (–) probe on the negative (–) post.
Page 151 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 13 – GROUNDED KILL WIRE See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 152 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 14 – Ignition Spark, Continued: 2.1. Adjust the tester probes to approximately to 18,000 volts (18 Kv) setting (SE – Small Engine Setting on the Thexton 404 tool). Connect the tester to the spark plug wire, and connect the alligator clip to a solid engine ground.
Page 153 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Ignition Coil – In Vehicle Test 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Disconnect the battery cables as instructed (Figure 11a-1, Page 11a-5). See WARNING "To avoid unintentionally starting..."...
Page 154 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 16 – Ignition Coil, Continued: 4. Using a multimeter set to 20k Ω (ohms), measure the resistance of the secondary coil and spark plug cap together. 4.1. Place the red (+) probe of the meter into the end of the spark plug cap that normally connects to the spark plug and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 11a-36, Page 11a-30).
Page 155 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Figure 11a-37 Ignition Coil and Cap Figure 11a-38 Spark Plug Cap Removal WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11a-39 Spark Plug Cap Test 6. Test the secondary coil separately from the spark plug cap. 6.1.
Page 156 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Ignition Coil – Bench Test 1. Remove the coil from the engine. See Ignition Coil Removal, Section 12a, Page 12a-23. 2. Using a multimeter set to 200 Ω (ohms), measure the primary coil resistance. 2.1.
Page 157 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures WAVETEK SECONDARY COIL 1000 WAVETEK 1000 2000 200k Ω 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Ω 200nA 1000 --- FUSED 750V Figure 11a-41 Primary Coil Resistance – Bench Test Figure 11a-42 Secondary Coil and Cap Resistance –...
Page 158 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 16 – Ignition Coil, Continued: 4. If not previously tested, test the spark plug cap separately from the secondary coil. 4.1. Remove the rubber gasket (1) on the plug cap (2) by rolling back the gasket onto the spark plug wire (3) (Figure 11a-37, Page 11a-31).
Page 159 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 18 – ENGINE KILL WIRE See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 160 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 21 – OIL LEVEL SENSOR See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 161 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures TEST PROCEDURE 24 – BATTERY TEST (UNDER LOAD) See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 162 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 25 – Fuel Level Sending Unit, Continued: 6. If the readings are within the speciﬁcations listed above, the fuel level sending unit is working properly. If the readings are incorrect, the fuel level sending unit has failed and the fuel tank must be replaced. See Fuel Tank Removal, Section 14, Page 14-23.
Page 163 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures 8. Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded earlier. If not, check the continuity of the blue and black wires (Figure 11a-46, Page 11a-39). 9.
Page 164 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 28 – Light Switch, Continued: 4. Using a multimeter set on 20 volts DC, place alligator clips on the multimeter probes. Connect the red (+) probe to the light switch terminal with the blue wire connected to it (Figure 11a-48, Page 11a-40). ∆...
Page 165 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures ∆ CAUTION • Before connecting battery cables, make sure no electrical components touch the front body trim or other parts of the vehicle frame. Place a dry towel between the body trim and the center dash to prevent an electrical short circuit.
Page 166 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-START ENGINE Test Procedures Test Procedure 30 – Voltage at Headlight Socket, Continued: 3. Remove the wire harness from the headlight (Figure 11a-50, Page 11a-42). 4. Using a multimeter set to 20 volts DC, place the black (–) probe of multimeter into the black wire terminal of the wire harness.
Page 167: Section 11B - Troubleshooting And Electrical System: Fe350, Pedal-Start Engine
SECTION 11B – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. 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.
Page 168 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Engine turns but fails Fuel tank is empty Section 14 – Fuel System to start. Fuel line or ﬁlters clogged Section 14 – Fuel System Fouled spark plug Section 13 –...
Page 169 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Spark plug fouls repeatedly, continued. Rings are heavily worn, low cylinder See the Engines and Transaxles manual pressure (CCI P/N 102396501) Section 11b – Troubleshooting and Ignition coil failed Electrical System: FE350, Pedal-Start Engine, Test Procedures 13, 14, and 15...
Page 170 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Starter/Generator does not charge Section 12b – Electrical Components: battery, continued. Starter/generator belt is loose or slipping FE350, Pedal-Start Engine, Belt Tension Adjustment on page 12b-10 Section 11b –...
Page 171: 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 172 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Wiring Diagram WIRING DIAGRAM VOLTAGE LIMITER 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-6 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 173 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) 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 11b-7...
Page 174 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Electrical Circuits ELECTRICAL CIRCUITS 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-8). The battery is the source of power for the system.
Page 175 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Electrical Circuits 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-9). See Test Procedure 15 –...
Page 176 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Electrical Circuits 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 177 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Electrical Circuits 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-12).
Page 178 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Electrical Circuits 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 MAINTENANCE POSITION Figure 11b-10 Maintenance Position For Figure 11b-11 Operate Position For Neutral Lockout Cam...
Page 179: Lighting Circuit
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Electrical Circuits 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-13). TO WIRE HARNESS ORANGE WHITE Figure 11b-13 Fuel Gauge and Sending Unit Circuit Figure 11b-14 Pedal-Start Hour Meter Circuit LIGHTING CIRCUIT The headlights receive power through the fuse block when the light switch is pulled to the ON position...
Page 180: Test Procedures
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURES INDEX OF TEST PROCEDURES 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 181 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURE 1 – BATTERY See General Warning, Section 1, Page 1-1. ∆ DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working around a battery.
Page 182 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 1 – Battery, Continued: 7. Record the reading. 8. Return the electrolyte to the cell from which it was taken. Replace vent cap. 9. Repeat steps 2 through 8 on all cells. BATTERY PLATES 1.250...
Page 183 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Voltage Test 1. Place the red (+) probe of a multimeter set at Volts DC, 20 volt range, on the positive (+) post and place the black (–) probe on the negative (–) terminal of the battery and take a voltage reading. If it shows less than 12.4 volts, or if the lowest speciﬁc gravity reading from the hydrometer test is less than 1.225, recharge the battery.
Page 184 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURE 3 – GROUND CABLES See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2.
Page 185 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 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. Figure 11b-20 Test Battery Ground Strap TEST PROCEDURE 4 –...
Page 186 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 4 – Key Switch (Starter Circuit), Continued: 8. Place the red (+) probe of the multimeter on the red wire terminal and the black (–) probe on the blue wire terminal of the key switch (Figure 11b-22, Page 11b-19).
Page 187 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 5. Set a multimeter to 200 Ω (ohms). Place the red (+) probe on one of the small posts of the solenoid and place the black (–) probe on the other small post. The reading should be 14 to16 Ω (ohms). If the reading is not within limits, replace the solenoid.
Page 188 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURE 7 – NEUTRAL LOCKOUT LIMIT SWITCH See General Warning, Section 1, Page 1-1. This limit switch is located on the Forward/Reverse switch assembly. A black wire, a green wire, and a white wire are connected to this limit switch (Figure 11b-4, Page 11b-8).
