Club Car TURF 272 Guide

TURF 272 AND CARRYALL 272
GASOLINE VEHICLES
MANUAL NUMBER 102190010
EDITION CODE 0802A00000
MAINTENANCE
SERVICE
2001-2002

2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual 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 maintenance and repair of the Turf/Carryall 272 vehicle, and
should be thoroughly reviewed prior to servicing the vehicle.The procedures provided must be properly imple-
mented, 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 the vehicle may render the vehicle 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 typical vehicle service; unique situations, however, do sometimes occur
when servicing a vehicle. 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, GA 30917; Attention: Technical Services, or contact a Club
Car Technical Service Representative at [phone], ext. 3580.
Copyright © 2002 Club Car, Inc.
Club Car and Carryall
are registered trademarks of Club Car, Inc.
This manual effective July 23, 2001

Page ii 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual
∆
WARNING
• Read Section 1 – Safety before attempting any service on this 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 vehicles and other products. These improvements may
affect servicing procedures. Any modification and/or significant change in specifications or proce-
dures will be forwarded to all Club Car dealers and will, when applicable, appear in future editions
of this manual.
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, GA 30917-4658 USA,
Attention: Warranty Department.

2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ............................................................................................................................... 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
General Information .......................................................................................................................... 2-1
SECTION 3 – GENERAL INFORMATION
General Information .......................................................................................................................... 3-1
Engine and Transaxle Identification ................................................................................................. 3-1
Serial Number Identification .............................................................................................................. 3-2
Storage ............................................................................................................................................. 3-2
Returning The Stored Vehicle To Service .................................................................................... 3-4
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 4-2
Front Body Repair ............................................................................................................................. 4-3
Abrasions and Haze ..................................................................................................................... 4-3
Light Scratches ............................................................................................................................. 4-3
Large Scratches and Abrasions .................................................................................................... 4-3
Tube Bumper .................................................................................................................................... 4-3
Tube Bumper Removal ................................................................................................................. 4-3
Tube Bumper Installation .............................................................................................................. 4-3
Front Body Components ................................................................................................................... 4-3
Dashboard Removal ..................................................................................................................... 4-3
Dashboard Installation .................................................................................................................. 4-4
Front Body Removal ..................................................................................................................... 4-4
Front Fender Removal .................................................................................................................. 4-6
Front Fender Installation ............................................................................................................... 4-6
Front Body Installation .................................................................................................................. 4-6
Seat .................................................................................................................................................. 4-6
Seat Removal ............................................................................................................................... 4-8
Seat Installation ............................................................................................................................ 4-8

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Seat Support .................................................................................................................................... 4-8
Seat Support Removal ................................................................................................................. 4-8
Seat Support Installation .............................................................................................................. 4-9
Armrest Removal ......................................................................................................................... 4-9
Armrest Installation ...................................................................................................................... 4-9
Cargo Bed ........................................................................................................................................ 4-9
Cargo Bed Removal ..................................................................................................................... 4-9
Cargo Bed Installation .................................................................................................................. 4-11
Bed Stop Bumper Adjustment ...................................................................................................... 4-11
Rear Fender ..................................................................................................................................... 4-11
Rear Fender Removal .................................................................................................................. 4-11
Rear Fender Installation ............................................................................................................... 4-12
Tailskirt ............................................................................................................................................. 4-12
Tailskirt Removal .......................................................................................................................... 4-12
Tailskirt Installation ....................................................................................................................... 4-14
Trailer Hitch ...................................................................................................................................... 4-14
Trailer Hitch Removal ................................................................................................................... 4-14
Trailer Hitch Installation ................................................................................................................ 4-14
Floor Mat .......................................................................................................................................... 4-15
Floor Mat Removal ....................................................................................................................... 4-15
Floor Mat Installation .................................................................................................................... 4-15
SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES
Brake Pedal ...................................................................................................................................... 5-2
Brake Pedal Removal .................................................................................................................. 5-2
Brake Pedal Installation ............................................................................................................... 5-3
Accelerator Pedal ............................................................................................................................. 5-4
Accelerator Pedal Removal .......................................................................................................... 5-4
Accelerator Pedal Installation ....................................................................................................... 5-5
Brake Pedal Adjustment ................................................................................................................... 5-6
Accelerator Pedal Adjustment .......................................................................................................... 5-7
SECTION 6A – MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYS-
TEMS
General Information ......................................................................................................................... 6a-2
Transaxle Identification .................................................................................................................... 6a-2
Brake System Inspection ................................................................................................................. 6a-3
Brake System Troubleshooting ........................................................................................................ 6a-6

