Club Car 2005 FE290 Manual

Club Car
MANUAL NUMBER 102680409
EDITION CODE 1204B0205A
FE290 GASOLINE VEHICLES
2005
MAINTENANCE
SERVICE
SUPPLEMENT

2005 FE290 Gasoline Vehicle Maintenance and Service Supplement 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 supplement provides detailed information for the maintenance and repair of FE290 gasoline vehicles and
should be used in conjunction with the appropriate maintenance and service manual. This supplement also
provides detailed information for removing and replacing FE290 engines and transaxles, but does not contain
information for the disassembly, repair or rebuilding of FE290 engines or transaxles. For complete detailed
disassembly, repair or rebuild procedures, see the Engines and Drivetrain Components, Repair and Rebuild
Manual (CCI P/N 102396501).
If you do not have the appropriate maintenance and service manual, you may order one from your local Club
Car representative. Maintenance and service manuals available include the following:
This supplement and corresponding maintenance and service manual should be thoroughly reviewed prior to
servicing the vehicle. The procedures provided must be properly implemented, and the DANGER, WARNING,
and CAUTION statements must be heeded.
This manual was written for the trained technician who already has 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 tech-
nician.
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 supplement, used in conjunction with the appropriate maintenance and service manual, covers all
aspects of typical vehicle service; however, unique situations 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 30917-4658, USA, Attention: Technical Services, or contact a Club Car Technical
Service Representative at [phone], ext. 3580.
2005 DS Golf Car Maintenance and Service Manual Publication Part No. 102680403
2005 Turf/Carryall Vehicle Maintenance and Service Manual Publication Part No. 102680404
2005 Villager/TransPorter Vehicle Maintenance and Service Manual Publication Part No. 102680405
Engines and Drivetrain Components, Repair and Rebuild Manual Publication Part No. 102396501
Copyright © 2004 Club Car, Inc.
Club Car, Carryall, ArmorFlex and Tranquility
are registered trademarks of Club Car, Inc.
This manual effective July 28, 2004.

Page ii 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
ý WARNING
• Read Section 1 – Safety in the appropriate maintenance and service manual 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 its 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 and Carryall distributors/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 supplement. 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 Administration.

2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page iii
CONTENTS
SECTION 10 – PERIODIC MAINTENANCE
General Warning ............................................................................................................................... 10-1
General Information .......................................................................................................................... 10-3
Periodic Service Schedule ................................................................................................................ 10-3
Periodic Lubrication Schedule .......................................................................................................... 10-5
Engine Oil ......................................................................................................................................... 10-6
Engine Oil Level Check ................................................................................................................ 10-6
Oil Viscosity .................................................................................................................................. 10-7
Fueling Instructions ........................................................................................................................... 10-7
Battery .............................................................................................................................................. 10-8
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM
General Information .......................................................................................................................... 11-1
Troubleshooting Guide ..................................................................................................................... 11-1
Electrical System .............................................................................................................................. 11-7
Test Procedures ............................................................................................................................... 11-7
Index of Test Procedures .............................................................................................................. 11-7
SECTION 12 – ELECTRICAL COMPONENTS
Starter/Generator .............................................................................................................................. 12-1
Voltage Regulator ............................................................................................................................. 12-12
Key Switch ........................................................................................................................................ 12-13
Solenoid ............................................................................................................................................ 12-14
Fuse .................................................................................................................................................. 12-15
Accelerator Pedal Limit Switch ......................................................................................................... 12-15
Kill Limit Switch ................................................................................................................................. 12-16
Neutral Lockout Limit Switch ............................................................................................................ 12-17
Neutral Lockout Cam ........................................................................................................................ 12-18
Reverse Warning Buzzer .................................................................................................................. 12-19
Reverse Buzzer Limit Switch ............................................................................................................ 12-20
Low Oil Warning Light ....................................................................................................................... 12-21
Fuel Gauge/Hour Meter .................................................................................................................... 12-22
Fuel Level Sending Unit .................................................................................................................... 12-23
RPM Limiter ...................................................................................................................................... 12-23
Ignition Coil ....................................................................................................................................... 12-24
Oil Level Sensor ............................................................................................................................... 12-27

