Club Car EX40D Setup guide

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

1. SPECIFICATIONS............................................... 1
2. GENERAL DESCRIPTION OF ENGINE COMPONENTS ................ 2
3. DISASSEMBLY AND REASSEMBLY ............................... 6
3-1 PREPARATIONS AND PRECAUTIONS ........................... 6
3-2 SPECIAL TOOLS............................................. 6
3-3 DISASSEMBLY PROCEDURE .................................. 7
3-4 REASSEMBLY PROCEDURE ................................... 19
4. ENGINE OIL ................................................... 32
5. IGNITION SYSTEM .............................................. 33
6. WIRING DIAGRAM .............................................. 33
7. OIL SENSOR................................................... 34
8. TROUBLESHOOTING ........................................... 35
9. ELECTRIC FUEL INJECTION SYSTEM ............................. 41
10. STANDARD REPAIR TABLES .................................... 49
10-1 STANDARD DIMENSIONS AND LIMITS OF USE .................. 49
10-2 SERVICE DATA (The following are only for your reference.)........... 54
10-3 TIGHTENING TORQUE....................................... 55
10-4 AIR GAP AND CLEARANCE ................................... 55
11.PERIODIC MAINTENANCE ....................................... 56
CONTENTS
Section Title Page

- 1 -
1. SPECIFICATIONS
*Specifications are subject to change without notice.
Model EX40D
Type Air-Cooled, 4-Cycle, Slant Single-Cylinder,
Horizontal P.T.O. Shaft, OHC Gasoline Engine
Bore & Stroke mm (in.) 89 × 65 (3.50 × 2.56)
Piston Displacement ml (cu.in.) 404 (24.65)
Compression Ratio 8.3
Maximum Output kW(HP)/r.p.m. per SAE J 1940 10.4 (14)/3600
Maximum Torque
N・m / r.p.m.
(kgf・m / r.p.m.)
(ft・lb. / r.p.m.)
27/2400
(2.8/2400)
(19.91/2400)
Direction of Rotation Counterclockwise as viewed from the P.T.O. shaft side
Cooling System Forced air cooling system
Lubrication System Splash lubrication system
Lubricant
Automobile engine oil ; Grade SE or higher (SG,SH or SJ in recomended)
SAE 10W-30-----Under ordinary atmospheric temperatures
SAE 5W-30-------In cold areas
Capacity of Lubricant L 1.2 (1.3 qt.)
Fuel system Throttle body single point injection
Fuel type Automobile unleaded gasoline
Fuel Supply System Regulated pressure with electric fuel pump type
Ignition System Flywheel magneto digital C.D.I.
Spark Plug NGK BR-6HS
Starting System Starter / Generator
Governor System None (Vehicle speed control)
Dry Weight kg (lb.) Approx. 24.4 (53.6)
Dimensions (L x W x H) mm (in.) 351 x 451 x 340 (13.8 x 17.8 x 13.4)

- 2 -
2. GENERAL DESCRIPTION OF ENGINE COMPONENTS
2-1 CYLINDER AND CRANKCASE
The cylinder and crankcase are aluminum die-casting
as a single piece. A special cast iron cylinder liner is
molded into the aluminum die-casting.
The crankcase has a mounting surface on the output
shaft side to which the main bearing cover is attached.
The cylinder is inclined to the right at an angle of 25
degrees from the horizontal as viewed from the output
shaft side.
2-2 MAIN BEARING COVER
The main bearing cover is an aluminum die-casting,
which is mounted on the output shaft side of the
crankcase. By removing the main bearing cover,
the
inside of the engine can be inspected with ease.
Pilots and bosses are machined into the cover
to facilitate the direct coupling of the engine with
machines such as generators and pumps.
Oil gauges (fillers) are on both sides of the cover for
easy maintenance.
2-3 CRANKSHAFT
The crankshaft is forged carbon steel, and the crank
pin is high-frequency inductionhardened.
The crank sprocket used to drive the chain and the
gear used to drive the governor gear are pressed into
the output end of the shaft.
2-4 CONNECTING ROD AND PISTON
The connecting rod is a specially heat-treated
aluminum alloy die-casting. Its large and small ends
function as bearings. A splasher built into the
connecting rod lubricates by splashing engine oil.
The piston is an aluminum alloy casting with grooves
for mounting one compression ring and one oil ring.
Fig.2-1
Fig.2-2
Fig.2-3
25°
Fig.2-4