Page 189 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 4. Disconnect the wires from all the terminals on the starter/generator. Then place the black (–) probe of a multimeter, set to 200 Ω (ohms), on the starter/generator housing (scratch through the ﬁnish to ensure a good ground).
Page 190 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURE 9 – WIRE CONTINUITY See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2.
Page 191 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures but rising steadily, check battery condition. See Hydrometer Test on page 11b-15. If the reading is lower than 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.
Page 192 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-30 Ignition Spark Test Figure 11b-31 Disconnect White/Black Engine Kill Wire TEST PROCEDURE 13 – IGNITION SPARK See General Warning, Section 1, Page 1-1.
Page 193 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 4. Using a multimeter set to 200 Ω (ohms), place the red (+) probe on the brown ground wire and place the black (–) probe on one of the black wire female bullet connectors. The reading should be no continuity. If the reading is not correct, replace the RPM limiter.
Page 194 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 15 – Ignition Coil, Continued: 4.1. Place the red (+) probe of the meter into the end of the spark plug cap that normally connects to the spark plug and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 11b-34, Page 11b-28).
Page 195 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 5.2. Remove the cap from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire (Figure 11b-36, Page 11b-29). Figure 11b-35 Ignition Coil and Cap Figure 11b-36 Spark Plug Cap Removal 5.3.
Page 196 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11b-38 Secondary Coil Test Without Cap Ignition Coil – Bench Test 1. Remove the coil from the engine. See Ignition Coil Removal, Section 12b, Page 12b-22. 2.
Page 197 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures WAVETEK SECONDARY COIL 1000 WAVETEK 1000 2000 200k Ω 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Ω 200nA 1000 --- FUSED 750V Figure 11b-39 Primary Coil Resistance – Bench Test Figure 11b-40 Secondary Coil and Cap Resistance –...
Page 198 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 15 – Ignition Coil, Continued: 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-41, Page 11b-31).
Page 199 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 5. 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. With the key switch OFF, the reading should be continuity (Figure 11b-44, Page 11b-33).
Page 200 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 19 – Reverse Buzzer Limit Switch, Continued: 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-10).
Page 201 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 6. 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 202 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 25 – Fuel Level Sending Unit, Continued: 2. Disconnect the battery cables as instructed (Figure 11b-1, Page 11b-5). See WARNING "To avoid unintentionally starting..." in General Warning, Section 1, Page 1-2. 3.
Page 203 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures TEST PROCEDURE 26 – FUEL GAUGE See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2.
Page 204 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 27 – Hour Meter, Continued: ∆ DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. Engine produces carbon monoxide, which is an odorless, deadly poison. 4.
Page 205 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures GROUND TERMINAL WAVETEK 1000 BLOCK 2000 200k Ω Ω 200nA 1000 --- FUSED 750V LIGHT SWITCH Figure 11b-49 Test Light Switch 5. Connect the red (+) probe to the light switch terminal with the blue wire connected to it. See following CAUTION.
Page 206 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures Test Procedure 30 – Headlight Diode, Continued: 6. Connect the battery, positive (+) cable ﬁrst. GROUND TERMINAL BLOCK WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V LIGHT SWITCH Figure 11b-50 Testing the Headlight Diode 7.
Page 207 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-START ENGINE Test Procedures 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 209: Section 12A - Electrical Components: Fe400, Key-Start Engine
SECTION 12A – ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. EARLIER CABLE MOUNTING HARDWARE AS SEEN FROM PASSENGER'S SIDE OF VEHICLE REMOVE NEGATIVE DISCONNECT BATTERY CABLES CABLE FIRST...
Page 210 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator A1 TERMINAL TERMINAL TERMINAL TO BATTERY GROUND POST Figure 12a-2 Starter/Generator Removal Disassembly of the Starter/Generator to Service the Brushes 1. Remove the two bolts (20) and pull commutator end cover (23) free of starter/generator housing (24) (Figure 12a-3, Page 12a-2).
Page 211 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Brush Inspection and Replacement 1. Visually inspect brushes. Replace brushes that are cracked or severely chipped. 2. Check the wear line on the side of the brush. If the end of the brush is within 1/16-inch (1.6 mm) of the wear line, replace all four brushes (Figure 12a-5, Page 12a-3).
Page 212 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Starter/Generator Assembly 1. Connect the brush wires to the holders using four lock washers (26) and four screws (25). Make sure the crossover leads are also connected. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12a-4, Page 12a-2).
Page 213 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Figure 12a-8 Armature and Output End Cover Assembly Figure 12a-9 Bearing Play Inspection Bearing Removal 1. Place the wedge attachment tool (CCI P/N 1012812) between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller (CCI P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 214 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator WEDGE ATTACHMENT BEARING PRESS RAM USE A 1/2-INCH TOOL PULLER SUPPORT SOCKET OR PIPE TOOL INNER RACE OF BEARING PRESS ON ARMATURE SHAFT USE A WEDGE 1/2-INCH ATTACHMENT SOCKET TOOL OR PIPE NOTE: BEARING IS SECTIONED FOR CLARITY Figure 12a-10 Bearing Removal POLE PIECE SCREW...
Page 215 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Commutator Cleaning and Inspection 1. Clean the carbon dust, dirt and oil from the commutator. Slight roughness of the commutator can be pol- ished away with 400 grit (or ﬁner) sandpaper. See following CAUTION. CAUTION •...
Page 216 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator ARMATURE WAVETEK 1000 2000 200k Ω COMMUTATOR Ω 200nA 1000 --- FUSED ARMATURE SHAFT 750V Figure 12a-13 Armature Ground Test Starter/Generator Rework Any rework must be performed by a qualiﬁed technician. Starter/Generator service speciﬁcations are listed in the following table.
Page 217 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator CAUTION • Route the ﬁeld terminal wires so that they will not contact the armature. 3. Install the four pole pieces into the housing. Use the four screws to secure pole pieces to the inside of the housing to retain the ﬁeld wires.
Page 218 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator Starter/Generator Installation, Continued: 6. Install the white wire from the solenoid to the F2 terminal on the starter/generator. Install the black wire from the frame to the 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).
Page 219: Voltage Regulator
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Voltage Regulator VOLTAGE REGULATOR See General Warning, Section 1, Page 1-1. Testing the Voltage Regulator See Test Procedure 12, Section 11a, Page 11a-26. Voltage Regulator Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 220: Diode
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Diode DIODE See General Warning, Section 1, Page 1-1. Testing the Diode See Test Procedure 10, Section 11a, Page 11a-24. Diode Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 221 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Diode RIGHT ANGLED Some wires SUPPORT omitted CARRYALL 472 for clarity. RED FROM VOLTAGE REGULATOR RED FROM DIODE RED FROM WHITE FROM FUSE BLOCK DIODE WHITE FROM STARTER/ RED FROM GENERATOR BATTERY ANGLED I-BEAM OUTER I-BEAM Figure 12a-18 Electrical Component Box and Diode Orientation CAUTION...