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Brake Drum Removal ....................................................................................................................... 6a-9
Front Wheel Brake Drum Removal ............................................................................................... 6a-9
Rear Wheel Brake Drum Removal ............................................................................................... 6a-10
Brake Shoe Removal ........................................................................................................................ 6a-11
Front Brake Shoe Removal .......................................................................................................... 6a-11
Rear Brake Shoe Removal ........................................................................................................... 6a-11
Brake Cluster Inspection and Cleaning ............................................................................................ 6a-12
Brake Shoe Installation ..................................................................................................................... 6a-14
Front Brake Shoe Installation ....................................................................................................... 6a-14
Rear Brake Shoe Installation ........................................................................................................ 6a-16
Brake Drum Installation .................................................................................................................... 6a-17
Front Wheel Brake Drum Installation ............................................................................................ 6a-17
Rear Wheel Brake Drum Installation ............................................................................................ 6a-19
Brake Cluster Assembly Replacement ............................................................................................. 6a-20
Front Brake Cluster Assembly Removal ....................................................................................... 6a-20
Front Brake Cluster Assembly Installation .................................................................................... 6a-21
Rear Brake Cluster Assembly Removal ....................................................................................... 6a-21
Rear Brake Cluster Assembly Installation .................................................................................... 6a-22
Wheel Cylinder Replacement ........................................................................................................... 6a-23
Front Wheel Cylinder Removal ..................................................................................................... 6a-23
Front Wheel Cylinder Installation .................................................................................................. 6a-23
Rear Wheel Cylinder Removal ..................................................................................................... 6a-24
Rear Wheel Cylinder Installation .................................................................................................. 6a-24
Brake Shoe Adjuster Replacement .................................................................................................. 6a-26
Front Brake Shoe Adjuster Removal ............................................................................................ 6a-26
Front Brake Shoe Adjuster Installation ......................................................................................... 6a-26
Rear Brake Shoe Adjuster Removal ............................................................................................. 6a-27
Rear Brake Shoe Adjuster Installation .......................................................................................... 6a-27
Hydraulic Line and Hose Replacement ............................................................................................ 6a-27
Front Brake Line Removal ............................................................................................................ 6a-28
Front Brake Line Installation ......................................................................................................... 6a-28
Front Brake Hose Assembly Removal .......................................................................................... 6a-28
Front Brake Hose Assembly Installation ....................................................................................... 6a-30
Rear Brake Line Removal ............................................................................................................. 6a-30
Rear Brake Line Installation .......................................................................................................... 6a-30
Rear Brake Hose Removal ........................................................................................................... 6a-31
Rear Brake Hose Installation ........................................................................................................ 6a-31