- 3 -
2-6 CAMSHAFT
The camshaft and the sprocket are made of special
sintered alloy. They are constructed as a single
piece. The camshaft is provided with intake and
exhaust cam, and the decompression release lever is
mounted on the sprocket shaft end side.
2-7 VALVE ARRANGEMENT
This engine has a chain-driven overhead cam and
overhead valve construction, with a single cam which
has individual profile for intake and exhaust to
perform high output.
Fig.2-6
Fig.2-5
TOP
RING
SECOND
RING
OIL
RING
1
2
3
BARREL
TAPER
TAPER
1
2
3
THREE-PIECE
CONSTRUCTION
EXHAUST VALVEINTAKE VALVE
2-5 PISTON RINGS
The piston rings are made of special cast iron. The profile of the top ring is a tapered face.
The oil ring is designed for better sealing and less oil consumption, in combination with 3 pieces.
Fig.2-7

- 4 -
2-11 TIMING CHAIN
Timing chain system is adopted and designed for
lubricating for the upper portion of cylinder head.
The timing chain is engaged between the sprocket
portion of integrated camshaft in the cylinder head and
the crankshaft gear sprocket.
The sprocket teeth in particular shape are adopted to
enhance the durability and to realize low noise level.
Fig.2-9
2-10 LUBRICATION SYSTEM
The rotating parts, sliding parts and valves of the engine are lubricated with oil in the crankcase.
The oil is splashed onto the parts by the oil splasher on the connecting rod.
2-9 COOLING SYSTEM
The engine uses a forced air-cooling system in which a synthetic resin cooling fan (which is separate from the
flywheel), reduce noise and forces cooling air into the cylinder and cylinder head.
Baffles are provided to guide the flow of cooling air.
TIMING CHAIN
OIL SPLASHER
2-8 CYLINDER HEAD
The cylinder head is on aluminum die-casting with a
dome-shaped combustion chamber. The intake and
exhaust ports are arranged in a cross direction to
improve combustion efficiency.
Fig.2-8

- 5 -
2-13 BALANCER
Unbalanced inertia force is cancelled by the balancer
which rotates at the same speed as the crankshaft to
effectively reduce vibration.
Fig.2-11
2-12 IGNITION SYSTEM
The ignition system is a flywheel magneto digital
C.D.I. system. The magneto consists of a flywheel
and ignition coil. The flywheel (cooling fan is
separete from the flywheel) is directly mounted on
the crankshaft and the ignition coil is directly
mounted on the crankcase.
Fig.2-10
IGNITION COIL
FAN
FLYWHEEL

- 6 -
Fig.3-1
3. DISASSEMBLY AND REASSEMBLY
3-1 PREPARATIONS AND PRECAUTIONS
(1) When disassembling the engine, memorize the location of each part so that you can reassemble the engine
correctly. If necessary, attach identification tags with the required assembly information to the parts.
(2) Store groups of parts in separate boxes. This will make reassembly easier.
(3) To prevent parts from being mislaid, keep each group provisionally assembled after removing the parts
from the engine.
(4) Handle the disassembled parts with the utmost care. Clean them with cleaning oil if necessary.
(5) Use the correct tools in the correct way when disassembling and reassembling the engine.
3-2 SPECIAL TOOLS
Tool name Use
Commercially available product Flywheel puller For pulling off the ywheel
Commercially available product Chain wrench For locking the ywheel
FLYWHEEL PULLER
675$3:5(1&+