Page 222: Key Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Key Switch Diode Installation, Continued: 6. Connect the intake hose to the carburetor and secure the hose with the hose clamp. 7. 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 223: Solenoid
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Solenoid Figure 12a-20 Center Dash Panel Removal SOLENOID See General Warning, Section 1, Page 1-1. Testing the Solenoid See Test Procedure 6, Section 11a, Page 11a-20. Solenoid Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 224: Fuse
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuse Solenoid Installation, Continued: 2. Connect all wires as indicated. 2.1. Connect the 6-gauge white wire from the starter/generator, 18-gauge red wire from the voltage reg- ulator, and the 12-gauge white wire from the diode to the large post on the solenoid. See Wiring Diagram, Section 11a, Page 11a-6.
Page 225: Lockout Cam Limit Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Lockout Cam Limit Switch LOCKOUT CAM LIMIT SWITCH See General Warning, Section 1, Page 1-1. Testing the Lockout Cam Limit Switch See Test Procedure 7, Section 11a, Page 11a-21. Lockout Cam Limit Switch Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 226: Reverse Warning Buzzer
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Reverse Warning Buzzer FORWARD/REVERSE FORWARD/REVERSE ASSEMBLY ASSEMBLY REVERSE BUZZER LOCKOUT LIMIT SWITCH LIMIT SWITCH Figure 12a-21 Lockout Cam and Reverse Buzzer Figure 12a-22 Lockout Cam Limit Switches Lockout Cam Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 227: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Reverse Buzzer Limit Switch 6. Remove the screw (3), nut (4), lock washer (5) and ﬂat washer (6) securing the front buzzer to the vertical frame support. 7. Remove the screws, nuts, lock washers and ﬂat washers securing the rear buzzer to the cross frame sup- port between the bed hinges under the rear of the bed.
Page 228: Oil Warning Light
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Oil Warning Light Reverse Buzzer Limit Switch Removal, Continued: 4. Remove the nuts (2) and washers (6) from the lockout cam limit switch (5) and slide the lockout cam limit switch off of the screws. Do not disconnect the wires. 5.
Page 229: Fuel Gauge/Hour Meter
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuel Gauge/Hour Meter Figure 12a-24 Fuel Gauge/Hour Meter and Oil Warning Light Assembly FUEL GAUGE/HOUR METER See General Warning, Section 1, Page 1-1. Testing the Fuel Gauge/Hour Meter See Test Procedure 26, Section 11a, Page 11a-38. Also see Test Procedure 27 – Hour Meter on page 11a-39.
Page 230: Fuel Level Sending Unit
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Fuel Level Sending Unit Fuel Gauge/Hour Meter Installation, Continued: 3. Connect the orange wire from the fuel level sending unit to the no. 1 terminal, the blue wire to the no. 2 terminal, the white wire to the No. 4 terminal and the black wire to the No. 3 terminal on the gauge/meter. See Wiring Diagram, Section 11a, Page 11a-6.
Page 231: 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-25 RPM Limiter Assembly IGNITION COIL See General Warning, Section 1, Page 1-1. The ignition coil is located under the ﬂywheel shroud of the engine.
Page 232 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ignition Coil Ignition Coil Removal, Continued: 7. Remove the pan head bolts (5) securing the fan shroud (8) to the fan housing (9) (Figure 12a-26, Page 12a-24). 8. Loosen, but do not remove, three bolts (6) attaching the fan housing as shown. 9.
Page 233 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ignition Coil 8. Install the gasket (1) on the cap (2). 9. Position the ignition coil (7) onto the cast mounting bosses on the engine crankcase and tighten the two mounting bolts (6) ﬁnger-tight. 10. Rotate the ﬂywheel (8) until the magnet is positioned directly under the ignition coil. Use a 0.012 inch (0.304 mm) bronze feeler gauge to set the air gap between the ignition coil and the ﬂywheel magnet.
Page 234: Oil Level Sensor
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Oil Level Sensor Ignition Coil Installation, Continued: 21. Install the starter/generator and belt. See Starter/Generator Installation on page 12a-9. 22. Connect the spark plug wire to the spark plug. 23. 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 235: Headlight Diode
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Headlight diode Headlight Bulb Installation NOTE: When handling halogen bulbs, do not touch glass portion of bulb. Oil from ﬁnger tips can cause premature failure of bulb. 1. Connect wire harness (4) to the halogen bulb assembly (6). The retaining tab should lock onto the halo- gen bulb assembly (Figure 12a-30, Page 12a-26).
Page 236: Light Switch
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Light Switch Headlight Diode Installation, Continued: 3. Connect the solid black wire from the ground terminal block to the positive (+) terminal on the diode. 4. Install the dash panel in reverse order of removal. See Key Switch Removal on page 12a-14. 5.
Page 237 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 238 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 239 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Battery 5. Remove the battery hold-down clamp from the battery and remove. See following WARNING. ∆ 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 240 ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Battery Battery Installation See General Warning, Section 1, Page 1-1 and DANGER on page 12a-28. 1. Place the battery into the vehicle with the battery posts facing the engine. 2. Secure the battery to the vehicle with the clamp and install bolt, washer and lock nut and tighten to 12 ft-lb (16.3 N·m).
Page 241: Ground Cables
ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Ground Cables ∆ WARNING • Do not jump-start a dead battery using another battery and jumper cables. GROUND CABLES Testing the Ground Cables See Test Procedure 3, Section 11a, Page 11a-18. 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 12a-33...
Page 243: Section 12B - Electrical Components: Fe350, Pedal-Start Engine
SECTION 12B – ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. EARLIER CABLE MOUNTING HARDWARE AS SEEN FROM PASSENGER'S SIDE OF VEHICLE REMOVE NEGATIVE DISCONNECT BATTERY CABLES CABLE FIRST...
Page 244 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator A1 TERMINAL TERMINAL TERMINAL TO BATTERY GROUND POST Figure 12b-2 Starter/Generator Removal Disassembly of the Starter/Generator to Service the Brushes 1. Remove the two bolts (20) and pull commutator end cover (23) free of starter/generator housing (24) (Figure 12b-3, Page 12b-2).
Page 245 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator Brush Inspection and Replacement 1. Visually inspect brushes. Replace brushes that are cracked or severely chipped. 2. Check the wear line on the side of the brush. If the end of the brush is within 1/16-inch (1.6 mm) of the wear line, replace all four brushes (Figure 12b-5, Page 12b-3).
Page 246 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator Starter/Generator Assembly 1. Connect the brush wires to the holders using four lock washers (26) and four screws (25). Make sure the crossover leads are also connected. Tighten screws to 31 in-lb (3.4 N·m) (Figure 12b-4, Page 12b-2). 2.
Page 247 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator Figure 12b-8 Armature and Output End Cover Assembly Figure 12b-9 Bearing Play Inspection Bearing Removal 1. Place the wedge attachment tool (CCI P/N 1012812) between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller (CCI P/N 1012811) to the wedge attachment tool and pull bearing off of the end of the armature shaft.