Page iv 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
Battery .............................................................................................................................................. 12-28
Ground Cables ................................................................................................................................. 12-32
SECTION 13 – FE290 ENGINE
General Information ......................................................................................................................... 13-1
Before Servicing ........................................................................................................................... 13-1
Engine Rotation ............................................................................................................................ 13-1
Spark Plug .................................................................................................................................... 13-1
Cylinder Head .................................................................................................................................. 13-3
General Information ...................................................................................................................... 13-3
Breather Valve (Reed Valve) ........................................................................................................ 13-3
Crankcase ........................................................................................................................................ 13-3
Engine Removal ........................................................................................................................... 13-3
Crankcase Cover Removal .......................................................................................................... 13-4
Oil Level Sensor ........................................................................................................................... 13-5
Crankcase Cover Installation ....................................................................................................... 13-6
Ignition Coil and Flywheel ................................................................................................................ 13-7
Flywheel Installation ......................................................................................................................... 13-9
Engine Installation ............................................................................................................................ 13-9
Torque Specifications ................................................................................................................... 13-11
Adjustments and Settings ............................................................................................................ 13-11
SECTION 14 – FUEL SYSTEM
General Information ......................................................................................................................... 14-1
Carburetor ........................................................................................................................................ 14-1
Main Jet Elevation/Size Chart ...................................................................................................... 14-2
Changing the Main Jet ................................................................................................................. 14-2
Engine Control Linkage .................................................................................................................... 14-5
General Information ...................................................................................................................... 14-5
Accelerator Rod ............................................................................................................................ 14-6
Governor Cable ............................................................................................................................ 14-8
Accelerator Cable ......................................................................................................................... 14-9
Closed Throttle or Idle Adjustment ............................................................................................... 14-11
Engine RPM Adjustment .............................................................................................................. 14-11

2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page v
Choke and Air Intake System ........................................................................................................... 14-12
General Information ...................................................................................................................... 14-12
Choke Button Removal ................................................................................................................. 14-12
Choke Button Installation .............................................................................................................. 14-12
Air Box Removal ........................................................................................................................... 14-13
Air Box Installation ........................................................................................................................ 14-13
Intake Duct Removal .................................................................................................................... 14-13
Intake Duct Installation ................................................................................................................. 14-15
Intake Duct Repair ........................................................................................................................ 14-15
Air Filter ........................................................................................................................................ 14-16
Fuel Filters ........................................................................................................................................ 14-16
General Information ...................................................................................................................... 14-16
Fuel Filter Removal ....................................................................................................................... 14-17
Fuel Filter Installation .................................................................................................................... 14-17
Fuel Pump ........................................................................................................................................ 14-19
General Information ...................................................................................................................... 14-19
Fuel Pump Removal ..................................................................................................................... 14-19
Fuel Pump Disassembly ............................................................................................................... 14-19
Fuel Pump Cleaning and Inspection ............................................................................................. 14-20
Fuel Pump Assembly .................................................................................................................... 14-20
Fuel Pump Installation .................................................................................................................. 14-21
Fuel Tank .......................................................................................................................................... 14-22
General Information ...................................................................................................................... 14-22
Fuel Tank Removal ....................................................................................................................... 14-22
Fuel Tank Disposal ....................................................................................................................... 14-23
Fuel Tank Storage ........................................................................................................................ 14-23
Fuel Tank Installation .................................................................................................................... 14-24
Fuel Lines ......................................................................................................................................... 14-25
Fuel Shut-Off Valve .......................................................................................................................... 14-26
SECTION 15 – EXHAUST SYSTEM
Muffler ............................................................................................................................................... 15-1
Muffler Removal ............................................................................................................................ 15-1
Muffler Installation ......................................................................................................................... 15-1
SECTION 16 – UNITIZED TRANSAXLE
General Information .......................................................................................................................... 16-1
Lubrication .................................................................................................................................... 16-2