- 7 -
3-3 DISASSEMBLY PROCEDURE
Step Parts to remove Remarks and procedures Fasteners
1
Drain the engine oill Remove a drain plug (M14 x 12mm) located on both
sides of the case.
Take care not to lose the gaskets.
*
To discharge oil quickly, remove the oil guage(M22).
14 mm spanner
2
Remove oil filler Remove oil filler from crankcase. M8 Bolt : 1 pc.
Fig.3-2
GASKE
T
GASKET
DRAIN PLUG
STEP 1

- 8 -
Fig.3-3
Step Parts to remove Remarks and procedures Fasteners
3
Blower housing (1) Remove the blower housing (synthetic resin) from
the crankcase.
10 mm box spanner
M6 x 16 mm : 5 pcs.
BLOWER HOUSING
M6 x 16 BOLT : 5 pcs.
STEP 3

- 9 -
Fig.3-4
Step Parts to remove Remarks and procedures Fasteners
4
Throttle body, Insulator Remove the carburetor from the cylinder head.
Remove the insulator & operation bracket.
GASKET
GASKET
ADAPTER
(AIR INTAKE)
THROTTLE BODY
GASKET
INSULATOR
STEP 4

- 10 -
FLYWHEEL
M6 x 25 BOLT and
WASHER : 2 pcs.
M6 x 8 BOLT : 1 pc.
CLAMP
COOLING BLOWER
M18 NUT : 1 pc.
WIRE : 1 pc.
IGNITION COIL
WASHER
STEP 5
STEP 6
STEP 7
Fig.3-5
Step Parts to remove Remarks and procedures Fasteners
5
Ignition coil Remove the spark plug cap from the spark plug and
remove the ignition coil from the crankcase.
10 mm box spanner
M6 x 25 mm
：
2 pcs.
6
Washer
Cooling Blower
Remove the starting pulley and cooling Blower from the
flywheel.Fit a box wrench or a socket wrench on the
flywheel nut and loosen the nut by knocking the wrench
sharply with a hammer. (See Fig. 3-6)
NOTE:
1. Do not insert a screwdriver or other object between the
flywheel blades which is a synthetic resin, otherwise the
risk of damaging the blades might be occurred.
2. Knock the wrench with a hammer in a counter clockwise
direction.
24 mm box spanner or
socket wrench
M18 nut
7
Flywheel Remove the flywheel from the crankshaft. Leave the nut
temporarily to prevent the flywheel from dropping out. Fit
the flywheel puller as shown in Figure 3-7 and remove
the flywheel from the crankshaft by rotating the bolt at the
center in a clockwise direction.
(Knock the center bolt with a hammer sometimes)
Flywheel puller
Fig.3-6 Fig.3-7
FLYWHEEL PULLER
ATTACH NUT
TEMPORARILY

- 11 -
Step Parts to remove Remarks and procedures Fasteners
8
Baffle 1 (Case) Remove the Baffle 1 from the crankcase. 12 mm box spanner
M8 x 12 mm : 1 pc.
Fig.3-8
M8 x 12
BOLT : 1 pc.
BAFFLE 1
(CASE)
STEP 8

- 12 -
Fig.3-9
Step Parts to remove Remarks and procedures Fasteners
9
Wire clamp Disconnect the wire clamp.
NOTE:
Disconnect the wire clamp in this step, also an engine
which has the oil sensor.
However, please make sure do not damaged (cut off)
the oil sensor wire after disassembly procedure.
10 mm box spanner
M6 x 10 mm : 1 pc.
10
Spark plug Remove the spark plug from the cylinder head. 21 mm plug wrench
VIEW A
SPARK PLUG
A
M6 x 10 TAPPING BOLT : 1 pc.
WIRE CLAMP
STEP 9
STEP 10
WIRE CLAMP
OIL SENSOR
M6 x 10 TAPPING BOLT : 1 pc.

