Club car Fe 350 Manual

2009FE350

MaintenanceandService

Supplement

FE350GasolineVehicles

ManualNumber103472709

EditionCode0509A00000

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

ThissupplementprovidesdetailedinformationforthemaintenanceandrepairofFE350gasolinevehiclesandshould

beusedinconjunctionwiththeappropriatemaintenanceandservicemanual.Thissupplementalsoprovidesdetailed

informationforremovingandreplacingFE350enginesandtransaxles,butdoesnotcontaininformationforthe

disassembly,repairorrebuildingofFE350enginesortransaxles.Forcompletedetaileddisassembly,repairorrebuild

procedures,seetheEnginesandDrivetrainComponents,RepairandRebuildManual(CCIP/N102396501).

Ifyoudonothavetheappropriatemaintenanceandservicemanual,youmayorderonefromyourlocalClubCar

representative.Maintenanceandservicemanualsavailableincludethefollowing:

2008/2009Turf/CarryallVehicleMaintenanceandServiceManualPublicationPartNo.103373104

2008/2009TransportationVehicleMaintenanceandServiceManualPublicationPartNo.103373105

EnginesandDrivetrainComponents,RepairandRebuildManualPublicationPartNo.102396501

Thissupplementandcorrespondingmaintenanceandservicemanualshouldbethoroughlyreviewedpriortoservicing

thevehicle.Theproceduresprovidedmustbeproperlyimplemented,andtheDANGER,WARNING,andCAUTION

statementsmustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.

ItisthepolicyofClubCar,Inc.toassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledge

andfacilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,

periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublicationsalsorepresentClubCar’s

continuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar’sTechnicalServicesdepartmentfora

listofupcomingclasses.

Thissupplement,usedinconjunctionwiththeappropriatemaintenanceandservicemanual,coversallaspectsof

typicalvehicleservice;however,uniquesituationssometimesoccurwhenservicingavehicle.Ifitappearsthat

aservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorizedClubCardealeror

distributorforassistance.Youmayalsowritetousat:ClubCar,Inc.,P .O.Box204658;Augusta,GA30917–4658

USA,Attention:TechnicalServices.

ClubCar,Carryall,andArmorFlex

areregisteredtrademarksofClubCar,Inc.

ThismanualeffectiveMar20,2009

2009FE350MaintenanceandServiceSupplementPagei

FOREWORD

WARNING

•ReadSection1–Safetyintheappropriatemaintenanceandservicemanualbeforeattemptingany

serviceonthevehicle.

•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe

relevanttotheserviceorrepairtobeperformed.

NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCar,Inc.iscontinually

workingtofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicing

procedures.Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoall

ClubCarandCarryalldistributors/dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.

ClubCar,Inc.reservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithout

theobligationofmakingchangestounitspreviouslysold.

Therearenowarrantiesexpressedorimpliedinthissupplement.Seethelimitedwarrantyfoundinthe

vehicleowner’smanualorwriteto:ClubCar,Inc.,P .O.Box204658,Augusta,Georgia30917-4658,USA,

Attention:WarrantyAdministration.