Page vi 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
Axle Shaft ......................................................................................................................................... 16-3
Axle Shaft and Oil Seal Removal ................................................................................................. 16-3
Axle Bearing ................................................................................................................................. 16-4
Axle Shaft Installation ................................................................................................................... 16-6
Unitized Transaxle Removal ............................................................................................................ 16-7
Unitized Transaxle Installation ......................................................................................................... 16-16
Forward/Reverse Shifter Cable ........................................................................................................ 16-21
Forward/Reverse Shifter Cable Removal ..................................................................................... 16-21
Forward/Reverse Shifter Cable Installation .................................................................................. 16-21
Forward/Reverse Shifter Cable Adjustment ................................................................................. 16-22
SECTION 17 – TORQUE CONVERTER
General Information ......................................................................................................................... 17-1
Troubleshooting ............................................................................................................................... 17-1
Drive Belt .......................................................................................................................................... 17-2
Drive Belt Removal ....................................................................................................................... 17-3
Drive Belt Installation .................................................................................................................... 17-3
Drive Clutch ...................................................................................................................................... 17-4
Drive Clutch Removal ................................................................................................................... 17-4
Drive Clutch Cleaning and Inspection .......................................................................................... 17-5
Drive Clutch Disassembly ............................................................................................................ 17-7
Inspection of Drive Clutch Parts ................................................................................................... 17-9
Drive Clutch Assembly ................................................................................................................. 17-10
Drive Clutch Installation ................................................................................................................ 17-12
Driven Clutch .................................................................................................................................... 17-12
Driven Clutch Removal ................................................................................................................. 17-12
Driven Clutch Disassembly .......................................................................................................... 17-12
Driven Clutch Inspection .............................................................................................................. 17-13
Driven Clutch Assembly ............................................................................................................... 17-13
Driven Clutch Installation .............................................................................................................. 17-16
SECTION i – INDEX

2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10-1
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SECTION 10 – PERIODIC MAINTENANCE
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.
ý 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.
ý 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 servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF,
remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Chock the
wheels when servicing the vehicle.
• To avoid unintentionally starting the vehicle:
- Disconnect battery cables, negative (–) cable first (Figure 10-1, Page 10-3).
- 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.
WARNING CONTINUED ON NEXT PAGE...

PERIODIC MAINTENANCE General Warning
Page 10-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
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Aý WARNING
• 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.

PERIODIC MAINTENANCE General Information
2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10-3
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A
GENERAL INFORMATION
See General Warning on page 10-1.
To ensure trouble-free vehicle performance, it is very important to follow an established preventive mainte-
nance program (regularly scheduled service). Regular and consistent vehicle maintenance can prevent vehi-
cle down-time and expensive repairs that result from neglect. Any vehicle not functioning correctly should be
removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the
possibility of injury due to unsafe conditions.
Contact your local authorized Club Car distributor/dealer to perform all repairs and semiannual and annual
periodic service.
PERIODIC SERVICE SCHEDULE
See General Warning on page 10-1.
ý WARNING
• Service, repairs, and adjustments must be made per instructions in the maintenance and
service manual and this supplement.
NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, the preventive
maintenance procedures should be performed more often than recommended in the periodic ser-
vice and lubrication schedules.
Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to
keep the vehicle in optimum operating condition.
Figure 10-1 Battery Cable Removal
AS SEEN FROM
PASSENGER SIDE
OF VEHICLE
FRONT
OF VEHICLE
Remove
negative
cable first.
DISCONNECT BATTERY CABLES
BEFORE WORKING ON VEHICLE

