2004
Gasoline Vehicles
Maintenance
Service
Manual No. 102397620 Edition Code 1203E0310D
and
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance ef ciency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.
This manual provides detailed information for the maintenance and repair of the gasoline Precedent vehicle,
and should be thoroughly reviewed prior to servicing the vehicle. The procedures provided herein must be
properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.
This manual was written for the trained technician who already possesses knowledge and skills in electrical
and mechanical repair.
For this reason, Club Car advises that all repairs and/or
service be performed by an authorized Club Car distributor/dealer representative or by a Club Car factory-
trained technician.
It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and ef cient ser vice for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.
This manual covers all aspects of typical vehicle service; unique situations, however, do sometimes occur
when servicing a vehicle. If it appears that a service question is not answered in this manual, you may write
to us at: Club Car, Inc.; P.O. Box 204658; Augusta, Georgia 30917; Attention: Technical Services, or contact
a Club Car Technical Service Representative at (706) 863-3000, ext. 3580.
Copyright © 2003, 2004, 2010 Club Car, Inc.
is a registered
trademark of Club Car, Inc.
This manual effective October 15, 2003.
∆ WARNING
• Read Section 1 – Safety 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:
CONTENTS
SECTION 1 – SAFETY
General Warnings ............................................................................................................................. 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
SECTION 3 – GENERAL INFORMATION
Serial Number Identification .............................................................................................................. 3-1
Safety Committee ............................................................................................................................. 3-2
Storage ............................................................................................................................................. 3-2
Preparing the Gasoline Vehicle for Extended Off-Season Storage .............................................. 3-3
Returning the Stored Gasoline Vehicle to Service ........................................................................ 3-4
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 4-1
Seat .............................................................................................................................................. 4-1
Front and Rear Body Repair ............................................................................................................. 4-2
Stress Lines or Streaks ................................................................................................................. 4-2
Minor Impact Damage/Deformations ............................................................................................ 4-2
Minor Scratches and Surface Blemishes ...................................................................................... 4-2
Gouges, Punctures, Tears, Large Scratches, and Abrasions ....................................................... 4-2
Front Body ........................................................................................................................................ 4-3
Front Body Removal ..................................................................................................................... 4-3
Front Body Installation .................................................................................................................. 4-3
Front Bumper .................................................................................................................................... 4-5
Floor Mat and Retainers ................................................................................................................... 4-6
Floor Mat Retainer Removal ......................................................................................................... 4-6
Floor Mat Retainer Installation ...................................................................................................... 4-6
Kick Plate and Choke Button ............................................................................................................ 4-7
Kick Plate and Choke Button Removal ......................................................................................... 4-7
Kick Plate and Choke Button Installation ...................................................................................... 4-7
Rear Body ......................................................................................................................................... 4-8
Universal Accessory Mounting ..................................................................................................... 4-8
Backrest and Structural Accessory Module .................................................................................. 4-9
Rear Body Components Removal ................................................................................................ 4-11
Dash Assembly ................................................................................................................................ 4-14
Dash Assembly Removal ............................................................................................................. 4-14
Dash Assembly Installation .......................................................................................................... 4-15
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Pedal Group ..................................................................................................................................... 5-1
Pedal Group Removal .................................................................................................................. 5-1
GCOR .......................................................................................................................................... 5-3
Debris Shields .............................................................................................................................. 5-3
Brake Return Spring ..................................................................................................................... 5-3
Pawl Assembly ............................................................................................................................. 5-4
Accelerator Return Spring ............................................................................................................ 5-4
Pedal Group Installation ............................................................................................................... 5-6
SECTION 6 – WHEEL BRAKE ASSEMBLIES
General Information ......................................................................................................................... 6-1
Brake Shoe Removal ....................................................................................................................... 6-1
Brake Assembly Cleaning ................................................................................................................ 6-5
Brake Shoe Installation .................................................................................................................... 6-6
Brake Cable Equalizer Adjustment .................................................................................................. 6-8
Brake Cluster Removal and Installation ........................................................................................... 6-9
Brake Cluster Installation ............................................................................................................. 6-10
Brake Cable Removal and Installation ............................................................................................. 6-11
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information ......................................................................................................................... 7-1
Steering Wheel ................................................................................................................................. 7-1
Steering Wheel Removal ............................................................................................................. 7-1
Steering Wheel Installation .......................................................................................................... 7-2
Steering Column .............................................................................................................................. 7-2
Steering Column Removal ........................................................................................................... 7-2
Steering Column Installation ........................................................................................................ 7-4
Rack and Pinion ............................................................................................................................... 7-4
Rack and Pinion Removal ............................................................................................................ 7-4
Rack and Pinion Disassembly ...................................................................................................... 7-5
Rack and Pinion Assembly .......................................................................................................... 7-8
Rack and Pinion Installation ......................................................................................................... 7-9
Front Suspension ............................................................................................................................. 7-10
Lubrication .................................................................................................................................... 7-10
Wheel Alignment .......................................................................................................................... 7-10
Front Suspension Components ........................................................................................................ 7-12
Tie Rod End Removal ................................................................................................................... 7-12
Tie Rod Installation ....................................................................................................................... 7-12
Leaf Spring Removal .................................................................................................................... 7-13
Leaf Spring Installation ................................................................................................................. 7-13
