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 [phone], ext. 3580.
Copyright © 2004 Club Car, Inc.
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

Repair and Rebuild Manual – Engines and Drivetrain Components Page ix
Rear Differential Disassembly .......................................................................................................... 10-2
Pinion Gear Removal .................................................................................................................... 10-4
Ring Gear Removal ...................................................................................................................... 10-6
Clutch Carrier Assembly ............................................................................................................... 10-7
Ring Gear Installation ................................................................................................................... 10-8
Pinion Gear Installation ................................................................................................................. 10-9
Rear Differential Assembly ........................................................................................................... 10-9
Axle Shafts and Differential Installation ............................................................................................ 10-10
SECTION i – INDEX

Page x Repair and Rebuild Manual – Engines and Drivetrain Components

Repair and Rebuild Manual – Engines and Drivetrain Components Page 1-1
1
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 boxes labeled DANGER, WARNING, or
CAUTION. These special statements relate to specific safety issues, and must be read, understood, and
heeded before proceeding.
∆ DANGER
•ADANGER indicates an immediate hazard that will result in severe personal injury or death.
∆
WARNING
•AWARNING indicates an immediate hazard that could result in severe personal injury or
death.
∆
CAUTION
•ACAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result
in product or property damage or minor personal injury.
CAUTION
•ACAUTION without the safety alert symbol indicates a potentially hazardous situation that
could result in property damage.
GENERAL WARNING
The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser-
viced. Service technicians should become familiar with these general safety statements, which can be found
throughout this manual. Also, other specific safety statements appear throughout this manual and on the vehi-
cle.
∆
DANGER
•Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area.Ventilate when charging or operating vehicle in an enclosed area.Wear a full face
shield and rubber gloves when working on or near batteries.
•Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or
clothing. Antidotes:
- External: Flush with water. Call a physician immediately.
-Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
-Eyes: Flush with water for 15 minutes. Call a physician immediately.
•Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the
vehicle and service area. Service only in a well-ventilated area.
•Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine
produces carbon monoxide, which is an odorless, deadly poison.

SAFETY General Warning
Page 1-2 Repair and Rebuild Manual – Engines and Drivetrain Components
1
∆
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.
The appropriate instructions must be used when performing maintenance, service, or
accessory installation.
•Prior to leaving the vehicle unattended or servicing the vehicle, set the park brake, place the
Forward/Reverse handle in the NEUTRAL position, turn the key switch to the OFF position,
and remove the key. Chock the wheels when servicing the vehicle.
•To avoid unintentionally starting the vehicle:
- Disconnect battery cables, negative (–) cable first (Figure 1-1, Page 1-3).
- Disconnect the spark plug wire from the spark plug.
•Frame ground – Do not allow tools or other metal objects to contact frame when
disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch
the vehicle frame, engine, or any other metal component.
•Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face
shield and rubber gloves when working on or near batteries.
•Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the
vehicle.
•Moving parts! Do not attempt to service the vehicle while it is running.
•Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning
could result in severe burns.
•Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
•Check the vehicle owner’s manual for proper location of all vehicle safety and operation
decals and make sure they are in place and are easy to read.
•Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
•Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic
floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold
vehicle in raised position. Use approved jack stands of proper weight capacity to support the
vehicle and chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
•If wires are removed or replaced, make sure wiring and wire harness are properly routed and
secured. Failure to properly route and secure wiring could result in vehicle malfunction,
property damage, personal injury, or death.
•For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle.
If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is
raised. Do not close bed until all persons are clear of cargo bed area. Keep hands clear of all
crush areas. Do not drop cargo bed; lower gently and keep entire body clear. Failure to heed
this warning could result in severe personal injury or death.
•Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance, severe personal injury, or death.
• Do not leave children unattended on vehicle.

SAFETY General Warning
Repair and Rebuild Manual – Engines and Drivetrain Components Page 1-3
1
Figure 1-1 Gasoline Vehicle
FRONT
OF VEHICLE
AS SEEN FROM
PASSENGER SIDE
OF VEHICLE
Remove
negative
cable first.
DISCONNECT BATTERY CABLES
BEFORE WORKING ON VEHICLE

1

Repair and Rebuild Manual – Engines and Drivetrain Components Page 2-1
2
SECTION 2 – FE290 ENGINE
∆
DANGER
• See General Warning on page 1-1.
∆
WARNING
• See General Warning on page 1-1.
GENERAL INFORMATION
See General Warning on page 1-1.
The FE290 gasoline engine is produced for pedal-start vehicles. This 4-cycle, single cylinder engine is
designed for reliable heavy-duty service. It has two major component assemblies: the cylinder assembly and
the crankcase assembly. The FE290 engine is provided with the MC008C-ES00 transaxle. See Transaxle
Models and Identification on page 5-1 .
SPECIAL ENGINE SERVICE TOOLS AVAILABLE FROM CLUB CAR
DESCRIPTION CCI P/N
Bearing and seal remover assembly 1016417
Bearing driver set 1016416
Compression gauge and adapter 101641002
Flywheel puller kit 1016627
Gear yoke 1016418
Piston ring compressor kit 1016414
Piston ring pliers 1016415
Valve clearance adjuster screw holder 1016413
Valve guide reamer 101641201
Valve guide reamer arbor 101641202
Valve spring compressor 101641101
Valve seat cutter guide 1016552
Valve seat cutter t wrench 1016551
Valve seat cutter 30° and 45° x 35 mm diameter 1016554
Valve seat cutter 45° x 32 mm diameter
(for FE290 engines only) 1016553

