Club Car FE290 User manual

MANUAL NUMBER

102396501

EDITION CODE 0904A00000

Engine Models:

• FE290

• FE350

• FE400

Unitized Transaxle Models:

• MC008C-ES00

• MC008C-FS00

• MC010C-BS00 (with Differential Lock)

• MC012C-AS00 (with Differential Lock)

• MC012C-BS00 (with Differential Lock)

All-Wheel Drive:

• Transmission

• Front Differential

• Rear Differential

Engines

and

Drivetrain

Components

REPAIR

AND

REBUILD

MANUAL

Gasoline and Diesel

Vehicles

Repair and Rebuild Manual – Engines and Drivetrain Components Page i

FOREWORD

Club Car vehicles are designed and built to provide the ultimate in performance efﬁciency; however, proper

maintenance and repair are essential for achieving maximum service life and continued safe and reliable

operation.

This manual provides detailed information for the repair and rebuild of the following:

•

FE290 Engine

•

FE350 Engine

•

FE400 Engine

•

MC008C-ES00 and MC008C-FS00 Unitized Transaxle

•

MC010C-BS00 Unitized Transaxle with Differential Lock

•

MC012C-AS00 and MC012C-BS00 Unitized Transaxle with Differential Lock

•

Transmission Models 420317 and 420682

•

Front Differential Models 6203-01-139-S and 6203-01-189-S

•

Rear Differential Models 420366 and 420851

This manual should be thoroughly reviewed prior to servicing. The procedures provided herein must be prop-

erly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.

This manual was written for the trained technician who already possesses knowledge and skills in electrical

and mechanical repair.

If the technician does not have such knowledge and skills, attempted service or

repairs to these components may render them unsafe.

For this reason, Club Car advises that all repairs and/

or service be performed by an authorized 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.

This manual covers all aspects of engine and drivetrain component repair and rebuild; unique situations, how-

ever, do sometimes occur when servicing. If it appears that a service question is not answered in this manual,

you may write to us at: Club Car, Inc.; P.O. Box 204658; Augusta, Georgia 30917; Attention: Technical Ser-

vices, or contact a Club Car Technical Service Representative at (706) 863-3000, ext. 3580.

Club Car

is a registered

trademark of Club Car, Inc.

This manual effective July 2004.

Page ii Repair and Rebuild Manual – Engines and Drivetrain Components

∆

WARNING

• Read General Warning, Section 1, Page 1-1 before attempting any service on the vehicle.

•Before servicing vehicle, read complete section(s) and any referenced information that may

be relevant to the service or repair to be performed.

NOTE:

This manual represents the most current information at the time of publication. Club Car, Inc. is

continually working to further improve our other products. These improvements may affect servic-

ing procedures. Any modiﬁcation and/or signiﬁcant change in speciﬁcations or procedures will be

forwarded to all Club Car dealers and will, when applicable, appear in future editions of this man-

ual.

Club Car, Inc. reserves the right to change speciﬁcations and designs at any time without notice

and without the obligation of making changes to units previously sold.

There are no warranties expressed or implied in this manual. See the limited warranty found in the

vehicle owner’s manual or write to Club Car, Inc., P.O. BOX 204658, Augusta, Georgia 30917-4658

USA, Attention: Warranty Department.

Repair and Rebuild Manual – Engines and Drivetrain Components Page iii

CONTENTS

SECTION 1 – SAFETY

General Warning ............................................................................................................................... 1-1

SECTION 2 – FE290 ENGINE

General Information .......................................................................................................................... 2-1

Special Engine Service Tools Available from Club Car .................................................................... 2-1

Recommended Replacement Parts for Engine Teardown ........................................................... 2-2

Before Servicing ........................................................................................................................... 2-2

Mechanical Systems ..................................................................................................................... 2-2

Cylinder Components ....................................................................................................................... 2-4

Cylinder Head ............................................................................................................................... 2-4

General Information ...................................................................................................................... 2-4

Cylinder Shroud Removal ............................................................................................................. 2-4

Rocker Arm and Push Rod Removal ............................................................................................ 2-7

Cylinder Head Removal ................................................................................................................ 2-7

Valve Removal .............................................................................................................................. 2-8

Breather Valve (Reed Valve) ........................................................................................................ 2-8

Cylinder Head Cleaning and Inspection ....................................................................................... 2-9

Valve Guides ................................................................................................................................ 2-9