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Master Cylinder and Bell Crank Replacement ................................................................................. 6a-31
Bell Crank Removal ..................................................................................................................... 6a-31
Bell Crank Installation .................................................................................................................. 6a-32
Master Cylinder Removal ............................................................................................................. 6a-32
Master Cylinder Installation .......................................................................................................... 6a-33
Bleeding the Hydraulic Brake System .............................................................................................. 6a-33
Purging the Hydraulic System ...................................................................................................... 6a-35
Filling the Hydraulic System ......................................................................................................... 6a-36
Park Brake System .......................................................................................................................... 6a-37
Park Brake Cable Removal .......................................................................................................... 6a-37
Park Brake Cable Installation ....................................................................................................... 6a-37
Park Brake Handle Removal ........................................................................................................ 6a-39
Park Brake Handle Installation ..................................................................................................... 6a-39
Park Brake Adjustment ................................................................................................................ 6a-39
SECTION 6B – MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYS-
TEMS
General Information ......................................................................................................................... 6b-2
Transaxle Identification .................................................................................................................... 6b-2
Brake System Inspection ................................................................................................................. 6b-3
Brake System Troubleshooting ........................................................................................................ 6b-6
Brake Drum Removal ....................................................................................................................... 6b-9
Front Wheel Brake Drum Removal .............................................................................................. 6b-9
Rear Wheel Brake Drum Removal ............................................................................................... 6b-10
Brake Shoe Removal ....................................................................................................................... 6b-11
Front Brake Shoe Removal .......................................................................................................... 6b-11
Rear Brake Shoe Removal .......................................................................................................... 6b-11
Brake Cluster Inspection and Cleaning ............................................................................................ 6b-12
Brake Shoe Installation .................................................................................................................... 6b-14
Front Brake Shoe Installation ....................................................................................................... 6b-14
Rear Brake Shoe Installation ....................................................................................................... 6b-16
Brake Drum Installation .................................................................................................................... 6b-17
Front Wheel Brake Drum Installation ........................................................................................... 6b-17
Rear Wheel Brake Drum Installation ............................................................................................ 6b-19
Brake Cluster Assembly Replacement ............................................................................................. 6b-20
Front Brake Cluster Assembly Removal ...................................................................................... 6b-20
Front Brake Cluster Assembly Installation ................................................................................... 6b-21
Rear Brake Cluster Assembly Removal ....................................................................................... 6b-21
Rear Brake Cluster Assembly Installation .................................................................................... 6b-22

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Wheel Cylinder Replacement ........................................................................................................... 6b-23
Front Wheel Cylinder Removal ..................................................................................................... 6b-23
Front Wheel Cylinder Installation .................................................................................................. 6b-23
Rear Wheel Cylinder Removal ..................................................................................................... 6b-24
Rear Wheel Cylinder Installation .................................................................................................. 6b-24
Brake Shoe Adjuster Replacement .................................................................................................. 6b-25
Front Brake Shoe Adjuster Removal ............................................................................................ 6b-26
Front Brake Shoe Adjuster Installation ......................................................................................... 6b-26
Rear Brake Shoe Adjuster Removal ............................................................................................. 6b-26
Rear Brake Shoe Adjuster Installation .......................................................................................... 6b-27
Hydraulic Line and Hose Replacement ............................................................................................ 6b-27
Front Brake Line Removal ............................................................................................................ 6b-27
Front Brake Line Installation ......................................................................................................... 6b-29
Front Brake Hose Assembly Removal .......................................................................................... 6b-29
Front Brake Hose Assembly Installation ....................................................................................... 6b-29
Rear Brake Line Removal ............................................................................................................. 6b-30
Rear Brake Line Installation .......................................................................................................... 6b-30
Rear Brake Hose Removal ........................................................................................................... 6b-30
Rear Brake Hose Installation ........................................................................................................ 6b-31
Master Cylinder and Bell Crank Replacement .................................................................................. 6b-31
Bell Crank Removal ...................................................................................................................... 6b-31
Bell Crank Installation ................................................................................................................... 6b-31
Master Cylinder Removal ............................................................................................................. 6b-32
Master Cylinder Installation .......................................................................................................... 6b-32
Bleeding the Hydraulic Brake System .............................................................................................. 6b-33
Purging the Hydraulic System ...................................................................................................... 6b-35
Filling the Hydraulic System ......................................................................................................... 6b-36
Park Brake System ........................................................................................................................... 6b-36
Park Brake Cable Removal .......................................................................................................... 6b-36
Park Brake Cable Installation ....................................................................................................... 6b-37
Park Brake Handle Removal ........................................................................................................ 6b-38
Park Brake Handle Installation ..................................................................................................... 6b-39
Park Brake Adjustment ................................................................................................................. 6b-39
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information .......................................................................................................................... 7-2
Steering Wheel ................................................................................................................................. 7-2
Steering Wheel Removal .............................................................................................................. 7-2
Steering Wheel Installation ........................................................................................................... 7-4