PERIODIC MAINTENANCE Periodic Service Schedule
Page 10-4 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
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ý WARNING
• If any problems are found during scheduled inspection or service, do not operate the vehicle
until repairs are made. Failure to make necessary repairs could result in fire, property
damage, severe personal injury, or death.
PERIODIC SERVICE SCHEDULE
REGULAR INTERVAL SERVICE
Monthly service by owner
or trained technician
Engine
Check engine oil level; change if
necessary. See Periodic Lubrication
Schedule on page 10-5.
Check engine cooling air intake; visually
inspect unshrouded area around engine
exhaust for grass and debris, and clean if
necessary.
Tires
Check air pressure and adjust if
necessary. See Section 2 –
Specifications in the appropriate
maintenance and service manual.
General vehicle Wash engine compartment and underside
of vehicle. Do not wash engine when hot.
Semiannual service by trained
technician only
(every 50 hours of
operation or every 100 rounds
for golf cars)
Battery
Clean terminals and wash dirt from
casing; check electrolyte level. See
Battery, Section 12, Page 12-28.
Front wheel alignment and camber
Check and adjust if necessary. See
Section 7 – Steering and Front
Suspension in the appropriate
maintenance and service manual.
Electrical wiring and connections Check for tightness and damage.
Brake system
Check brake shoes; replace if necessary.
See Section 6 – Wheel Brake
Assemblies in the appropriate
maintenance and service manual.
Lubricate brake slides per lubrication
schedule. See Section 6 – Wheel Brake
Assemblies in the appropriate
maintenance and service manual.
Check brake cables for damage; replace if
necessary.
Annual service by
trained technician only
(every 100 hours of
operation or every 200
rounds for golf cars)
Engine
Check for leaks around gaskets, fill plugs,
etc.
Inspect, clean and gap spark plug; replace
if necessary.
Engine air intake system
Check air filter element; clean or replace if
necessary. Dispose of used filter element
properly.
Check clamps for tightness; check hose
for cracks.
General vehicle Check for loose hardware and tighten if
necessary.
Two year service by trained technician
only (every 200 hours of operation or
every 400 rounds for golf cars)
Fuel filters Replace. Dispose of used filters properly.

PERIODIC MAINTENANCE Periodic Lubrication Schedule
2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10-5
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PERIODIC LUBRICATION SCHEDULE
See General Warning on page 10-1.
PERIODIC LUBRICATION SCHEDULE
REGULAR INTERVAL SERVICE LUBRICATION
POINT RECOMMENDED LUBRICANT
Semiannually by owner
or trained technician (every
50 hours of operation or
every 100 rounds for golf
cars)
Brake pedal shaft bearings Dry Moly Lube –(CCI P/N 1012151)
Brake linkage and pivots Dry Moly Lube – (CCI P/N 1012151)
Accelerator push rod pivots,
mounts, and shifter cable pivots Dry Moly Lube – (CCI P/N 1012151)
Front suspension (5 fittings) Chassis Lube – EP NLGI Grade 2
Brake slides Dry Moly Lube – (CCI P/N 1012151)
Annually by trained
technician only
(every 100 hours of
operation or every 200
rounds for golf cars)
Check/fill unitized transaxle to
plug level
27 oz. (0.8 liter) 80-90 WT. API class GL-3
or 80-90 WT. AGMA class EP Gear Lube
Inspect front wheel bearings
(Repack as necessary)
(Not applicable for DS)
Chassis Lube – EP NLGI Grade 2
First change 100 hours.
Additional change every
200 hours of operation (or
every 400 rounds for golf
cars) or annually,
whichever comes first.
Change engine oil and oil filter
32 oz. (0.97 liter) without filter; 38 oz. (1.16
liters) with filter. 10W30 above 32 °F (0 °C)
or SAE 5W20 below 32 °F (0 °C) API class
SE, SF, or SG Oil (or higher)
Figure 10-2 Lubrication Points
1
2
3
4
5
6
7
8
5
5
3
4
4
4
2
2
1
1
7
7
4
3
83
6
5
3
4
3
5
FLOORBOARD
* If equipped with four-wheel brakes.
** Not applicable for DS
*
*
**
**