- 13 -
Fig.3-11
Step Parts to remove Remarks and procedures Fasteners
11
Rocker cover (1) Remove the rocker cover from the cylinder head.
(2) Remove the gasket (rocker cover).
10 mm box spanner
M6 x 12mm : 4 pcs.
12
Rocker arm Remove the pin (rocker arm) and the rocker arm from
the cylinder head at the compression top dead center.
(See Fig. 3-12)
ROCKER ARM
(EXHAUST VALVE SIDE)
ROCKER ARM
(INTAKE VALVE SIDE)
PIN
(ROCKER ARM)
Punch marks
The position of compression top dead center
Fig.3-12
ROCKER ARM
(EXHAUST VALVE SIDE)
PIN
(ROCKER ARM)
VIEW A
A
ROCKER ARM
(INTAKE VALVE SIDE)
ROCKER COVER
GASKET(ROCKER COVER)
M6 x 12 BOLT : 4 pcs.
STEP 11
STEP 12
Fig.3-10

- 14 -
Fig.3-14
Step Parts to remove Remarks and procedures Fasteners
13
Main bearing cover Remove the flange bolts of main bearing cover from
the crankcase.
Remove the main bearing cover while tapping gently
around the cover using a plastic hammer or similar
tool. (See Fig. 3-14)
Be careful not to damage the oil gauge or oil seal or
not to lose the pipe knocks.
12 mm box spanner
M8 x 38mm : 8 pcs.
Fig.3-13
MAIN BEARING COVER
M8 x 38 BOLT : 8 pcs.
PIPE KNOCK
STEP 13

- 15 -
TENSIONER
SPRING
(TENSIONER)
CHAIN
PIN
(TENSIONER)
PIN
(CAMSHAFT)
CAMSHAFT
M6 x 12 BOLT : 1 pc.
Bolt used to prevent the
pin (camshaft) from coming out
CHAIN
STEP 14
STEP 14
Fig.3-15
Step Parts to remove Remarks and procedures Fasteners
14
Tensioner, Camshaft (1) Remove the tensioner. (See Fig. 3-16)
Do not lose the pin (tensioner).
(2) Remove the retaining bolt of pin (camshaft) from
the cylinder head. (See Fig. 3-17)
(3) Remove the pin (camshaft), taking care not to
scratch the O-ring.
(4) Remove the chain from the camshaft sprocket and
then take out the camshaft. (See Fig. 3-18)
(5) Remove the chain from the crankshaft.
10mm box spanner or
spanner
M6 x 12mm : 1 pc.
Pliers
Fig.3-18
Fig.3-17
CHAIN
CAMSHAFT
Fig.3-16
PIN (TENSIONER)
PIN (CAMSHAFT)
M6 x 12 BOLT : 1 pc.
Bolt used to prevent the
pin (camshaft) from coming out

- 16 -
Fig.3-19
Fig.3-20
Step Parts to remove Remarks and procedures Fasteners
15
Cylinder head,
Chain guide
(1) Remove the cylinder head from the crankcase.
(2) Remove the cylinder head gasket from the cylinder head.
Take care not to lose the dowel pin.
(3) Remove the chain guide from the top side of the
crankcase.
(If the chain guide is removed from the inner side of the
crankcase, it might be damaged.)
12 mm box spanner
M10 × 75mm : 4 pcs.
M8 × 35mm : 2 pcs.
16
Intake and exhaust
valves
(1) Remove the collet valve from the spring retainer.
(See Fig. 3-20)
(2) Remove the intake valve and the exhaust valve.
INTAKE
VALVE
VALVE SPRING COLLET VALVE
SPRING RETAINER
GASKET
EXHAUST
VALVE
CYLINDER HEAD
VALVE SPRING
COLLET VALVE
SPRING RETAINER
STEM SEAL
STEM SEAL
CHAIN GUIDE
PUSH
M8 x 35 BOLT : 2 pcs.
M10 x 75 BOLT : 4 pcs.
DOWEL PIN
DOWEL PIN
RETAINER PLATE
(EXHAUST ONLY)
STEP 15
STEP 16