Page 248 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator Field Coil Removal, Continued: WEDGE ATTACHMENT BEARING PRESS RAM USE A 1/2-INCH TOOL PULLER SOCKET OR PIPE SUPPORT TOOL INNER RACE OF BEARING PRESS ON ARMATURE SHAFT USE A WEDGE 1/2-INCH ATTACHMENT SOCKET TOOL OR PIPE NOTE: BEARING IS SECTIONED FOR CLARITY...
Page 249 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator • Worn armature bearing or shaft • Dirty or oily commutator Commutator Cleaning and Inspection 1. Clean the carbon dust, dirt and oil from the commutator. Slight roughness of the commutator can be pol- ished away with 400 grit (or ﬁner) sandpaper.
Page 250 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator ARMATURE WAVETEK 1000 2000 200k Ω COMMUTATOR Ω 200nA 1000 --- FUSED 750V ARMATURE SHAFT Figure 12b-13 Armature Ground Test Starter/Generator Rework Any rework must be performed by a qualiﬁed technician. Starter/Generator service speciﬁcations are listed in the following table.
Page 251 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator 3. Install the four pole pieces into the housing. Use the four screws to secure pole pieces to the inside of the housing to retain the ﬁeld wires. Tighten screws to 9 ft-lb (12.2 N·m) (Figure 12b-11, Page 12b-6). 4.
Page 252 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Starter/Generator Starter/Generator Installation, Continued: TYPICAL 2 PLACES END VIEW Figure 12b-14 Starter/Generator Assembly Figure 12b-15 Belt Tension Gauge Belt Tension Adjustment Belt tension should be checked periodically. If the belt slips when starter/generator motor operates, adjust belt to correct tension.
Page 253: Voltage Regulator
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Voltage Regulator VOLTAGE REGULATOR See General Warning, Section 1, Page 1-1. Testing the Voltage Regulator See Test Procedure 11, Section 11b, Page 11b-24. Voltage Regulator Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 254: Key Switch
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Key Switch KEY SWITCH See General Warning, Section 1, Page 1-1. Testing the Key Switch See Test Procedure 17, Section 11b, Page 11b-32. Also see Test Procedure 4 – Key Switch (Starter Circuit) on page 11b-19. Key Switch Removal 1.
Page 255: Solenoid
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Solenoid Figure 12b-18 Center Dash Panel Removal SOLENOID See General Warning, Section 1, Page 1-1. Testing the Solenoid See Test Procedure 6, Section 11b, Page 11b-20. Solenoid Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 256: Fuse
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Fuse Solenoid Installation, Continued: 2.3. Connect the 18-gauge blue wire from the key switch to the small post on the solenoid. 2.4. Connect the 18-gauge orange wire from the accelerator pedal limit switch to the other small post on the solenoid.
Page 257 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Kill Limit Switch Kill Limit Switch Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Disconnect the battery cables as instructed (Figure 12b-1, Page 12b-1). See WARNING "To avoid unintentionally starting..."...
Page 258: Neutral Lockout Limit Switch
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Neutral Lockout Limit Switch NEUTRAL LOCKOUT LIMIT SWITCH See General Warning, Section 1, Page 1-1. Testing the Neutral Lockout Limit Switch See Test Procedure 7, Section 11b, Page 11b-22. Neutral Lockout Limit Switch Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 259: Neutral Lockout Cam
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Neutral Lockout Cam NEUTRAL LOCKOUT CAM See General Warning, Section 1, Page 1-1. If the cam lobes have worn to the point where they will no longer actuate the lockout cam limit switch, the cam must be replaced.
Page 260: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Reverse Buzzer Limit Switch Reverse Warning Buzzer Installation, Continued: 4. Install the dash in reverse order of removal. See Key Switch Removal on page 12b-12. 5. 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 261: Oil Warning Light
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Oil Warning Light 3. Place the Forward/Reverse handle in REVERSE to make sure that both switches actuate. 4. Connect the orange wire to the common (COM) black wire terminal and the red/white wire to the normally open (NO) blue wire terminal of the reverse buzzer limit switch (4) (Figure 12b-20, Page 12b-16).
Page 262: Fuel Gauge/Hour Meter
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Fuel Gauge/Hour Meter Oil Warning Light Installation 1. Push a new unit into hole in dash until plastic tabs engage dash (Figure 12b-23, Page 12b-19). 2. Connect yellow wire from the key switch and yellow wire from the oil level sensor to the oil light. 3.
Page 263: Fuel Level Sending Unit
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Fuel Level Sending Unit FUEL LEVEL SENDING UNIT See General Warning, Section 1, Page 1-1. The fuel level sending unit is an integral part of the fuel tank and should never be removed. Thoroughly test the fuel level sending unit before replacement of fuel tank.
Page 264: Ignition Coil
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Ignition Coil RPM Limiter Installation, Continued: RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK FEMALE BULLET KILL CIRCUIT WIRE TERMINAL BLACK WIRE Figure 12b-24 RPM Limiter Assembly IGNITION COIL See General Warning, Section 1, Page 1-1. The ignition coil is located under the ﬂywheel shroud of the engine.
Page 265 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Ignition Coil 8. Loosen, but do not remove, the three bolts (6) attaching the fan housing as shown. 9. Remove the remaining four bolts (10) attaching the fan housing (Figure 12b-25, Page 12b-23), then while opening the housing, detach the spark plug wire grommet (4) from the housing (Figure 12b-27, Page 12b-24).
Page 266 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Ignition Coil Ignition Coil Installation, Continued: 11. Connect the 18-gauge black wire (12) to the spade terminal (13) on the coil (Figure 12b-26, Page 12b-23). 12. Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch on the housing.
Page 267: Oil Level Sensor
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Oil Level Sensor OIL LEVEL SENSOR See General Warning, Section 1, Page 1-1. Testing the Oil Level Sensor See Test Procedure 21, Section 11b, Page 11b-34. Oil Level Sensor Removal See Oil Level Sensor Installation, Section 13, Page 13-5. Oil Level Sensor Installation See Oil Level Sensor Installation, Section 13, Page 13-5.
Page 268: Headlight Diode
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Headlight Diode Headlight Bulb Installation NOTE: When handling halogen bulbs, do not touch glass portion of bulb. oil from ﬁnger tips can cause pre- mature failure of bulb. 1. Connect wire harness (4) to the halogen bulb assembly (6). The retaining tab should lock onto the halo- gen bulb assembly (Figure 12b-29, Page 12b-25).
Page 269: Light Switch
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Light Switch 2. Connect the black/white wire from the harness to the negative (–) terminal on the diode. 3. Connect the solid black wire from the ground terminal block to the positive (+) terminal on the diode. 4.