Kingpin and Steering Spindle Removal ........................................................................................ 7-13
Kingpin and Steering Spindle Installation ..................................................................................... 7-13
Control Arm Removal ................................................................................................................... 7-14
Control Arm Installation ................................................................................................................ 7-17
Shock Absorber Removal ............................................................................................................. 7-17
Shock Absorber Installation .......................................................................................................... 7-17
Front Wheel Bearings and Hubs ...................................................................................................... 7-17
Front Wheel Free Play Inspection ................................................................................................ 7-17
Front Hub Removal ....................................................................................................................... 7-17
Hub Installation ............................................................................................................................. 7-18
SECTION 8 – WHEELS AND TIRES
General Information .......................................................................................................................... 8-1
Wheels .............................................................................................................................................. 8-1
Wheel Removal ............................................................................................................................ 8-1
Wheel Installation ......................................................................................................................... 8-1
Tires .................................................................................................................................................. 8-2
Tire Removal ................................................................................................................................ 8-2
Tire Repair .................................................................................................................................... 8-3
Tire Installation ............................................................................................................................. 8-3
SECTION 9 – REAR SUSPENSION
General Information .......................................................................................................................... 9-1
Shock Absorbers .............................................................................................................................. 9-1
Shock Absorber Removal and Inspection ..................................................................................... 9-1
Shock Absorber Installation .......................................................................................................... 9-1
Leaf Springs ..................................................................................................................................... 9-1
Leaf Spring Removal .................................................................................................................... 9-1
Leaf Spring Installation ................................................................................................................. 9-4
SECTION 10 – PERIODIC MAINTENANCE
General Information .......................................................................................................................... 10-1
Pre-Operation and Daily Safety Checklist ........................................................................................ 10-1
Performance Inspection ................................................................................................................ 10-2
Periodic Service Schedule ................................................................................................................ 10-2
Periodic Lubrication Schedule .......................................................................................................... 10-4
Periodic Lubrication Schedule ...................................................................................................... 10-4
Engine Oil ......................................................................................................................................... 10-5
Engine Oil Level Check ................................................................................................................ 10-5
Oil Viscosity .................................................................................................................................. 10-6
Fueling Instructions .......................................................................................................................... 10-6
Battery .............................................................................................................................................. 10-7
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM
General Information ......................................................................................................................... 11-1
Troubleshooting Guide ..................................................................................................................... 11-1
Electrical System .............................................................................................................................. 11-7
Electrical Circuits .............................................................................................................................. 11-7
Starter Circuit ............................................................................................................................... 11-7
Generator Circuit .......................................................................................................................... 11-8
Engine Ignition Circuit .................................................................................................................. 11-9
Engine Kill Circuit ......................................................................................................................... 11-9
Reverse Buzzer Circuit ................................................................................................................ 11-10
Low Oil Warning Light Circuit ....................................................................................................... 11-10
Neutral Lockout Circuit ................................................................................................................. 11-10
Fuel Gauge and Sending Unit Circuit ........................................................................................... 11-12
Hour Meter Circuit ........................................................................................................................ 11-12
Test Procedures ............................................................................................................................... 11-13
Index of Test Procedures ............................................................................................................. 11-13
SECTION 12 – ELECTRICAL COMPONENTS
Starter/Generator ............................................................................................................................. 12-1
Voltage Regulator ............................................................................................................................ 12-12
Key Switch ....................................................................................................................................... 12-13
Solenoid ........................................................................................................................................... 12-14
Fuse ................................................................................................................................................. 12-15
GCOR .............................................................................................................................................. 12-15
Neutral Lockout Limit Switch ............................................................................................................ 12-16
Neutral Lockout Cam ....................................................................................................................... 12-18
Reverse Warning Buzzer ................................................................................................................. 12-18
Reverse Buzzer Limit Switch ........................................................................................................... 12-19
Low Oil Warning Light ...................................................................................................................... 12-20
Fuel Gauge ...................................................................................................................................... 12-21
Fuel Level Sending Unit ................................................................................................................... 12-23
Hour Meter ....................................................................................................................................... 12-23
RPM Limiter ...................................................................................................................................... 12-24
Ignition Coil ....................................................................................................................................... 12-25
Oil Level Sensor ............................................................................................................................... 12-28
Battery .............................................................................................................................................. 12-28
Ground Cables ................................................................................................................................. 12-32
SECTION 13 – FE290 ENGINE
General Information .......................................................................................................................... 13-1
Special Engine Service Tools Available from Club Car ................................................................ 13-1
Before Servicing ........................................................................................................................... 13-2
Mechanical Systems ..................................................................................................................... 13-2