Valve Seats ................................................................................................................................... 2-11

Valves ........................................................................................................................................... 2-13

Rocker Arm and Rocker Shaft Inspection ..................................................................................... 2-15

Push Rod Inspection ..................................................................................................................... 2-16

Cylinder Head Installation ............................................................................................................. 2-16

Valve Clearance Check and Adjustment ...................................................................................... 2-18

Breather Valve (Reed Valve) ........................................................................................................ 2-18

Installation Of Remaining Engine Components ............................................................................ 2-19

Crankcase Components ................................................................................................................... 2-20

Crankcase Cover Removal ........................................................................................................... 2-20

Camshaft and Tappets ................................................................................................................. 2-22

Piston and Connecting Rod .............................................................................................................. 2-22

Cylinder Block ................................................................................................................................... 2-25

Ignition Coil and Flywheel ................................................................................................................. 2-27

Oil Pump ........................................................................................................................................... 2-29

Oil Pressure Relief Valve .............................................................................................................. 2-30

Page iv Repair and Rebuild Manual – Engines and Drivetrain Components

Crankshaft and Counterbalance ...................................................................................................... 2-31

Counterbalance Weight ................................................................................................................ 2-34

Oil Screen .................................................................................................................................... 2-36

Ball Bearing .................................................................................................................................. 2-37

Oil Seals ....................................................................................................................................... 2-37

Piston and Connecting Rod Installation ....................................................................................... 2-39

Crankshaft Axial Play Adjustment .................................................................................................... 2-40

Crankcase Cover Installation ....................................................................................................... 2-42

Engine Assembly ............................................................................................................................. 2-43

Engine Installation ............................................................................................................................ 2-44

Service Specifications ..................................................................................................................... 2-45

Specifications for Resizing Cylinder Bore .................................................................................. 2-46

Torque Specifications ................................................................................................................. 2-46

Adjustments and Settings .......................................................................................................... 2-47

SECTION 3 – FE350 ENGINE

General Information ......................................................................................................................... 3-1

Special Engine Service Tools Available From Club Car ................................................................. 3-1

Recommended Replacement Parts For Engine Teardown ......................................................... 3-2

Before Servicing ........................................................................................................................... 3-2

Mechanical Systems .................................................................................................................... 3-2

Cylinder Components ....................................................................................................................... 3-4

Cylinder Head .............................................................................................................................. 3-4

General Information ..................................................................................................................... 3-4

Cylinder Shroud Removal ............................................................................................................ 3-4

Rocker Arm and Push Rod Removal ........................................................................................... 3-7

Cylinder Head Removal ............................................................................................................... 3-7

Valve Removal ............................................................................................................................. 3-8

Breather Valve (Reed Valve) ....................................................................................................... 3-8

Cylinder Head Cleaning and Inspection ....................................................................................... 3-9

Valve Guides ................................................................................................................................ 3-10

Valve Seats .................................................................................................................................. 3-11

Valves .......................................................................................................................................... 3-13

Rocker Arm and Rocker Shaft inspection .................................................................................... 3-15

Push Rod Inspection .................................................................................................................... 3-16

Cylinder Head Installation ............................................................................................................ 3-16

Valve Clearance Check and Adjustment ...................................................................................... 3-17

Breather Valve (Reed Valve) ....................................................................................................... 3-17

Installation of Remaining Engine Components ............................................................................ 3-18

Repair and Rebuild Manual – Engines and Drivetrain Components Page v

Crankcase Components ................................................................................................................... 3-20

Crankcase Cover Removal ........................................................................................................... 3-20

Camshaft and Hydraulic Lifters ..................................................................................................... 3-21

Piston and Connecting Rod .............................................................................................................. 3-23

Cylinder Block ................................................................................................................................... 3-26

Ignition Coil and Flywheel ................................................................................................................. 3-28

Oil Pump ........................................................................................................................................... 3-29

Oil Pressure Relief Valve .............................................................................................................. 3-31

Crankshaft and Counterbalance ....................................................................................................... 3-32

Counterbalance Weight ................................................................................................................ 3-35

Oil Screen ..................................................................................................................................... 3-38

Ball Bearing .................................................................................................................................. 3-38

Oil Seals ....................................................................................................................................... 3-39

Piston and Connecting Rod Installation ........................................................................................ 3-41

Crankshaft Axial Play Adjustment ................................................................................................. 3-42