Page 270 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 271 ELECTRICAL COMPONENTS: FE350, PEDAL-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 272: Charging The Battery
ELECTRICAL COMPONENTS: FE350, PEDAL-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 273 ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Battery Battery Installation General Warning, Section 1, Page 1-1 and DANGER on page 12b-27. 1. Place the battery into the vehicle with the battery posts 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 274: Ground Cables
ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE Ground Cables ∆ WARNING • Do not jump-start a dead battery using another battery and jumper cables. GROUND CABLES Testing the Ground Cables See Test Procedure 3, Section 11b, Page 11b-18. Page 12b-32 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 275: Section 13 - Fe350 And Fe400 Engines
SECTION 13 – FE350 AND FE400 ENGINES ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION See General Warning, Section 1, Page 1-1. The Turf/Carryall 272 model vehicles are powered by one of two engine models: FE350 or FE400. The FE350 powers the ’pedal-start’...
Page 276: Spark Plug
FE350 AND FE400 ENGINES General Information SPARK PLUG Spark plugs are selected to suit speciﬁc engine design and vehicle operating conditions. The spark plug (CCI P/N 101881101) is designed for both the FE350 and FE400 engines, providing maximum life and efﬁcient combustion of fuel.
Page 277: Cylinder
FE350 AND FE400 ENGINES Cylinder CYLINDER See General Warning, Section 1, Page 1-1. Test cylinder compression using a standard compression tester. Low compression would normally indicate a problem in the cylinder assembly such as defective rings, gaskets, etc. • Key-Start Engines: Both FE350 and FE400 model engines are equipped with an automatic compres- sion release valve (ACR).
Page 278: Crankcase Cover Removal
FE350 AND FE400 ENGINES Crankcase Engine Removal, Continued: 4. Remove mufﬂer. See Mufﬂer Removal, Section 15, Page 15-1. 5. Remove engine mounting hardware (items 1, 2, 5 and 6) (Figure 13-1, Page 13-4). 6. Lift engine from the mounting plate. 7.
Page 279: Oil Level Sensor
FE350 AND FE400 ENGINES Crankcase STARTER/ GENERATOR Figure 13-2 Oil Level Sensor Wire Figure 13-3 Crankcase Cover OIL LEVEL SENSOR Testing the Oil Level Sensor See Test Procedure 21 – Oil Level Sensor on page 11a-36. Or see Test Procedure 21 – Oil Level Sensor on page 11b-34.
Page 280: Ignition Coil And Flywheel
FE350 AND FE400 ENGINES Ignition Coil and Flywheel IGNITION COIL AND FLYWHEEL See General Warning, Section 1, Page 1-1. Ignition Coil and Flywheel Removal 1. Loosen three screws and remove the remaining four screws attaching the ﬂywheel housing as shown, then remove the housing (Figure 13-5, Page 13-6).
Page 281: Crankcase Cover Installation
FE350 AND FE400 ENGINES Flywheel Installation 0.012 inch (0.304 mm) Figure 13-7 Flywheel Nut Removal Figure 13-8 Adjust Ignition Coil Air Gap CRANKCASE COVER INSTALLATION CAUTION • Before assembly, make sure parts are clean. • Do not reuse the gasket. Install a new one. •...
Page 282: Engine Installation
FE350 AND FE400 ENGINES Engine Installation Flywheel Installation, Continued: CAUTION • The ﬂywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to loosen. • 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.
Page 283: Torque Specifications
FE350 AND FE400 ENGINES Engine Installation 11. 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). 12. Adjust the engine RPM setting. See Engine RPM Adjustment, Section 14, Page 14-11. 12.1.
Page 285: Section 14 - Fuel System
SECTION 14 – FUEL SYSTEM ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The FE350 and FE400 engines are equipped with a ﬂoat bowl type carburetor with ﬁxed jets that require no adjustment.
Page 286: 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 287 FUEL SYSTEM Carburetor 1.10. Remove the carburetor retaining nuts (19), intake pipe (17) and carburetor (12). See following NOTE. NOTE: Note the orientation of the gasket (16), between the carburetor intake pipe (17) and the carburetor body (12) so that it can be replaced in the same orientation (Figure 14-2, Page 14-4). Disconnect the throttle return spring (11).
Page 288 FUEL SYSTEM Carburetor Changing the Main Jet, Continued: EARLIER STYLE GOVERNOR CABLE END CURRENT STYLE GOVERNOR CABLE TYPICAL 2 PLACES Figure 14-2 Carburetor Installation Page 14-4 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 289 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 290: Engine Control Linkage
FUEL SYSTEM Engine Control Linkage Changing the Main Jet, Continued: 22. Install the intake hose (23) and secure with hose clamp (22). NOTE: Make sure the intake hose is not twisted during installation. 23. Turn fuel shut-off valve (on fuel tank) to the ON position (Figure 14-21, Page 14-29, and Figure 14-22, Page 14-30).
Page 291 FUEL SYSTEM Engine Control Linkage Figure 14-4 Accelerator Rod Accelerator Rod Installation and Adjustment 1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Adjust accelerator pedal position. See Accelerator Pedal Adjustment, Section 5, Page 5-6. 3.
Page 292: Governor Cable
FUEL SYSTEM Engine Control Linkage Accelerator Rod Installation and Adjustment, Continued: 8.1. Pedal-Start vehicles: 8.1.1. Press the accelerator pedal 4° to 8°. The starter solenoid should click, indicating activation. Continue to press the accelerator pedal 8° to 12°. The carburetor throttle should begin to actuate.
Page 293: Accelerator Cable
FUEL SYSTEM Engine Control Linkage 6. Use a 1/8-inch punch or scratch awl to turn the governor arm shaft counterclockwise until it stops. Then pull the governor lever arm rearward until the carburetor throttle is in the “wide open throttle” (WOT) posi- tion.
Page 294: Closed Throttle Or Idle Adjustment
FUEL SYSTEM Engine Control Linkage Accelerator Cable Removal, Continued: 6. Remove the E-ring (7) on the spring end of the cable at the accelerator cable bracket (5) (Figure 14-8, Page 14-12). Pull the cable housing out of the bracket. 7. Disconnect the spring (16) from the engine governor arm by rotating the arm counterclockwise one-half turn.
Page 295: Engine Rpm Adjustment
FUEL SYSTEM Engine Control Linkage IDLE SCREW Figure 14-7 Idle Screw ENGINE RPM ADJUSTMENT ∆ DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 1.
Page 296 FUEL SYSTEM Engine Control Linkage EARLIER STYLE CURRENT STYLE TYPICAL 2 PLACES EARLIER STYLE EARLIER STYLE CURRENT STYLE Figure 14-8 Governor and Accelerator Cables Page 14-12 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 297: Choke And Air Intake System
FUEL SYSTEM Choke and Air Intake System CHOKE AND AIR INTAKE SYSTEM See General Warning, Section 1, Page 1-1. CHOKE CABLE REMOVAL 1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
Page 298: Intake Duct Repair
FUEL SYSTEM Choke and Air Intake System Air Box Installation, Continued: 2.2. Place hose (16) onto air box top (4) and secure with wire clamp (15). 2.3. Attach choke cable (18) to the air box top (4). See Choke Cable Installation on page 14-13. 3.