CONTENTS
SECTION1—SAFETY.....................................................................................................................................1-1
SECTION2—VEHICLESPECIFICATIONS.......................................................................................................2-1
SECTION3—GENERALINFORMATION..........................................................................................................3-1
SECTION4—BODYANDTRIM.......................................................................................................................4-1
SECTION5—ACCELERATORANDBRAKEPEDALGROUP..........................................................................5-1
SECTION6—WHEELBRAKEASSEMBLIES...................................................................................................6-1
SECTION7—STEERINGANDFRONTSUSPENSION......................................................................................7-1
SECTION8—WHEELSANDTIRES.................................................................................................................8-1
SECTION9—REARSUSPENSION..................................................................................................................9-1
SECTION10—PERIODICMAINTENANCE.....................................................................................................10-1
GeneralWarning.........................................................................................................................................10-1
DisablingtheVehicle................................................................................................................................10-2
DisconnectingtheBattery–GasolineVehicles..........................................................................................10-2
ConnectingtheBattery–GasolineVehicles..............................................................................................10-3
Pre-OperationandDailySafetyChecklist......................................................................................................10-3
PerformanceInspection...........................................................................................................................10-4
GeneralInformation.....................................................................................................................................10-5
S10andS27EngineDifferences..............................................................................................................10-5
NeutralLockout(Maintenance/OperateSwitch).............................................................................................10-5
PeriodicServiceSchedules..........................................................................................................................10-6
PeriodicLubricationSchedules....................................................................................................................10-8
EngineOil...................................................................................................................................................10-9
EngineOilLevelCheck............................................................................................................................10-9
EngineOilAndFilterChange...................................................................................................................10-9
FuelingInstructions.....................................................................................................................................10-12
Battery.......................................................................................................................................................10-13
SECTION11—TROUBLESHOOTINGANDELECTRICALSYSTEM.................................................................11-1
GeneralInformation......................................................................................................................................11-1
TroubleshootingGuide..................................................................................................................................11-1
WiringDiagrams...........................................................................................................................................11-6
ElectricalSystem........................................................................................................................................11-16
TestProcedures.........................................................................................................................................11-16
SECTION12—ELECTRICALCOMPONENTS................................................................................................12-1
Starter/Generator.........................................................................................................................................12-1
Starter/GeneratorRemoval......................................................................................................................12-1
DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................12-2
BrushInspectionandReplacement...........................................................................................................12-2
2009FE350MaintenanceandServiceSupplementPageiii

BrushSpringInspectionandReplacement................................................................................................12-3

Starter/GeneratorAssembly.....................................................................................................................12-3

DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................12-4

BearingCleaningandInspection..............................................................................................................12-5

BearingRemoval.....................................................................................................................................12-5

FieldCoilRemoval...................................................................................................................................12-6

VisualInspectionofArmature...................................................................................................................12-6

CommutatorCleaningandInspection.......................................................................................................12-7

ArmatureGroundTest..............................................................................................................................12-8

VisualInspectionofFieldCoils.................................................................................................................12-9

Starter/GeneratorRework........................................................................................................................12-9

Starter/GeneratorAssembly.....................................................................................................................12-9

Starter/GeneratorInstallation...................................................................................................................12-10

BeltTensionAdjustment..........................................................................................................................12-12

VoltageRegulator.......................................................................................................................................12-13

VoltageRegulatorRemoval.....................................................................................................................12-13

VoltageRegulatorInstallation..................................................................................................................12-13

KeySwitch.................................................................................................................................................12-14

KeySwitchRemoval...............................................................................................................................12-14

KeySwitchInstallation............................................................................................................................12-15

Solenoid.....................................................................................................................................................12-16

SolenoidRemoval..................................................................................................................................12-16

SolenoidInstallation................................................................................................................................12-16

Fuse..........................................................................................................................................................12-18

FuseRemoval........................................................................................................................................12-18

FuseInstallation.....................................................................................................................................12-18

KillLimitSwitch..........................................................................................................................................12-19

KillLimitSwitchRemoval........................................................................................................................12-19

KillLimitSwitchInstallation.....................................................................................................................12-19

NeutralLockoutLimitSwitch.......................................................................................................................12-20

NeutralLockoutLimitSwitchRemoval.....................................................................................................12-20

NeutralLockoutLimitSwitchInstallation...................................................................................................12-21

ReverseWarningBuzzer.............................................................................................................................12-21

FrontReverseWarningBuzzerRemoval..................................................................................................12-21

FrontReverseWarningBuzzerInstallation...............................................................................................12-22

RearReverseWarningBuzzerRemoval..................................................................................................12-23

RearReverseWarningBuzzerInstallation................................................................................................12-23

ReverseBuzzerLimitSwitch.......................................................................................................................12-24

ReverseBuzzerLimitSwitchRemoval.....................................................................................................12-24

ReverseBuzzerLimitSwitchInstallation..................................................................................................12-24

LowOilWarningLight.................................................................................................................................12-25

LowOilWarningLightRemoval...............................................................................................................12-25

LowOilWarningLightInstallation............................................................................................................12-25

FuelGauge/HourMeter..............................................................................................................................12-26

GeneralInformation................................................................................................................................12-26

FuelGauge/HourMeterRemoval............................................................................................................12-26

FuelGauge/HourMeterInstallation..........................................................................................................12-26

FuelLevelSendingUnit..............................................................................................................................12-26

RPMLimiter...............................................................................................................................................12-27

RPMLimiterRemoval.............................................................................................................................12-27