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Steering Column .............................................................................................................................. 7-5
Steering Column Removal ........................................................................................................... 7-5
Steering Column Disassembly ..................................................................................................... 7-6
Steering Column Assembly .......................................................................................................... 7-6
Steering Column Installation ........................................................................................................ 7-7
Rack and Pinion ............................................................................................................................... 7-7
Rack and Pinion Removal ............................................................................................................ 7-7
Rack and Pinion Disassembly ...................................................................................................... 7-8
Rack and Pinion Assembly .......................................................................................................... 7-11
Rack and Pinion Installation ......................................................................................................... 7-12
Front Suspension ............................................................................................................................. 7-14
Lubrication .................................................................................................................................... 7-14
Wheel Alignment .......................................................................................................................... 7-14
Front Suspension Components ........................................................................................................ 7-16
Kingpin and Steering Spindle Removal ........................................................................................ 7-16
Kingpin and Steering Spindle Installation ..................................................................................... 7-16
A-Arm Removal ............................................................................................................................ 7-17
A-Arm Installation ......................................................................................................................... 7-19
Shock Absorber Removal ............................................................................................................ 7-19
Shock Absorber Installation ......................................................................................................... 7-20
Front Wheel Bearings and Hubs ...................................................................................................... 7-21
Front Wheel Free Play Inspection ................................................................................................ 7-21
Front Wheel Bearings and Hub Removal ..................................................................................... 7-21
Front Wheel Bearings and Hub Installation .................................................................................. 7-21
SECTION 8 – WHEELS AND TIRES
General Information ......................................................................................................................... 8-2
Wheels ............................................................................................................................................. 8-2
Wheel Removal ............................................................................................................................ 8-2
Wheel Installation ......................................................................................................................... 8-3
Tires ................................................................................................................................................. 8-3
Tire Repair ................................................................................................................................... 8-3
Tire Removal ................................................................................................................................ 8-3
Tire Installation ............................................................................................................................. 8-3
SECTION 9 – REAR SUSPENSION
General Information ......................................................................................................................... 9-2
Shock Absorbers .............................................................................................................................. 9-2
Shock Absorber Removal and Inspection .................................................................................... 9-2
Shock Absorber Installation ......................................................................................................... 9-5

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Multi-Leaf Springs ............................................................................................................................. 9-5
Multi-Leaf Spring Removal ........................................................................................................... 9-5
Multi-Leaf Spring Installation ........................................................................................................ 9-6
Snubber ............................................................................................................................................ 9-7
Snubber Removal ......................................................................................................................... 9-7
Snubber Installation ...................................................................................................................... 9-7
SECTION 10 – PERIODIC MAINTENANCE
General Information .......................................................................................................................... 10-2
Pre-Operation and Daily Safety Checklist ........................................................................................ 10-3
Performance Inspection ................................................................................................................ 10-3
Periodic Service Schedule ................................................................................................................ 10-4
Periodic Lubrication Schedule .......................................................................................................... 10-5
Master Cylinder ................................................................................................................................. 10-6
Brake Fluid .................................................................................................................................... 10-6
Engine Oil ......................................................................................................................................... 10-6
Oil Viscosity .................................................................................................................................. 10-7
Fueling Instructions .......................................................................................................................... 10-7
Battery .............................................................................................................................................. 10-8
SECTION 11A – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400, KEY-
START ENGINE
General Information .......................................................................................................................... 11a-2
Troubleshooting Guide ..................................................................................................................... 11a-3
Electrical System .............................................................................................................................. 11a-7
Wiring Diagram ................................................................................................................................. 11a-8
Electrical Circuits .............................................................................................................................. 11a-10
Starter Circuit ................................................................................................................................ 11a-10
Generator Circuit .......................................................................................................................... 11a-10
Engine Ignition Circuit ................................................................................................................... 11a-11
Engine Kill Circuit .......................................................................................................................... 11a-11
Reverse Buzzer Circuit ................................................................................................................. 11a-12
Low Oil Warning Circuit ................................................................................................................ 11a-12
Lockout Cam Circuit ..................................................................................................................... 11a-13
Fuel Gauge and Sending Unit Circuit ........................................................................................... 11a-14
Hour Meter Circuit ......................................................................................................................... 11a-15
Lighting Circuit .............................................................................................................................. 11a-15