Lubrication System ....................................................................................................................... 13-4
Spark Plug .................................................................................................................................... 13-5
Engine Mounting Plate ..................................................................................................................... 13-6
Cylinder Head ................................................................................................................................... 13-6
General Information ...................................................................................................................... 13-6
Cylinder Shroud Removal ............................................................................................................. 13-7
Rocker Arm and Push Rod Removal ............................................................................................ 13-9
Cylinder Head Removal ................................................................................................................ 13-10
Valve Removal .............................................................................................................................. 13-10
Breather Valve (Reed Valve) ........................................................................................................ 13-11
Cylinder Head Cleaning and Inspection ....................................................................................... 13-12
Valve Guides ................................................................................................................................ 13-12
Valve Seats ................................................................................................................................... 13-13
Valves ........................................................................................................................................... 13-16
Rocker Arm and Rocker Shaft Inspection ..................................................................................... 13-18
Push Rod Inspection ..................................................................................................................... 13-18
Cylinder Head Installation ............................................................................................................. 13-19
Valve Clearance Check and Adjustment ...................................................................................... 13-20
Breather Valve (Reed Valve) ........................................................................................................ 13-21
Installation of Remaining Engine Components ............................................................................. 13-22
Crankcase ........................................................................................................................................ 13-23
Engine Removal ........................................................................................................................... 13-23
Crankcase Cover Removal ........................................................................................................... 13-24
Oil Level Sensor ........................................................................................................................... 13-25
Camshaft and Tappets ................................................................................................................. 13-26
Piston and Connecting Rod .............................................................................................................. 13-27
Cylinder Block ................................................................................................................................... 13-30
Ignition Coil and Flywheel ................................................................................................................. 13-32
Oil Pump ........................................................................................................................................... 13-33
Oil Pressure Relief Valve .............................................................................................................. 13-35
Crankshaft and Counterbalance ...................................................................................................... 13-37
Counterbalance Weight ................................................................................................................ 13-39
Oil Screen .................................................................................................................................... 13-42
Ball Bearing .................................................................................................................................. 13-42
Oil Seals ....................................................................................................................................... 13-43
Piston and Connecting Rod Installation ....................................................................................... 13-45
Crankshaft Axial Play Adjustment .................................................................................................... 13-46
Crankcase Cover Installation ....................................................................................................... 13-48
Engine Assembly ............................................................................................................................. 13-49
Service Specifications ...................................................................................................................... 13-51
Specifications for Resizing Cylinder Bore .................................................................................... 13-52
Torque Specifications ................................................................................................................... 13-52
Adjustments and Settings ............................................................................................................ 13-53
SECTION 14 – FUEL SYSTEM
General Information ......................................................................................................................... 14-1
How the Carburetor Works ............................................................................................................... 14-1
Main System ................................................................................................................................ 14-1
Slow Speed System ..................................................................................................................... 14-2
Choke and Fresh Air System ....................................................................................................... 14-2
Float System ................................................................................................................................ 14-2
Carburetor ........................................................................................................................................ 14-4
Main Jet Elevation/Size Chart ...................................................................................................... 14-5
Changing the Main Jet ................................................................................................................. 14-5
Engine Control Linkage .................................................................................................................... 14-9
General Information ..................................................................................................................... 14-9
Governor Cable ............................................................................................................................ 14-9
Accelerator Cable ......................................................................................................................... 14-9
Closed Throttle or Idle Adjustment ............................................................................................... 14-12
Engine RPM Adjustment .............................................................................................................. 14-12
Choke and Air Intake System ........................................................................................................... 14-13
General Information ..................................................................................................................... 14-13
Choke Button ............................................................................................................................... 14-14
Air Intake Components Removal ................................................................................................. 14-14
Air Intake Components Installation .............................................................................................. 14-14
Air Filter ........................................................................................................................................ 14-15
Fuel Filter ......................................................................................................................................... 14-16
General Information ..................................................................................................................... 14-16
Fuel Filter Removal ...................................................................................................................... 14-16
Fuel Filter Installation ................................................................................................................... 14-18
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2004 Club Car Precedent Gas Factory Service & Work Shop Manual
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Description
Upon purchasing this manual, you will receive a .PDF file containing an email address for further assistance. After contacting the provided email, you will receive a reply with a link to access the manual for your 2004 Club Car Precedent Gas.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every nut and bolt. With hundreds of pages, it equips you to address various issues, from routine maintenance like oil changes to more complex tasks such as transmission swaps. The manual includes numerous illustrations to assist you and features easy-to-understand text throughout.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual offers a step-by-step approach to maintaining and repairing your vehicle, imparting the expertise that factory-trained technicians possess. By leveraging the knowledge within this manual, any owner can confidently make informed decisions regarding their machine's maintenance and repair needs.
Rest assured, along with the high-quality service manual, we are committed to providing excellent customer service, ensuring your satisfaction.