RPMLimiterInstallation..........................................................................................................................12-28

IgnitionCoil................................................................................................................................................12-28

IgnitionCoilRemoval..............................................................................................................................12-28

IgnitionCoilInstallation...........................................................................................................................12-29

OilLevelSensor.........................................................................................................................................12-31

OilLevelSensorRemoval.......................................................................................................................12-31

OilLevelSensorInstallation....................................................................................................................12-31

Relay.........................................................................................................................................................12-31

RelayRemoval.......................................................................................................................................12-31

RelayInstallation....................................................................................................................................12-32

Headlights..................................................................................................................................................12-33

HeadlightBulbRemoval..........................................................................................................................12-33

HeadlightBulbInstallation.......................................................................................................................12-33

VoltageLimiter...........................................................................................................................................12-34

Pageiv2009FE350MaintenanceandServiceSupplement

VoltageLimiterRemoval.........................................................................................................................12-34

VoltageLimiterInstallation.......................................................................................................................12-34

HeadlightSwitch.........................................................................................................................................12-35

HeadlightSwitchRemoval.......................................................................................................................12-35

HeadlightSwitchinstallation....................................................................................................................12-35

Taillights.....................................................................................................................................................12-35

TaillightBulbRemoval.............................................................................................................................12-35

TaillightBulbInstallation..........................................................................................................................12-36

TaillightRemoval....................................................................................................................................12-36

TaillightInstallation..................................................................................................................................12-36

BrakeLightRelay.......................................................................................................................................12-37

BrakeLightRelayRemoval.....................................................................................................................12-37

BrakeLightRelayInstallation..................................................................................................................12-38

ParkBrakeLimitSwitch..............................................................................................................................12-39

ParkBrakeLimitSwitchRemoval............................................................................................................12-39

ParkBrakeLimitSwitchInstallation.........................................................................................................12-39

BrakePedalLimitSwitch.............................................................................................................................12-40

BrakePedalLimitSwitchRemoval...........................................................................................................12-40

BrakePedalLimitSwitchInstallation........................................................................................................12-40

Horn..........................................................................................................................................................12-41

HornRemoval........................................................................................................................................12-41

HornInstallation.....................................................................................................................................12-41

HornSwitch................................................................................................................................................12-42

HornSwitchRemoval.............................................................................................................................12-42

HornSwitchInstallation...........................................................................................................................12-42

Battery.......................................................................................................................................................12-42

GeneralInformation................................................................................................................................12-43

TestingtheBattery..................................................................................................................................12-43

PreventiveMaintenance..........................................................................................................................12-43

Self-Discharge........................................................................................................................................12-44

WaterLevel............................................................................................................................................12-44

VibrationDamage...................................................................................................................................12-44

MineralContent......................................................................................................................................12-45

BatteryRemoval.....................................................................................................................................12-46

ChargingtheBattery...............................................................................................................................12-46

BatteryInstallation..................................................................................................................................12-46

BatteryStorage......................................................................................................................................12-47

ChargingaDeadBattery.........................................................................................................................12-47

GroundCables...........................................................................................................................................12-47

SECTION13—S10FE350ENGINE...............................................................................................................13-1

GeneralInformation.....................................................................................................................................13-1

BeforeServicing......................................................................................................................................13-1

EngineRotation.......................................................................................................................................13-1

SparkPlug..............................................................................................................................................13-1

CylinderHead.............................................................................................................................................13-3

GeneralInformation.................................................................................................................................13-3

BreatherValve(ReedValve).....................................................................................................................13-3

Crankcase...................................................................................................................................................13-3

EngineRemoval......................................................................................................................................13-4

CrankcaseCoverRemoval.......................................................................................................................13-4

OilLevelSensor......................................................................................................................................13-5

CrankcaseCoverInstallation....................................................................................................................13-6

IgnitionCoilandFlywheel.............................................................................................................................13-7

IgnitionCoilandFlywheelRemoval..........................................................................................................13-7

FlywheelInstallation................................................................................................................................13-8

IgnitionCoilInspectionandRepair............................................................................................................13-9

IgnitionCoilInstallation............................................................................................................................13-9

CrankcaseCoverInstallation....................................................................................................................13-9

EngineInstallation.......................................................................................................................................13-9

TorqueSpecications..............................................................................................................................13-10

AdjustmentsandSettings........................................................................................................................13-11