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Circuit Testing .................................................................................................................................. 11a-15
Testing the Starter Circuit and Generator Circuit ......................................................................... 11a-16
Testing the Engine Ignition Circuit ............................................................................................... 11a-17
Testing the Engine Kill Circuit ...................................................................................................... 11a-17
Testing the Reverse Buzzer Circuit .............................................................................................. 11a-18
Testing the Low Oil Warning Circuit ............................................................................................. 11a-19
Testing the Lockout Cam Circuit .................................................................................................. 11a-20
Testing the Fuel Gauge and Sending Unit Circuit ........................................................................ 11a-20
Testing the Lighting Circuit ........................................................................................................... 11a-21
Test Procedures ............................................................................................................................... 11a-21
Index of Test Procedures ............................................................................................................. 11a-21
SECTION 11B – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE350, PEDAL-
START ENGINE
General Information ......................................................................................................................... 11b-2
Troubleshooting Guide ..................................................................................................................... 11b-3
Electrical System .............................................................................................................................. 11b-7
Starter Circuit ............................................................................................................................... 11b-10
Generator Circuit .......................................................................................................................... 11b-10
Engine Ignition Circuit .................................................................................................................. 11b-11
Engine Kill Circuit ......................................................................................................................... 11b-11
Reverse Buzzer Circuit ................................................................................................................ 11b-12
Low Oil Warning Circuit ................................................................................................................ 11b-12
Neutral Lockout Circuit ................................................................................................................. 11b-13
Fuel Gauge and Sending Unit Circuit ........................................................................................... 11b-14
Hour Meter Circuit ........................................................................................................................ 11b-15
Lighting Circuit ............................................................................................................................. 11b-15
Testing the Starter Circuit and Generator Circuit ......................................................................... 11b-16
Testing the Engine Ignition Circuit ............................................................................................... 11b-16
Testing the Engine Kill Circuit ...................................................................................................... 11b-17
Testing the Reverse Buzzer Circuit .............................................................................................. 11b-19
Testing the Low Oil Warning Circuit ............................................................................................. 11b-20
Testing the Neutral Lockout Circuit .............................................................................................. 11b-20
Testing the Fuel Gauge and Sending Unit Circuit ........................................................................ 11b-21
Testing the Lighting Circuit ........................................................................................................... 11b-22
Index of Test Procedure ............................................................................................................... 11b-23
SECTION 12A – ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE
Starter/Generator ............................................................................................................................. 12a-2
Voltage Regulator ............................................................................................................................ 12a-13
Diode ................................................................................................................................................ 12a-14

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Key Switch ........................................................................................................................................ 12a-16
Solenoid ............................................................................................................................................ 12a-17
Fuse .................................................................................................................................................. 12a-18
Lockout Cam Limit Switch ................................................................................................................ 12a-20
Lockout Cam .................................................................................................................................... 12a-21
Reverse Warning Buzzer .................................................................................................................. 12a-22
Reverse Buzzer Limit Switch ............................................................................................................ 12a-23
Oil Warning Light .............................................................................................................................. 12a-24
Fuel Gauge/Hour Meter .................................................................................................................... 12a-25
Fuel Level Sending Unit ................................................................................................................... 12a-26
RPM Limiter ...................................................................................................................................... 12a-26
Ignition Coil ....................................................................................................................................... 12a-27
Oil Level Sensor ............................................................................................................................... 12a-30
Headlights ......................................................................................................................................... 12a-31
Headlight Diode ................................................................................................................................ 12a-32
Light Switch ...................................................................................................................................... 12a-33
Battery .............................................................................................................................................. 12a-33
Ground Cables ................................................................................................................................. 12a-38
SECTION 12B – ELECTRICAL COMPONENTS: FE350, PEDAL-START ENGINE
Starter/Generator .............................................................................................................................. 12b-2
Voltage Regulator ............................................................................................................................. 12b-13
Key Switch ........................................................................................................................................ 12b-14
Solenoid ............................................................................................................................................ 12b-15
Kill Limit Switch ................................................................................................................................. 12b-18
Neutral Lockout Limit Switch ............................................................................................................ 12b-19
Neutral Lockout Cam ........................................................................................................................ 12b-20
Reverse Warning Buzzer .................................................................................................................. 12b-21
Reverse Buzzer Limit Switch ............................................................................................................ 12b-22
Oil Warning Light .............................................................................................................................. 12b-23
Fuel Gauge/Hour Meter .................................................................................................................... 12b-24
RPM Limiter ...................................................................................................................................... 12b-25
Ignition Coil ....................................................................................................................................... 12b-26
Oil Level Sensor ............................................................................................................................... 12b-29
Headlights ......................................................................................................................................... 12b-30
Voltage Limiter .................................................................................................................................. 12b-31
Light Switch ...................................................................................................................................... 12b-32
Battery .............................................................................................................................................. 12b-32
Charging the Battery ..................................................................................................................... 12b-35
Ground Cables ................................................................................................................................. 12b-37