Camshaft Axial Play Adjustment ................................................................................................... 3-43

Crankcase Cover Installation ........................................................................................................ 3-44

Engine Assembly .............................................................................................................................. 3-45

Engine Installation ............................................................................................................................ 3-46

Service Specifications ...................................................................................................................... 3-47

Specifications for Resizing Cylinder Bore .................................................................................... 3-48

Torque Specifications ................................................................................................................... 3-48

Adjustment and Settings ............................................................................................................... 3-49

SECTION 4 – FE400 ENGINE

General Information .......................................................................................................................... 4-1

Special Engine Service Tools Available From Club Car .................................................................. 4-1

Recommended Replacement Parts For Engine Teardown ......................................................... 4-2

Before Servicing ........................................................................................................................... 4-2

Cylinder Head ................................................................................................................................... 4-2

General Information ...................................................................................................................... 4-2

Muffler Removal and Installation ...................................................................................................... 4-3

Cylinder Block ................................................................................................................................... 4-3

Engine Installation ............................................................................................................................ 4-6

Service Specifications ..................................................................................................................... 4-6

Specifications for Resizing Cylinder Bore ..................................................................................... 4-6

Torque Specifications ................................................................................................................... 4-6

Adjustment and Settings ............................................................................................................... 4-6

Page vi Repair and Rebuild Manual – Engines and Drivetrain Components

SECTION 5 – MC008C-ES00 AND MC008C-FS00 UNITIZED TRANSAXLES

General Information ......................................................................................................................... 5-1

Transaxle Models and Identification ................................................................................................. 5-1

Axle Shaft ......................................................................................................................................... 5-2

Unitized Transaxle Removal ............................................................................................................ 5-2

Unitized Transaxle Disassembly ...................................................................................................... 5-2

Component Disassembly ................................................................................................................. 5-6

Governor Gear Disassembly ........................................................................................................ 5-6

Differential Gear Case Disassembly ............................................................................................ 5-9

Shifter Fork Disassembly ............................................................................................................. 5-11

Synchronizer Gear Disassembly .................................................................................................. 5-11

Intermediate Gear Disassembly ................................................................................................... 5-12

Idler Shaft Disassembly ............................................................................................................... 5-13

Unitized Transaxle Component Inspection ...................................................................................... 5-14

Component Assembly ...................................................................................................................... 5-14

Idler Shaft Assembly .................................................................................................................... 5-14

Intermediate Gear Assembly ........................................................................................................ 5-14

Synchronizer Gear Assembly ....................................................................................................... 5-15

Shifter Fork Assembly .................................................................................................................. 5-18

Differential Gear Case Assembly ................................................................................................. 5-19

Governor Gear Assembly ............................................................................................................. 5-21

Unitized Transaxle Assembly ........................................................................................................... 5-21

Axle Tubes ....................................................................................................................................... 5-26

Unitized Transaxle Installation ......................................................................................................... 5-26

Lubrication ........................................................................................................................................ 5-26

SECTION 6 – MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK

General Information ......................................................................................................................... 6-1

Transaxle Models And Identification ................................................................................................ 6-1

Axle Shaft ......................................................................................................................................... 6-2

Unitized Transaxle Removal ............................................................................................................ 6-2

Unitized Transaxle Disassembly ...................................................................................................... 6-2

Component Disassembly ................................................................................................................. 6-7

Differential Gear Lock Housing Disassembly ............................................................................... 6-7

Governor Gear Disassembly ........................................................................................................ 6-7

Differential Gear Case Disassembly ............................................................................................ 6-8

Shifter Fork Disassembly ............................................................................................................. 6-10

Synchronizer Gear Disassembly .................................................................................................. 6-10

Intermediate Gear Disassembly ................................................................................................... 6-12

Idler Shaft Disassembly ............................................................................................................... 6-12

Repair and Rebuild Manual – Engines and Drivetrain Components Page vii

Unitized Transaxle Component Inspection ....................................................................................... 6-13

Component Assembly ...................................................................................................................... 6-14

Idler Shaft Assembly ..................................................................................................................... 6-14

Intermediate Gear Assembly ........................................................................................................ 6-14

Synchronizer Gear Assembly ....................................................................................................... 6-14

Shifter Fork Assembly ................................................................................................................... 6-16

Differential Gear Case Assembly .................................................................................................. 6-17

Governor Gear Assembly ............................................................................................................. 6-19