PERIODIC MAINTENANCE Engine Oil
Page 10-6 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
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AENGINE OIL
See General Warning on page 10-1.
Even though the low oil warning light on the dash should illuminate if the engine oil level is low, the engine oil
level should be checked monthly. The vehicle should be on a level surface when checking oil.
ENGINE OIL LEVEL CHECK
1. Remove the oil level dipstick from the oil filler tube and wipe oil from the stick (Figure 10-3, Page 10-6).
See following CAUTION.
ý CAUTION
• Do not remove dipstick while engine is running.
2. Check oil level by fully inserting the dipstick into the oil filler tube and immediately removing it again.
3. If the oil level is at or below the low level mark on the dipstick gauge, add oil until the level is between low
and full level (safe level).
NOTE: Properly recycle or dispose of used oil in accordance with local, state, and federal regulations.
Figure 10-3 Check Engine Oil Level Figure 10-4 Fuel Tank
Club Car
1
Remove dip stick
and clean.
Reinsert dip stick
until fully seated.
2
Low
Level
Safe
Level
3
Full
Level
Oil must be in
the Safe Level.
TO
CARBURETOR
VENT TUBES
SHUT-OFF
VALVE
VENT

PERIODIC MAINTENANCE Fueling Instructions
2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 10-7
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OIL VISCOSITY
Choose the viscosity according to the temperature as indicated by the oil viscosity chart (Figure 10-5,
Page 10-7). See following NOTE.
NOTE: Using multi-grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. Check oil level
more frequently when using multi-grade oils.
FUELING INSTRUCTIONS
See General Warning on page 10-1.
ý DANGER
• Turn key switch to the OFF position before fueling.
• Do not pour fuel into the fuel tank when the engine is hot or while it is running.
• To avoid electric arc caused by static electricity, the fuel storage/pumping device must be
grounded. If the pump is not grounded, the vehicle must be grounded to the pump before and
during the fueling operation.
• If the vehicle has an all-weather enclosure installed, the fuel tank must be properly vented as
shown (Figure 10-4, Page 10-6).
• To avoid the possibility of fire, clean up any spilled fuel before operating the vehicle.
ý CAUTION
• To allow for expansion, do not fill higher than one inch (2.54 cm) from the top of the fuel tank.
Avoid spilling fuel.
NOTE: Whenever possible, avoid using oxygenated fuels and fuels that are blended with alcohol. Vehicles
to be stored for extended periods should be prepared for storage as instructed. See Preparing the
Vehicle for Extended Storage in Section 3 of the appropriate maintenance and service man-
ual.
Figure 10-5 Oil Viscosity Chart
°
°
°°°°°°
C
°°
°°°
°°
-20 C -10 C 0 C 10 C 20 C
-4 F F 32 F 68 F 86 F 104 F
SAE 5W-20
SAE 10W-30/SAE 10W-40
SAE 30
SAE 40
30 40
14 50 F

PERIODIC MAINTENANCE Battery
Page 10-8 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
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AFueling Instructions, Continued:
1. Lift and remove seat bottom.
2. The fuel tank is located on the passenger side of the vehicle (Figure 10-4, Page 10-6). Remove fuel cap
and fill the fuel tank with fresh, unleaded fuel only. See preceding CAUTION and NOTE.
3. Replace fuel cap on tank. Make sure cap is tightened securely.
4. Replace seat bottom.
BATTERY
For periodic battery maintenance, see Battery, Section 12, Page 12-28.