Page xii 2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual
SECTION 13 – FE350 AND FE400 ENGINES
General Information ......................................................................................................................... 13-2
Special Engine Service Tools Available from Club Car ............................................................... 13-3
Before Servicing ........................................................................................................................... 13-3
Mechanical Systems .................................................................................................................... 13-3
Lubrication System ....................................................................................................................... 13-5
Hydraulic Lifters ........................................................................................................................... 13-6
Spark Plug .................................................................................................................................... 13-7
Engine Mounting Plate ..................................................................................................................... 13-8
Cylinder Head .................................................................................................................................. 13-8
General Information ..................................................................................................................... 13-8
Cylinder Shroud Removal ............................................................................................................ 13-9
Rocker Arm and Push Rod Removal ........................................................................................... 13-10
Cylinder Head Removal ............................................................................................................... 13-10
Valve Removal ............................................................................................................................. 13-11
Breather Valve (Reed Valve) ....................................................................................................... 13-12
Cylinder Head Cleaning and Inspection ....................................................................................... 13-13
Valve Guides ................................................................................................................................ 13-13
Valve Seats .................................................................................................................................. 13-14
Valves .......................................................................................................................................... 13-17
Rocker Arm and Rocker Shaft inspection .................................................................................... 13-18
Push Rod Inspection .................................................................................................................... 13-19
Cylinder Head Installation ............................................................................................................ 13-19
Valve Clearance Check and Adjustment ...................................................................................... 13-19
Breather Valve (Reed Valve) ....................................................................................................... 13-20
Installation of Remaining Engine Components ............................................................................ 13-21
Crankcase ........................................................................................................................................ 13-22
Engine Removal ........................................................................................................................... 13-22
Crankcase Cover Removal .......................................................................................................... 13-22
Oil Level Sensor ........................................................................................................................... 13-22
Camshaft and Hydraulic Lifters .................................................................................................... 13-25
Piston and Connecting Rod ............................................................................................................. 13-26
Cylinder Block .................................................................................................................................. 13-29
Ignition Coil and Flywheel ................................................................................................................ 13-31
Oil Pump .......................................................................................................................................... 13-33
Oil Pressure Relief Valve ............................................................................................................. 13-34
Crankshaft and Counterbalance ...................................................................................................... 13-36
Counterbalance Weight ................................................................................................................ 13-38
Oil Screen .................................................................................................................................... 13-41
Ball Bearing .................................................................................................................................. 13-41
Oil Seals ....................................................................................................................................... 13-42