Page 299: Intake Duct Installation
FUEL SYSTEM Choke and Air Intake System 2.5. Remove the front wheels. 2.6. Remove the bolt (1) that connects the steering joint to the steering column shaft (Figure 14-9, Page 14-14). See following NOTE. NOTE: The bolt must be removed completely before the splined coupling can be separated. Make an alignment mark on the steering column shaft and the steering joint for use during replace- ment.
Page 300 FUEL SYSTEM Choke and Air Intake System Intake Duct Installation, Continued: NOTE: It is best to have a second person guide the air box end of the duct into position as it is pushed from the front of the vehicle. Insert the end of the intake duct through the slot in the front of the air box mounting plate.
Page 301: Air Filter
• 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 302: Fuel Filter Installation
FUEL SYSTEM Fuel Pump FUEL FILTER INSTALLATION CAUTION • Fuel ﬁlters are marked with ﬂow direction arrows. Make sure that ﬁlters are installed with arrows pointing in the direction of fuel ﬂow from tank to carburetor. 1. Install the primary fuel ﬁlter (17) in reverse of removal. Use new clamps (16) (Figure 14-16, Page 14-26 or Figure 14-17, Page 14-27).
Page 303: Fuel Pump Disassembly
FUEL PUMP DISASSEMBLY NOTE: A fuel pump rebuild kit is available from Club Car (CCI P/N 1014524). 1. Remove four screws (24) and lock washers (25) from front of the fuel pump (Figure 14-10, Page 14-19).
Page 304 FUEL SYSTEM Fuel Pump REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 14-12 Turf/Carryall 272 Air Intake and Choke Assemblies Page 14-20 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 305 FUEL SYSTEM Fuel Pump REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 14-13 Carryall 472 Air Intake and Choke Assemblies 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 14-21...
Page 306: Fuel Pump Cleaning And Inspection
FUEL SYSTEM Fuel Pump FUEL PUMP CLEANING AND INSPECTION 1. Use a nonﬂammable solvent to clean the front cover, pumping chamber and back cover. Be sure the vent on the front cover is clean both inside and out. 2. Inspect the valve assemblies (31, 32, and 33), gaskets and diaphragms for damage (Figure 14-10, Page 14-19).
Page 307: Fuel Tank
FUEL SYSTEM Fuel Tank ∆ DANGER • Repair any fuel leaks before using the vehicle. FUEL TANK See General Warning, Section 1, Page 1-1. ∆ WARNING • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure.
Page 308: Fuel Tank Storage Or Disposal
FUEL SYSTEM Fuel Tank Fuel Tank Removal, Continued: 8. Loosen, but do not remove, the carburetor drain screw (11) (Figure 14-3, Page 14-5) and drain fuel remaining in the carburetor bowl into an approved container. 9. Use a siphon with a suction device and siphon all fuel out of the tank and into an approved container. See following DANGER and WARNING.
Page 309: Fuel Tank Installation
FUEL SYSTEM Fuel Tank FUEL TANK INSTALLATION 1. Turf/Carryall 272: 1.1. Position the retaining straps (13 and 10) and install the fuel tank (Figure 14-16, Page 14-26). 1.1.1. Position the straps in the indentions on the tank. 1.2. Install the screws (12 and 14) into the speed nuts (11) and tighten screws to 25 in-lb (2.8 N·m) (Figure 14-16, Page 14-26).
Page 310 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 311 FUEL SYSTEM Fuel Tank SEE ABOVE GAS TANK FUEL PICKUP TUBE TYPICAL 2 PLACES ROUTING LENGTH FUEL LINE Solid Color Clear Fuel tank to primary fuel filter 2.5 in. (6.4 cm) Primary fuel filter to fuel pump 46.5 in. (118.1 cm) Fuel pump to secondary fuel filter 10.15 in.
Page 312: Fuel Lines
FUEL SYSTEM Fuel Lines Fuel Tank Installation, Continued: 11. Start the engine and allow it to idle. 11.1. Pedal-Start vehicles: 11.1.1.Place the neutral lockout cam in the MAINTENANCE position. 11.1.2.Turn the key switch to the ON position. 11.1.3.Press the accelerator pedal to start the engine, and idle. See following DANGER. 11.2.
Page 313: Fuel Shut-Off Valve
FUEL SYSTEM Fuel Shut-Off Valve ∆ WARNING • Make sure fuel lines are the right length and are properly routed. Failure to heed this warning could result in damage to fuel lines and ﬁre. Fuel line no. 1 runs directly from the fuel tank to the primary fuel ﬁlter (17). Arrow indicates ﬂow (Figure 14-16, Page 14-26 or Figure 14-17, Page 14-27).
Page 314 FUEL SYSTEM Fuel Shut-Off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 14-22 Incorrect Fuel Shut-off Valve Page 14-30 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 315: Section 15 - Exhaust System
SECTION 15 – EXHAUST SYSTEM ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. MUFFLER MUFFLER REMOVAL NOTE: The following procedure is the same for both FE350 and FE400 engines. 1.
Page 316 EXHAUST SYSTEM Muffler Mufﬂer Installation, Continued: 8. Connect the spark plug wire. 9. 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). 10.
Page 317 EXHAUST SYSTEM Muffler TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 15-1 Exhaust System – FE400 Engine 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual Page 15-3...
Page 318 EXHAUST SYSTEM Muffler TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 15-2 Exhaust System – FE350 Engine Page 15-4 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 319: Section 16 - Mc012C-As00 Unitized Transaxle With Differential Lock
SECTION 16 – MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The Turf/Carryall 272 and Carryall 472 vehicle are equipped with a heavy-duty, fully-synchronized unitized transaxle with differential lock.
Page 320: Lubrication
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK General Information Shifter Lever A shifter lever, connected to a shifter arm, is used to change the gears to one of three shift positions: FOR- WARD (F), NEUTRAL (N), or REVERSE (R) (Figure 16-2, Page 16-2). Bring the vehicle to a complete stop before changing FORWARD or REVERSE direction.
Page 321: Axle Shaft
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Neutral Lockout • Pedal-Start Vehicles: During normal vehicle operation, the neutral lockout feature prevents the engine from running when the Forward/Reverse handle is in the NEUTRAL position. If the vehicle is started in FORWARD or REVERSE and then shifted to NEUTRAL, the engine will stop running.
Page 322 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft Axle Shaft, Bearing, and Oil Seal Removal, Continued: 5. To remove the wheel bolt ﬂange on the MC012C transaxle (Figure 16-5, Page 16-4): 5.1. Remove rubber boot (26) from large ﬂat washer (23). 5.2.
Page 323: Axle Shaft, Bearing, And Oil Seal Installation
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Axle Shaft AXLE SHAFT, BEARING, AND OIL SEAL INSTALLATION 1. Replace the old oil seal with a new seal (89). Make sure the axle tube hub is free of debris. 2. Replace the old bearing with a new bearing (88). Slip the new bearing onto the machined journal, adja- cent to the machined seal hub on the end of the axle (Figure 16-8, Page 16-6).