2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-1
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SECTION 11 – TROUBLESHOOTING AND
ELECTRICAL SYSTEM
ý DANGER
• See General Warning, Section 10, Page 10-1.
ý WARNING
• See General Warning, Section 10, Page 10-1.
GENERAL INFORMATION
This section contains the information required to correctly troubleshoot the vehicle. A troubleshooting guide is
provided for general troubleshooting. In addition to troubleshooting, this section contains general information
on the electrical system and the circuits of the electrical system.
TROUBLESHOOTING GUIDE
The following troubleshooting guide will be helpful in identifying operating difficulties should they occur. The
guide includes the symptom, probable cause(s) and suggested checks. The procedures used in making these
checks can be found in the referenced sections in this supplement or the appropriate maintenance and ser-
vice manual.
TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSES REFER TO
Engine does not start easily. Spark plug is partially fouled or in poor
condition Section 13 – FE290 Engine
Spark plug wire is damaged or loose Section 13 – FE290 Engine
Loose wire connection at ignition coil or
RPM limiter
Section 11 – Troubleshooting and
Electrical System
Test Procedures 13, 14 and 15
Intermittent ignition coil failure
Section 11 – Troubleshooting and
Electrical System
Test Procedures 13, 14 and 15
Low cylinder compression Section 13 – FE290 Engine
Water or dirt in the fuel system and/or
carburetor; dirty or clogged fuel filter Section 14 – Fuel System
Troubleshooting Guide continued on next page...

TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide
Page 11-2 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
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Engine does not start easily, continued Carburetor improperly adjusted Section 14 – Fuel System
Starter/generator belt is slipping Belt Tension Adjustment, Section 12,
Page 12-11
Engine starts but does not run
smoothly.
Spark plug is fouled or in poor condition Section 13 – FE290 Engine
Spark plug wire is damaged or loose Section 13 – FE290 Engine
Intermittent ignition coil failure
Section 11 – Troubleshooting and
Electrical System
Test Procedures 13, 14 and 15
Water or dirt in the fuel system and/or
carburetor; dirty or clogged fuel filter Section 14 – Fuel System
Fuel pump malfunction; fuel pressure to
carburetor too low Section 14 – Fuel System
Engine turns but fails to start. Fuel tank is empty Section 14 – Fuel System
Fuel line or filters clogged Section 14 – Fuel System
Fouled spark plug Section 13 – FE290 Engine
Spark plug wire damaged or loose Section 13 – FE290 Engine
Loose wire connection at ignition coil or
RPM limiter
Section 11 – Troubleshooting and
Electrical System
Test Procedures 13, 14 and 15
Ignition coil or RPM limiter failed
Section 11 – Troubleshooting and
Electrical System
Test Procedures 13, 14 and 15
Engine flooded with fuel as result of
excess choking
Section 3 – General Information in the
appropriate maintenance and service
manual. See Choke.
Kill circuit grounded
Section 11 – Troubleshooting and
Electrical System
Test Procedures 16, 17, 18
Fuel pump malfunction or failure Section 14 – Fuel System
Engine overheats. Fan screen is partially blocked or plugged Section 13 – FE290 Engine
Governor is improperly adjusted Section 14 – Fuel System
Carburetor is too lean; check main jet size Section 14 – Fuel System
Engine pre-ignites. Excessive carbon deposits on piston head
or in combustion chamber Section 13 – FE290 Engine
Spark plug heat range is incorrect Section 13 – FE290 Engine
Unsuitable or contaminated fuel Section 14 – Fuel System
Loss of engine power. Exhaust valve is restricted with carbon
deposit Section 13 – FE290 Engine
Muffler or exhaust pipe restricted with
carbon or other substance Section 15 – Exhaust System
Ignition coil failed
Section 11 – Troubleshooting and
Electrical System
Test Procedures 13, 14 and 15
Troubleshooting Guide continued on next page...
TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSES REFER TO

TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide
2005 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 11-3
1
1
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Loss of engine power, continued Air filter is dirty or clogged Section 14 – Fuel System
Governor is improperly adjusted Section 14 – Fuel System
Throttle linkage out of adjustment Section 14 – Fuel System
Low cylinder compression Section 13 – FE290 Engine
Spark plug failed Section 13 – FE290 Engine
Restricted fuel flow Section 14 – Fuel System
Torque converter is not back shifting
properly Section 17 – Torque Converter
Spark plug fouls repeatedly. Incorrect plug Section 13 – FE290 Engine
Spark plug wire is damaged Section 13 – FE290 Engine
Unsuitable fuel, or incorrect (rich) fuel
mixture Section 14 – Fuel System
Ignition coil failed
Section 11 – Troubleshooting and
Electrical System
Test Procedures 13, 14 and 15
Dirt entering combustion chamber Check intake system for leaks.
Section 14 – Fuel System
Rings are heavily worn, low cylinder
pressure Section 13 – FE290 Engine
Carburetor floods. Inlet valve or seat is leaking,
dirty, worn, or damaged Section 14 – Fuel System
Float is damaged and filled with fuel Section 14 – Fuel System
Float needle valve not functioning
properly Section 14 – Fuel System
Carburetor vent is clogged Section 14 – Fuel System
Starter fails to operate. Neutral lockout cam is in the wrong
position
Test Procedure 7 – Neutral Lockout Limit
Switch on page 11-15
Fuse is blown Test Procedure 2 – Fuse on page 11-11
Battery is dead Test Procedure 1 – Battery on page 11-8
Starter control circuit is not operating Test Procedure 4 – Key Switch (Starter
Circuit) on page 11-12
Starter/generator failed Test Procedure 8 – Starter/Generator
(Starter Function) on page 11-15
Starter solenoid failed Test Procedure 6 – Solenoid on
page 11-13
Accelerator pedal limit switch failed Test Procedure 5 – Accelerator Pedal
Limit Switch on page 11-13
Key switch failed Test Procedure 4 – Key Switch (Starter
Circuit) on page 11-12
Troubleshooting Guide continued on next page...
TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSES REFER TO

TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide
Page 11-4 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
1
1
A
Starter fails to operate, continued Neutral lockout limit switch failed Test Procedure 7 – Neutral Lockout Limit
Switch on page 11-15
Loose or broken wire in starter/generator
circuit Starter/Generator, Section 12, Page 12-1
Cylinder and/or crankcase flooded with
fuel Section 14 – Fuel System
Starter/Generator does not charge
battery.
Loose or broken wire in starter/generator
circuit
Test Procedure 10 – Starter/Generator
(Generator Function) on page 11-17
Generator field coil is shorted Test Procedure 10 – Starter/Generator
(Generator Function) on page 11-17
Brushes are worn or commutator is dirty Starter/Generator, Section 12, Page 12-1
Starter/generator belt is loose or slipping Belt Tension Adjustment, Section 12,
Page 12-11
Voltage regulator failed Test Procedure 11 – Voltage Regulator on
page 11-18
Battery failed Test Procedure 1 – Battery on page 11-8
Transmission does not engage or
disengage smoothly.
Transmission shifter linkage is binding or
is out of adjustment Section 16 – Unitized Transaxle
Idle RPM setting is set too high Section 14 – Fuel System
Insufficient (low) level of lubricant or
wrong type of lubricant in transmission Section 16 – Unitized Transaxle
Internal gears are damaged or worn Section 16 – Unitized Transaxle
Synchronizer rings are worn, damaged or
jammed Section 16 – Unitized Transaxle
Excessive vehicle vibration. Engine mounting nuts or bolts are loose Section 13 – FE290 Engine
Snubber on frame is worn or damaged Section 13 – FE290 Engine
Misaligned muffler mounting clamp Section 15 – Exhaust System
Damaged drive belt or starter belt Section 17 – Torque Converter
Damaged drive clutch Section 17 – Torque Converter
Damaged driven clutch Section 17 – Torque Converter
Damaged starter/generator pulley Starter/Generator, Section 12, Page 12-1
RPM setting is incorrect Engine RPM Adjustment, Section 14,
Page 14-11
Torque converter does not shift
smoothly.
Drive belt is worn, cracked, glazed, or
frayed Section 17 – Torque Converter
Drive clutch malfunction Section 17 – Torque Converter
Driven clutch malfunction Section 17 – Torque Converter
Governor is sticking Section 16 – Unitized Transaxle
Troubleshooting Guide continued on next page...
TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSES REFER TO