2009FE350MaintenanceandServiceSupplementPagev

SECTION14—S27FE350ENGINE...............................................................................................................14-1

GeneralInformation.....................................................................................................................................14-1

BeforeServicing......................................................................................................................................14-1

EngineRotation.......................................................................................................................................14-1

SparkPlug..............................................................................................................................................14-1

CylinderHead.............................................................................................................................................14-3

GeneralInformation.................................................................................................................................14-3

BreatherValve(ReedValve).....................................................................................................................14-3

ValveClearanceCheckandAdjustment....................................................................................................14-3

Crankcase...................................................................................................................................................14-4

EngineRemoval......................................................................................................................................14-4

CrankcaseCoverRemoval.......................................................................................................................14-5

OilLevelSensor......................................................................................................................................14-6

CrankcaseCoverInstallation....................................................................................................................14-7

IgnitionCoilandFlywheel.............................................................................................................................14-8

IgnitionCoilandFlywheelRemoval..........................................................................................................14-8

FlywheelInstallation................................................................................................................................14-9

IgnitionCoilInspectionandRepair...........................................................................................................14-10

IgnitionCoilInstallation...........................................................................................................................14-10

CrankcaseCoverInstallation...................................................................................................................14-10

EngineInstallation......................................................................................................................................14-10

TorqueSpecications..............................................................................................................................14-11

AdjustmentsandSettings........................................................................................................................14-12

SECTION15—S10FE350FUELSYSTEM.....................................................................................................15-1

GeneralInformation.....................................................................................................................................15-1

Carburetor...................................................................................................................................................15-1

MainJetElevation/SizeChart...................................................................................................................15-3

ChangingtheMainJet.............................................................................................................................15-3

EngineControlLinkage................................................................................................................................15-6

GeneralInformation.................................................................................................................................15-6

AcceleratorRod.......................................................................................................................................15-6

GovernorCable.......................................................................................................................................15-8

AcceleratorCable...................................................................................................................................15-10

ClosedThrottleorIdleAdjustment...........................................................................................................15-10

EngineRPMAdjustment.........................................................................................................................15-11

ChokeandAirIntakeSystem......................................................................................................................15-12

GeneralInformation................................................................................................................................15-12

ChokeCableRemoval............................................................................................................................15-12

ChokeCableInstallation.........................................................................................................................15-12

AirBoxRemoval.....................................................................................................................................15-13

AirBoxInstallation..................................................................................................................................15-13

IntakeDuctRemoval...............................................................................................................................15-13

IntakeDuctInstallation............................................................................................................................15-14

IntakeDuctRepair..................................................................................................................................15-18

AirFilter.................................................................................................................................................15-18

FuelFilters.................................................................................................................................................15-19

GeneralInformation................................................................................................................................15-19

FuelFilterRemoval.................................................................................................................................15-19

FuelFilterInstallation..............................................................................................................................15-19

FuelPump.................................................................................................................................................15-22

GeneralInformation................................................................................................................................15-22

FuelPumpRemoval...............................................................................................................................15-22

FuelPumpDisassembly..........................................................................................................................15-22

FuelPumpCleaningandInspection.........................................................................................................15-23

FuelPumpAssembly..............................................................................................................................15-23

FuelPumpInstallation.............................................................................................................................15-24

FuelTank...................................................................................................................................................15-25

GeneralInformation................................................................................................................................15-25

FuelTankRemoval.................................................................................................................................15-25

FuelTankDisposal.................................................................................................................................15-26

FuelTankStorage..................................................................................................................................15-26

Pagevi2009FE350MaintenanceandServiceSupplement

FuelTankInstallation..............................................................................................................................15-27

FuelLines..................................................................................................................................................15-28

FuelShut-OffValve.....................................................................................................................................15-29

SECTION16—S27FE350FUELSYSTEM....................................................................................................16-1

GeneralInformation.....................................................................................................................................16-1

Carburetor...................................................................................................................................................16-1

MainJetElevation/SizeChart...................................................................................................................16-2

ChangingtheMainJet.............................................................................................................................16-3

EngineControlLinkage................................................................................................................................16-6

GeneralInformation.................................................................................................................................16-6

AcceleratorRod.......................................................................................................................................16-6

GovernorCable.......................................................................................................................................16-8

AcceleratorCable....................................................................................................................................16-9