Page 324: Unitized Transaxle Removal
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal TYPICAL 8 PLACES Figure 16-8 Differential Axle and Wheel Hub Assembly UNITIZED TRANSAXLE REMOVAL See General Warning, Section 1, Page 1-1. ∆ WARNING • To perform this procedure, the hydraulic system must be opened. As a result, the brakes must be bled after the correct reinstallation of the brake components.
Page 325 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal CLAMP Figure 16-9 Carburetor Vent Tube 4.2. Disconnect the air intake hose from the carburetor (Figure 16-10, Page 16-7). 4.3. Disconnect impulse line from fuel pump (Figure 16-11, Page 16-7). CLAMP IMPULSE LINE Figure 16-10 Air Intake Hose Figure 16-11 Impulse Line...
Page 326 MC012C-AS00 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 16-12 Differential Lock Cable Bracket 1. Apply pressure to locking tabs of the cable.
Page 327 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal TOP VIEW Loosen retaining nuts to remove Remove fuel line. accelerator cable from electric box. Figure 16-14 Fuel Line Figure 16-15 Accelerator Cable ENGINE GROUND TOP VIEW RETAINING NUT SPRING RELEASE NUTS Figure 16-16 Engine Ground Wire Figure 16-17 Shifter Cable...
Page 328 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: STARTER/ GENERATOR YELLOW YELLOW WHITE OIL LEVEL SENSOR JUMPER WIRE GROUND Figure 16-18 Generator Wires Figure 16-19 Oil Level Sensor Jumper Wire WHITE/BLACK WIRE BLACK WIRE Figure 16-20 Engine Kill Switch Wire 5.15.
Page 329 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal PLASTIC WIRE TIE FLEX BRAKE HOSE Figure 16-21 Cover Brake Hose Fitting CABLE SUPPORT BRACKET Figure 16-22 Park Brake Cable Figure 16-23 Brake Hose 8. Use a hydraulic jack under the transaxle (Figure 16-25, Page 16-12) and raise the vehicle. Place jack stands, set at approximately 17-1/2 inches (44.5 cm) in height, under the frame (Figure 16-26, Page 16-12).
Page 330 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Figure 16-24 Shock Absorbers PROPER POSITIONING PROPER POSITIONING OF FLOOR JACK OF JACK STANDS APPROX. 17-1/2" (44.5 cm) Figure 16-25 Raise Vehicle Figure 16-26 Position Jack Stands Page 16-12 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 331 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal REMOVE BOLTS, THEN ROTATE SHACKLES UP AND AWAY FROM SPRINGS. Figure 16-27 Spring Retainer Bolts Figure 16-28 Rear Shackles 13. Carefully lift the snubber out of the snubber bracket in the vehicle frame and lower it to the ﬂoor (Figure 16-29, Page 16-13).
Page 332 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Removal Unitized Transaxle Removal, Continued: 17. Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle (Figure 16-33, Page 16-14). 18. Loosen, but do not remove, the governor arm retaining bolt. Remove the governor arm from the shaft (Figure 16-34, Page 16-14).
Page 333: Unitized Transaxle Installation
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation BRACKET Figure 16-35 Accelerator Cable Bracket Figure 16-36 Forward/Reverse Shifter Bracket TRANSAXLE MOUNTING BOLT AND NUT (TYPICAL 4 PLACES) WOODEN BLOCKS TRANSAXLE MOUNTING NUTS (TYPICAL 2 PLACES) Figure 16-37 Differential Lock Arm and Bracket Figure 16-38 Transaxle Mounting UNITIZED TRANSAXLE INSTALLATION See General Warning, Section 1, Page 1-1.
Page 334 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 6. Install the differential lock cable and bracket. 6.1. Connect the differential lock cable spring (1) to the differential lock arm on the housing (Figure 16-40, Page 16-16). 6.2.
Page 335 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation 11. Install the key onto the input shaft (Figure 16-47, Page 16-19). 12. Position the driven clutch on the transaxle input shaft and install the washer (yellow side facing out) and mounting bolt and tighten to 14 ft-lb (19.0 N·m) (Figure 16-47, Page 16-19).
Page 336 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Figure 16-44 Shock Absorber Figure 16-45 Leaf Springs Figure 16-46 Leaf Springs and Shackles Page 16-18 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 337 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation SNUBBER SNUBBER BRACKET Figure 16-47 Driven Clutch Figure 16-48 Snubber 19. Connect the park brake cables. See Park Brake Cable Installation, Section 6, Page 6-34. 20. Use a 3/8-inch ﬂare nut wrench to connect the brake hoses to the left and right rear brake clusters and bleed the air from the brake lines.
Page 338 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 25. Connect the 6-gauge white wire to the F2 post and the 6-gauge black ground wire to the A2 post of the starter generator and tighten to 48 in-lb (5.4 N·m). Connect the 16-gauge yellow wire to the DF post and tighten to 30 in-lb (3.4 N·m) (Figure 16-51, Page 16-20).
Page 339 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation TOP VIEW CLAMP ACCELERATOR CABLE Figure 16-54 Connect Cable to Cam Figure 16-55 Connect Fuel Line 28. Connect accelerator cable to actuator cam in the electrical box. Position the accelerator cable in mount- ing slot in the wall of the electrical box and tighten mounting nuts to 18 in-lb (2.0 N·m) (Figure 16-54, Page 16-21).
Page 340 MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation Unitized Transaxle Installation, Continued: CLAMP Figure 16-58 Carburetor Vent Tube 34. Install transaxle drain plug and tighten to 21 ft-lb (28.5 N·m). 35. Fill transaxle with 29 oz. (.85 liter) 80-90 WT. API Class GL-3 or 80-90 WT. AGMA Class 5 EP gear lubri- cant.
Page 341: Forward/Reverse Shifter Cable
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Forward/Reverse Shifter Cable Push cable into the bracket. Figure 16-60 Differential Cable Installation TOP VIEW SHIFTER SHIFTER F N R LEVER Figure 16-61 Forward/Reverse Positions FORWARD/REVERSE SHIFTER CABLE See General Warning, Section 1, Page 1-1. If the Forward/Reverse shifter cable is damaged in any way, it must be replaced.
Page 342: Forward/Reverse Shifter Cable Installation
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Forward/Reverse Shifter Cable FORWARD/REVERSE SHIFTER CABLE INSTALLATION 1. Route the cable to the transaxle shifter lever, beginning at the Forward/Reverse shifter. 2. Secure the cable with retaining nut (5) on each side of the shifter cable support bracket at the transaxle (Figure 16-62, Page 16-24) and tighten nuts to 22 ft-lb (29.8 N·m).
Page 343: Forward/Reverse Shifter Cable Adjustment
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Differential Lock System FORWARD/REVERSE SHIFTER CABLE ADJUSTMENT Place the shifter lever in the NEUTRAL position (straight up) (Figure 16-61, Page 16-23). For minor adjust- ments, the nut (1) may be loosened and the ball joint socket (2) rotated to get the proper adjustment (Figure 16-62, Page 16-24).