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Crankshaft Axial Play Adjustment ..................................................................................................... 13-45
Crankcase Cover Installation ........................................................................................................ 13-48
Engine Assembly .............................................................................................................................. 13-49
Service Specifications ...................................................................................................................... 13-51
Specifications for Resizing Cylinder Bore ..................................................................................... 13-52
Torque Specifications ................................................................................................................... 13-52
Adjustment and Settings ............................................................................................................... 13-53
SECTION 14 – FUEL SYSTEM
General Information .......................................................................................................................... 14-2
How the Carburetor Works ............................................................................................................... 14-2
Main System ................................................................................................................................. 14-2
Slow Speed System ...................................................................................................................... 14-3
Choke and Fresh Air System ........................................................................................................ 14-3
Float System ................................................................................................................................. 14-4
Carburetor ......................................................................................................................................... 14-5
Main Jet Elevation/Size Chart ....................................................................................................... 14-6
Changing the Main Jet .................................................................................................................. 14-6
Engine Control Linkage .................................................................................................................... 14-10
General Information ...................................................................................................................... 14-10
Accelerator Rod ............................................................................................................................ 14-10
Governor Cable ............................................................................................................................ 14-12
Accelerator Cable ......................................................................................................................... 14-12
Closed Throttle or Idle Adjustment ............................................................................................... 14-14
Engine RPM Adjustment ............................................................................................................... 14-14
Choke and Air Intake System ........................................................................................................... 14-16
General Information ...................................................................................................................... 14-16
Choke Cable Removal .................................................................................................................. 14-17
Choke Cable Installation ............................................................................................................... 14-17
Air Box Removal ........................................................................................................................... 14-17
Air Box Installation ........................................................................................................................ 14-17
Intake Duct Repair ........................................................................................................................ 14-18
Intake Duct Removal .................................................................................................................... 14-18
Intake Duct Installation ................................................................................................................. 14-19
Air Filter ........................................................................................................................................ 14-20
Fuel Filters ........................................................................................................................................ 14-21
General Information ...................................................................................................................... 14-21
Fuel Filter Removal ....................................................................................................................... 14-21
Fuel Filter Installation .................................................................................................................... 14-22

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Fuel Pump ........................................................................................................................................ 14-22
General Information ..................................................................................................................... 14-22
Fuel Pump Removal ..................................................................................................................... 14-24
Fuel Pump Disassembly .............................................................................................................. 14-24
Fuel Pump Cleaning and Inspection ............................................................................................ 14-25
Fuel Pump Assembly ................................................................................................................... 14-25
Fuel Pump Installation .................................................................................................................. 14-26
Fuel Tank ......................................................................................................................................... 14-26
General Information ..................................................................................................................... 14-28
Fuel Tank Removal ...................................................................................................................... 14-28
Fuel Tank Disposal ...................................................................................................................... 14-29
Fuel Tank Storage ........................................................................................................................ 14-29
Fuel Tank Installation ................................................................................................................... 14-30
Fuel Lines ......................................................................................................................................... 14-31
Fuel Shut-Off Valve .......................................................................................................................... 14-32
SECTION 15 – EXHAUST SYSTEM
General Information ......................................................................................................................... 15-2
Muffler .............................................................................................................................................. 15-2
Muffler Removal ........................................................................................................................... 15-2
Muffler Installation ........................................................................................................................ 15-3
SECTION 16A – MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
Transaxle Models and Identification ................................................................................................. 16a-2
Lubrication .................................................................................................................................... 16a-3
Axle Shaft ......................................................................................................................................... 16a-5
Axle Shaft, Bearing, and Oil Seal Removal .................................................................................. 16a-5
Axle Bearing Removal .................................................................................................................. 16a-7
Axle Shaft, Bearing, and Oil Seal Installation ............................................................................... 16a-7
Unitized Transaxle Removal ............................................................................................................ 16a-9
Unitized Transaxle Disassembly ...................................................................................................... 16a-18
Component Disassembly ................................................................................................................. 16a-20
Differential Gear Lock Housing Disassembly ............................................................................... 16a-20
Governor Gear Disassembly ........................................................................................................ 16a-22
Differential Gear Case Disassembly ............................................................................................ 16a-22
Shifter Fork Disassembly ............................................................................................................. 16a-25
Synchronizer Gear Disassembly .................................................................................................. 16a-25
Intermediate Gear Disassembly ................................................................................................... 16a-26
Idler Shaft Disassembly ............................................................................................................... 16a-27