FE290 ENGINE Special Engine Service Tools Available from Club Car
Page 2-2 Repair and Rebuild Manual – Engines and Drivetrain Components
2
RECOMMENDED REPLACEMENT PARTS FOR ENGINE TEARDOWN
BEFORE SERVICING
To eliminate unnecessary work, carefully read the applicable information and instructions before beginning
engine service. Diagrams, DANGER, WARNING, CAUTION and NOTE statements and detailed descriptions
have been included wherever necessary. Nevertheless, even a detailed account has limitations. Therefore,
anyone attempting engine service should have knowledge and experience in small engine service and repair.
NOTE: Engine rotation is clockwise as viewed from the clutch side of the engine.
MECHANICAL SYSTEMS
Adjustments
All adjustments shall be made in accordance with Adjustments and Settings on page 2-47.
Edges
∆
WARNING
•Watch for sharp edges, especially during major engine disassembly and assembly. Protect
your hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
Force
Common sense should dictate how much force is necessary for assembly and disassembly. If a part seems
especially difficult to remove or install, stop and determine what may be causing the problem. Whenever tap-
ping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for the removal of
screws (particularly those held by a locking agent) in order to avoid damaging the heads.
DESCRIPTION CCI P/N
Air Filter 1015426
Carburetor insulator to throttle bracket gasket 1016439
Carburetor to intake manifold gasket 1016438
Drive belt 1016203
Exhaust gasket 1015330
Exhaust system (muffler) 101859301
FE290 gasket kit (for all internal gaskets) 102304701
Ignition coil (with internal igniter) 101909201
Insulator gasket 1016440
Muffler clamp 1017689
Oil filter 1016467
Oil level sensor 1016494
Oil seal 1016568
Starter/Generator belt 101916701
Spark plug 101881101
Throttle bracket to carburetor gasket 1016441

FE290 ENGINE Special Engine Service Tools Available from Club Car
Repair and Rebuild Manual – Engines and Drivetrain Components Page 2-3
2
Dirt
Clean the engine thoroughly before servicing it. See following CAUTION.
CAUTION
•Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or
other parts will work as an abrasive and shorten the life of the engine. Before installing a new
part, clean off any dust or metal filings.
Tightening Sequence
Where there is a tightening sequence indicated, the bolts, nuts, or screws must be tightened in the order and
by the method indicated.When installing a part that is secured with several bolts, nuts, or screws, hand tighten
all, then tighten to specified torque in the proper sequence to avoid distortion of the part or leakage. Con-
versely, when loosening the bolts, nuts or screws, loosen all about a quarter of a turn first and then remove
them.
Torque
The torque values given in this manual should always be adhered to. Applying too little or too much torque
may lead to serious damage.
Lubricant
Some oils and greases should only be used in certain applications and may be harmful if used in an applica-
tion for which they are not intended.
Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces
have adequate lubrication. During assembly, oil or grease (whichever is more suitable) should be applied to
any rubbing surface.
Press
A part installed using a press or driver, such as a seal, should first be coated with oil on its outer or inner cir-
cumference (contact surface) so that it will go into place smoothly.
Oil Seal, Grease Seal
During assembly use new oil or grease seals to replace any that were removed, as removal generally dam-
ages seals. To avoid damaging the seal lips, a seal guide is required for installation. Before a shaft passes
through a seal, apply a small amount of lubricant (preferably high temperature grease) to the lip to reduce rub-
ber-to-metal friction.
Gasket, O-Ring
When in doubt as to the condition of a gasket or O-ring, replace it with a new one. To avoid leaks, the mating
surface around the gasket or O-rings should be free of foreign matter and perfectly smooth.
Ball Bearing Installation
When installing a ball bearing, the bearing race which has a press fit should be pushed by a suitable driver.
This prevents severe stress on the balls and races, and prevents damage. Press on the inner race if the ball
bearing is being pressed onto a shaft, or on the outer race if the ball bearing is being pressed into a housing.
Press the ball bearing until it is seated against the housing or on the shaft.

FE290 ENGINE Cylinder Components
Page 2-4 Repair and Rebuild Manual – Engines and Drivetrain Components
2
Circlip, Retaining Ring
Replace circlips and retaining rings that were removed with new circlips and retaining rings. During installa-
tion, take care to compress or expand them only enough for installation.
High Flash-point Solvent
Use a high flash-point solvent when cleaning parts. Club Car recommends Stoddard solvent (generic name),
a commercial solvent commonly available in North America. Always follow manufacturer and container direc-
tions regarding the use of any solvent.
Molybdenum Disulfide (MoS
2
) Grease
NOTE: This manual makes reference to molybdenum disulfide grease in the assembly of certain engine
parts. Always refer to manufacturer’s recommendations printed on the container before using such
special lubricants.
Engine Rotation
When turning the crankshaft by hand, always turn it clockwise as viewed from the clutch side of the engine.
This will ensure proper adjustments.
CYLINDER COMPONENTS
CYLINDER HEAD
See General Warning on page 1-1.
GENERAL INFORMATION
Prior to attempting time-consuming repairs to the cylinder assembly, a cylinder compression test should be
performed using a standard compression tester. Low compression would normally indicate a problem in the
cylinder assembly such as defective rings, gaskets, etc. At a cranking speed of 550-600 rpm, the compression
should be typically 156 psi. This value could vary slightly depending on wear of components affecting com-
pression.
CYLINDER SHROUD REMOVAL
CAUTION
• Before removal and disassembly, clean the engine.
1. Remove governor guard (1) (Figure 2-1, Page 2-5) .
2. Earlier Style Governor Cable End:
2.1. Remove cotter pin (3) and clevis pin (2) from throttle valve lever (Figure 2-1, Page 2-5) .
3. Current Style Governor Cable End:
3.1. Remove the ’Z’ shaped cable end from the throttle valve lever (Figure 2-1, Page 2-5) .