Page 344: Differential Lock Cable Removal
MC012C-AS00 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 16-63, Page 16-27). 3. Use a pair of pliers and apply pressure to the locking tabs of the cable end (1) where it attaches to the differential lock handle mounting bracket (Figure 16-12, Page 16-8).
Page 345 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 347: Section 17 - Torque Converter
SECTION 17 – TORQUE CONVERTER ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. To provide optimum perfor- mance for the OHV engines and powertrain, the vehicle uses a pair of tuned clutches.
Page 348 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 349: Troubleshooting
Maintaining proper adjustment of each of these is critical to the overall performance of the vehicle. If the engine and governor adjustments are within Club Car speciﬁcations but, 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 350: Drive Belt Installation
TORQUE CONVERTER Drive Clutch Drive Belt Removal, Continued: 4. Grasp the belt midway between the drive and driven clutches. Lift upward on the belt to force the sheaves of the driven clutch apart, then roll the belt off the driven clutch by rotating the clutch counterclockwise (Figure 17-2, Page 17-3).
Page 351: Drive Clutch Cleaning And Inspection
Drive Clutch CAUTION • Do not hit or tap the clutch with a hammer. Do not pry the clutch. These actions will damage the clutch. Use Club Car clutch holder while tightening or loosening drive VEHICLE BODY clutch retaining bolt.
Page 352: Drive Clutch Disassembly
TORQUE CONVERTER Drive Clutch DRIVE CLUTCH DISASSEMBLY CAUTION • The drive clutch is balanced as an assembly. Before disassembly, make match marks on the clutch cover and on the moveable face assembly so they can be reassembled in the same positions (Figure 17-5, Page 17-6).
Page 353: Inspection Of Drive Clutch Parts
TORQUE CONVERTER Drive Clutch 5. Remove the clutch weights. 5.1. Remove the screws and ﬂat washers attaching the weights (Figure 17-9, Page 17-9). 5.2. Pull the weight assemblies, with pins, from the clutch. 5.3. Remove the plastic washers, weights and wave washer from the pins. Before removing, note the orientations of the wave washer and of the primary and secondary weights to one another (Figure 17-12, Page 17-10 and Figure 17-13, Page 17-10).
Page 354 TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES Figure 17-7 Drive Clutch Assembly Page 17-8 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 355 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 Use a scribe to remove PRESS RAM spiral back-up rings from both...
Page 356: Drive Clutch Assembly
TORQUE CONVERTER Drive Clutch DRIVE CLUTCH ASSEMBLY 1. Press idler bearing (3) onto the shaft of the ﬁxed face assembly (2). Press on the inner race of the bearing only. Make sure that the cup side of bearing is facing away from the ﬁxed face (Figure 17-7, Page 17-8). 2.
Page 357: Drive Clutch Installation
TORQUE CONVERTER Drive Clutch 11. Install the weight assemblies into the slots in the hub casting (Figure 17-9, Page 17-9). Make sure the mounting pin protrudes an equal amount on each side of the weights when the assemblies are in position (Figure 17-14, Page 17-11).
Page 358: Driven Clutch
TORQUE CONVERTER Driven Clutch Drive Clutch Installation, Continued: DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED Figure 17-15 Correct Orientation of Drive Button Take-up Spring 4. Install the drive belt as instructed. See Drive Belt Installation on page 17-4. 5. Connect the spark plug wire. 6.
Page 359: Driven Clutch Disassembly
TORQUE CONVERTER Driven Clutch 3. Disconnect the spark plug wire. See WARNING "To avoid unintentionally starting..." in General Warning, Section 1, Page 1-2. 4. Remove the drive belt as instructed. See Drive Belt Removal on page 17-3. 5. Remove the bolt (11) and mounting washer (12) from the clutch shaft (Figure 17-16, Page 17-14). 6.
Page 360 TORQUE CONVERTER Driven Clutch TYPICAL 3 PLACES Figure 17-16 Driven Clutch Assembly Page 17-14 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 361 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 5.1.
Page 362 TORQUE CONVERTER Driven Clutch Driven Clutch Assembly, Continued: CAM PRESS TOOL Figure 17-19 Cam Press Tool Figure 17-20 Cam Installation Tool 5.2.1. With the clutch loosely assembled, set the edge of the clutch body (5) on a clean, ﬂat sur- face.
Page 363: Driven Clutch Installation
TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH INSTALLATION 1. To install the driven clutch, reverse the removal procedure. Make sure that the washer (12) is mounted with the ﬂat portion of the washer against the driven clutch as shown (Figure 17-16, Page 17-14). Secure with a new bolt bolt (11).
Page 365 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. bumper, tube installation ............4-2 accelerator removal ............. 4-2 pedal adjustment ............ 5-6 removal ............5-5 cargo bed air filter .............. 14-17 axle bumper adjustment .........
Page 366 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. exhaust system headlights muffler .............. 15-1 see also lighting circuit installation ........... 15-1 testing ............11a-41 removal ............15-1 hour meter see fuel gauge/hour meter hydrometer test ..........11a-15 fender, front...
Page 367 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. assembly ..........12a-4, 12a-8 belt tension adjustment ....... 12a-10 neutral lockout field coil see lockout cam inspection ..........12a-8 installation .............
Page 368 INDEX – KEY-START VEHICLES This index applies to key-start vehicles only. Refer to pedal-start index for references pertaining to pedal-start vehicles. lockout cam limit switch ....... 11a-21 low oil warning light ........11a-36 oil level sensor ..........11a-36 reverse buzzer ..........11a-35 reverse buzzer limit switch ......
Page 369 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. wheel cylinder, front removal ............6-19 accelerator bumper, tube pedal installation ............4-2 adjustment ............ 5-6 removal ............. 4-2 limit switch testing ........
Page 370 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. exhaust system muffler .............. 15-1 headlight switch installation ........... 15-1 testing ............11b-38 removal ............15-1 headlights see also lighting circuit testing ............11b-40 fender, front hour gauge...
Page 371 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. spark plug gap adjustment ..........13-2 neutral lockout specifications see also lockout cam vehicle ............... 2-1 starter/generator testing ............. 11b-35 armature circuit ground test ..........
Page 372 INDEX – PEDAL-START VEHICLES This index applies to pedal-start vehicles only. Refer to key-start index for references pertaining to key-start vehicles. headlight switch ........... 11b-38 hour meter ........... 11b-37 ignition coil ........... 11b-27 ignition test ..........11b-26 key switch engine kill circuit ........11b-32 starter circuit ...........
Page 373 2003-2004 Turf/Carryall 272/472 Gasoline Vehicle Maintenance and Service Manual...
Page 376 Club Car, Inc. www.clubcar.com Phone 1.706.863.3000 P.O. Box 204658 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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Carryall 272 2003 Carryall 472 2003 Turf 272 2004 Carryall 272 2004 Carryall 472 2004