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Unitized Transaxle Component Inspection ....................................................................................... 16a-28
Idler Shaft Assembly ..................................................................................................................... 16a-28
Intermediate Gear Assembly ........................................................................................................ 16a-29
Synchronizer Gear Assembly ....................................................................................................... 16a-29
Shifter Fork Assembly ................................................................................................................... 16a-31
Differential Gear Case Assembly .................................................................................................. 16a-31
Governor Gear Assembly ............................................................................................................. 16a-33
Differential Gear Lock Housing Assembly .................................................................................... 16a-33
Unitized Transaxle Assembly ........................................................................................................... 16a-34
Unitized Transaxle Installation .......................................................................................................... 16a-42
Forward/Reverse Shifter Cable ........................................................................................................ 16a-50
Forward/Reverse Shifter Cable Removal ..................................................................................... 16a-50
Forward/Reverse Shifter Cable Installation .................................................................................. 16a-50
Forward/Reverse Shifter Cable Adjustment ................................................................................. 16a-51
Differential Lock System ................................................................................................................... 16a-52
Differential Lock System Inspection .............................................................................................. 16a-52
Differential Lock Cable Removal .................................................................................................. 16a-52
Differential Lock Cable Installation ............................................................................................... 16a-53
SECTION 16B – MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
Transaxle Models ............................................................................................................................. 16b-2
Lubrication .................................................................................................................................... 16b-3
Axle Shaft ......................................................................................................................................... 16b-5
Axle Shaft and Oil Seal Removal .................................................................................................. 16b-5
Axle Bearing ................................................................................................................................. 16b-6
Axle Shaft and Oil Seal Installation ............................................................................................... 16b-9
Unitized Transaxle Removal ............................................................................................................. 16b-9
Unitized Transaxle Disassembly ....................................................................................................... 16b-18
Component Disassembly .................................................................................................................. 16b-21
Differential Gear Lock Housing Disassembly ............................................................................... 16b-21
Governor Gear Disassembly ........................................................................................................ 16b-22
Differential Gear Case Disassembly ............................................................................................. 16b-22
Shifter Fork Disassembly .............................................................................................................. 16b-25
Synchronizer Gear Disassembly .................................................................................................. 16b-25
Intermediate Gear Disassembly ................................................................................................... 16b-26
Idler Shaft Disassembly ................................................................................................................ 16b-27

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Unitized Transaxle Component Inspection ...................................................................................... 16b-28
Idler Shaft Assembly .................................................................................................................... 16b-28
Intermediate Gear Assembly ........................................................................................................ 16b-29
Synchronizer Gear Assembly ....................................................................................................... 16b-29
Shifter Fork Assembly .................................................................................................................. 16b-31
Differential Gear Case Assembly ................................................................................................. 16b-31
Governor Gear Assembly ............................................................................................................. 16b-33
Differential Gear Lock Housing Assembly .................................................................................... 16b-33
Unitized Transaxle Assembly ........................................................................................................... 16b-34
Unitized Transaxle Installation ......................................................................................................... 16b-41
Forward/Reverse Shifter Cable ........................................................................................................ 16b-49
Forward/Reverse Shifter Cable Removal ..................................................................................... 16b-49
Forward/Reverse Shifter Cable Installation .................................................................................. 16b-50
Forward/Reverse Shifter Cable Adjustment ................................................................................. 16b-51
Differential Lock System .................................................................................................................. 16b-51
Differential Lock System Inspection ............................................................................................. 16b-51
Differential Lock Cable Removal .................................................................................................. 16b-52
Differential Lock Cable Installation ............................................................................................... 16b-52
SECTION 17 – TORQUE CONVERTER
General Information ......................................................................................................................... 17-2
Drive Belt .......................................................................................................................................... 17-4
Drive Belt Removal ...................................................................................................................... 17-4
Drive Belt Installation ................................................................................................................... 17-5
Drive Clutch ...................................................................................................................................... 17-5
Drive Clutch Removal .................................................................................................................. 17-5
Drive Clutch Cleaning and Inspection .......................................................................................... 17-6
Drive Clutch Disassembly ............................................................................................................ 17-7
Inspection of Drive Clutch Parts ................................................................................................... 17-10
Drive Clutch Assembly ................................................................................................................. 17-11
Drive Clutch Installation ............................................................................................................... 17-13
Driven Clutch .................................................................................................................................... 17-14
Driven Clutch Removal ................................................................................................................ 17-14
Driven Clutch Disassembly .......................................................................................................... 17-14
Driven Clutch Inspection .............................................................................................................. 17-14
Driven Clutch Assembly ............................................................................................................... 17-16
Driven Clutch Installation ............................................................................................................. 17-18

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SECTION ia – INDEX FOR FE400 KEY-START VEHICLES
SECTION ib – INDEX FOR FE350 PEDAL-START VEHICLES

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