Differential Gear Lock Housing Assembly .................................................................................... 6-19

Unitized Transaxle Assembly ........................................................................................................... 6-20

Axle Tubes ........................................................................................................................................ 6-26

Unitized Transaxle Installation .......................................................................................................... 6-26

Lubrication ........................................................................................................................................ 6-26

SECTION 7 – MC012C-AS00 AND MC012C-BS00 UNITIZED TRANSAXLES WITH DIF-

FERENTIAL LOCKS

General Information .......................................................................................................................... 7-1

Transaxle Models and Identification ................................................................................................. 7-1

Axle Shaft ......................................................................................................................................... 7-2

Unitized Transaxle Removal ............................................................................................................. 7-2

Unitized Transaxle Disassembly ....................................................................................................... 7-2

Component Disassembly .................................................................................................................. 7-7

Differential Gear Lock Housing Disassembly ............................................................................... 7-7

Governor Gear Disassembly ........................................................................................................ 7-7

Differential Gear Case Disassembly ............................................................................................. 7-8

Shifter Fork Disassembly .............................................................................................................. 7-12

Synchronizer Gear Disassembly .................................................................................................. 7-12

Intermediate Gear Disassembly ................................................................................................... 7-13

Idler Shaft Disassembly ................................................................................................................ 7-14

Unitized Transaxle Component Inspection ....................................................................................... 7-15

Component Assembly ...................................................................................................................... 7-15

Idler Shaft Assembly ..................................................................................................................... 7-15

Intermediate Gear Assembly ........................................................................................................ 7-16

Synchronizer Gear Assembly ....................................................................................................... 7-16

Shifter Fork Assembly ................................................................................................................... 7-19

Differential Gear Case Assembly .................................................................................................. 7-20

Governor Gear Assembly ............................................................................................................. 7-22

Differential Gear Lock Housing Assembly .................................................................................... 7-22

Unitized Transaxle Assembly ........................................................................................................... 7-23

Axle Tubes ........................................................................................................................................ 7-29

Unitized Transaxle Installation .......................................................................................................... 7-29

Page viii Repair and Rebuild Manual – Engines and Drivetrain Components

Lubrication ........................................................................................................................................ 7-29

SECTION 8 – TRANSMISSION MODELS 420317 AND 420682

General Information ......................................................................................................................... 8-1

Model Identification .......................................................................................................................... 8-1

Service Fixture ................................................................................................................................. 8-1

Transmission Removal ..................................................................................................................... 8-2

Transmission Disassembly .............................................................................................................. 8-2

Input Shaft Disassembly .............................................................................................................. 8-8

Input Shaft Assembly ................................................................................................................... 8-8

Intermediate Shaft Disassembly .................................................................................................. 8-8

Output Shaft Disassembly ............................................................................................................ 8-12

Shifter Shaft Removal .................................................................................................................. 8-13

Shifter Shaft Installation ............................................................................................................... 8-14

Case Inspection ........................................................................................................................... 8-14

Shaft Seal Removal ..................................................................................................................... 8-15

Shaft Seal Installation .................................................................................................................. 8-15

Output Shaft Assembly ................................................................................................................ 8-15

Intermediate Shaft Assembly ....................................................................................................... 8-18

Intermediate and Output Shaft Assembly .................................................................................... 8-22

Transmission Assembly ................................................................................................................... 8-23

Transmission Installation .................................................................................................................. 8-27

SECTION 9 – FRONT DIFFERENTIAL MODELS 6203-01-139-S AND 6203-01-189-S

General Information ......................................................................................................................... 9-1

Axle Half Shaft Removal .................................................................................................................. 9-1

Front Differential Removal ............................................................................................................... 9-2

Tools Required For This Section ................................................................................................. 9-3

Front Differential Coil And Output Cover .......................................................................................... 9-3

Coil and Output Cover Removal .................................................................................................. 9-3

Coil and Output Cover Installation ............................................................................................... 9-6

Front Differential ............................................................................................................................... 9-8

Front Differential Disassembly ..................................................................................................... 9-8

Front Differential Assembly .......................................................................................................... 9-14

Front Differential Installation ............................................................................................................ 9-18

Axle Half Shaft Installation ............................................................................................................... 9-18

SECTION 10 – REAR DIFFERENTIAL MODELS 420366 AND 420851

General Information ......................................................................................................................... 10-1

Axle Shafts and Differential Removal ............................................................................................... 10-2