ClosedThrottleorIdleAdjustment...........................................................................................................16-10

EngineRPMAdjustment.........................................................................................................................16-11

ChokeandAirIntakeSystem......................................................................................................................16-12

GeneralInformation................................................................................................................................16-12

ChokeCableRemoval............................................................................................................................16-12

ChokeCableInstallation.........................................................................................................................16-12

AirBoxRemoval.....................................................................................................................................16-15

AirBoxInstallation..................................................................................................................................16-15

IntakeDuctRemoval...............................................................................................................................16-15

IntakeDuctInstallation............................................................................................................................16-16

IntakeDuctRepair..................................................................................................................................16-17

AirFilter.................................................................................................................................................16-17

FuelFilters.................................................................................................................................................16-18

GeneralInformation................................................................................................................................16-18

FuelFilterRemoval.................................................................................................................................16-18

FuelFilterInstallation..............................................................................................................................16-18

FuelPump.................................................................................................................................................16-21

GeneralInformation................................................................................................................................16-21

FuelPumpRemoval...............................................................................................................................16-21

FuelPumpDisassembly..........................................................................................................................16-22

FuelPumpCleaningandInspection.........................................................................................................16-22

FuelPumpAssembly..............................................................................................................................16-23

FuelPumpInstallation.............................................................................................................................16-23

FuelTank...................................................................................................................................................16-25

GeneralInformation................................................................................................................................16-25

FuelTankRemoval.................................................................................................................................16-25

FuelTankDisposal.................................................................................................................................16-26

FuelTankStorage..................................................................................................................................16-26

FuelTankInstallation..............................................................................................................................16-27

FuelLines..................................................................................................................................................16-28

FuelShut-OffValve.....................................................................................................................................16-29

SECTION17—EXHAUSTSYSTEM................................................................................................................17-1

Mufer........................................................................................................................................................17-1

MuferRemoval......................................................................................................................................17-1

MuferInstallation....................................................................................................................................17-1

SECTION18—UNITIZEDTRANSAXLE..........................................................................................................18-1

GeneralInformation.....................................................................................................................................18-1

ShifterLever............................................................................................................................................18-1

NeutralLockout.......................................................................................................................................18-1

GovernorSystem.....................................................................................................................................18-2

UnitizedTransaxleService.......................................................................................................................18-2

ToolsRequiredForThisSection...............................................................................................................18-3

Lubrication..............................................................................................................................................18-3

AxleShaft...................................................................................................................................................18-3

AxleShaftandOilSealRemoval..............................................................................................................18-3

2009FE350MaintenanceandServiceSupplementPagevii

AxleBearing............................................................................................................................................18-4

AxleShaftInstallation..............................................................................................................................18-6

UnitizedTransaxleRemoval.........................................................................................................................18-8

UnitizedTransaxleInstallation.....................................................................................................................18-15

Forward/ReverseShifterCable....................................................................................................................18-20

Forward/ReverseShifterCableRemoval..................................................................................................18-20

Forward/ReverseShifterCableInstallation...............................................................................................18-20

Forward/ReverseShifterCableAdjustment..............................................................................................18-22

SECTION19—TORQUECONVERTER..........................................................................................................19-1

GeneralInformation.....................................................................................................................................19-1

Troubleshooting...........................................................................................................................................19-1

DriveBelt....................................................................................................................................................19-3

DriveBeltRemoval..................................................................................................................................19-3

DriveBeltInstallation...............................................................................................................................19-3

DriveClutch................................................................................................................................................19-4

DriveClutchRemoval..............................................................................................................................19-4

DriveClutchCleaningandInspection........................................................................................................19-5

DriveClutchDisassembly.........................................................................................................................19-7

InspectionofDriveClutchParts................................................................................................................19-9

DriveClutchAssembly............................................................................................................................19-10

DriveClutchInstallation..........................................................................................................................19-11

DrivenClutch.............................................................................................................................................19-12

DrivenClutchRemoval...........................................................................................................................19-12

DrivenClutchDisassembly......................................................................................................................19-12

DrivenClutchInspection.........................................................................................................................19-13

DrivenClutchAssembly..........................................................................................................................19-13

DrivenClutchInstallation.........................................................................................................................19-16

SECTIONi—INDEX

Pageviii2009FE350MaintenanceandServiceSupplement