2003 Club Car Turf 2 (Gas) OEM Service & Repair Manual

Club Car MANUAL NUMBER 102318808 EDITION CODE 1202C00000 FE350 GASOLINE VEHICLES 2003 MAINTENANCE SERVICE SUPPLEMENT

2003 FE350 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 FE350 gasoline vehicles and should be used in conjunction with the appropriate maintenance and service manual. 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: 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 technician. It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowledge 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 (706) 863-3000, ext. 3580. 2003 Turf/Carryall Vehicle Maintenance and Service Manual Publication Part No. 102318802 2003 Transportation Vehicle Maintenance and Service Manual Publication Part No. 102318803 Copyright © 2002 Club Car, Inc. Club Car, Carryall, and ArmorFlex are registered trademarks of Club Car, Inc. This manual effective July 14, 2002.

Page ii 2003 FE350 Gasoline Vehicle Maintenance and Service Supplement ∆ 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 procedures 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.

2003 FE350 Gasoline Vehicle Maintenance and Service Supplement Page iii CONTENTS SECTION 10 – PERIODIC MAINTENANCE General Warning ................................................................................................................................ 10-1 General Information ........................................................................................................................... 10-2 Pre-Operation and Daily Safety Checklist ......................................................................................... 10-3 Performance Inspection ................................................................................................................. 10-4 Periodic Service Schedule ................................................................................................................. 10-4 Periodic Lubrication Schedule ........................................................................................................... 10-6 Engine Oil .......................................................................................................................................... 10-7 Engine Oil Level Check ................................................................................................................. 10-7 Oil Viscosity ................................................................................................................................... 10-8 Fueling Instructions ........................................................................................................................... 10-8 Battery ............................................................................................................................................... 10-9 SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM General Information ........................................................................................................................... 11-1 Troubleshooting Guide ...................................................................................................................... 11-1 Wiring Diagrams ................................................................................................................................ 11-6 Electrical System ............................................................................................................................... 11-13 Electrical Circuits ............................................................................................................................... 11-13 Starter Circuit for Pedal-Start Vehicles .......................................................................................... 11-13 Starter Circuit for Key-Start Vehicles ............................................................................................. 11-14 Generator Circuit ........................................................................................................................... 11-15 Engine Ignition Circuit .................................................................................................................... 11-15 Engine Kill Circuit for Pedal-Start Vehicles .................................................................................... 11-16 Engine Kill Circuit for Key-Start Vehicle ......................................................................................... 11-16 Reverse Buzzer Circuit .................................................................................................................. 11-16 Low Oil Warning Light Circuit ........................................................................................................ 11-17 Neutral Lockout Circuit .................................................................................................................. 11-18 Fuel Gauge and Sending Unit Circuit ............................................................................................ 11-20 Hour Meter Circuit .......................................................................................................................... 11-20 Lighting Circuit ............................................................................................................................... 11-21 Brake Light Circuit ......................................................................................................................... 11-22 Horn Circuit .................................................................................................................................... 11-23

Page iv 2003 FE350 Gasoline Vehicle Maintenance and Service Supplement Circuit Testing .................................................................................................................................... 11-23 Testing the Starter Circuit and Generator Circuit ........................................................................... 11-24 Testing the Engine Ignition Circuit ................................................................................................. 11-24 Testing the Engine Kill Circuit ........................................................................................................ 11-25 Testing the Reverse Buzzer Circuit ................................................................................................ 11-26 Testing the Low Oil Warning Light Circuit ...................................................................................... 11-27 Testing the Neutral Lockout Circuit ................................................................................................ 11-28 Testing the Fuel Gauge and Sending Unit Circuit .......................................................................... 11-28 Testing the Lighting Circuit ............................................................................................................. 11-29 Testing the Brake Light Circuit ....................................................................................................... 11-31 Testing the Horn Circuit ................................................................................................................. 11-31 Test Procedures ................................................................................................................................. 11-31 Index of Test Procedures ............................................................................................................... 11-31 SECTION 12 – ELECTRICAL COMPONENTS Starter/Generator ............................................................................................................................... 12-1 Voltage Regulator .............................................................................................................................. 12-12 Key Switch ......................................................................................................................................... 12-13 Solenoid ............................................................................................................................................. 12-14 Fuse ................................................................................................................................................... 12-16 Kill Limit Switch .................................................................................................................................. 12-16 Neutral Lockout Limit Switch .............................................................................................................. 12-18 Neutral Lockout Cam ......................................................................................................................... 12-19 Reverse Buzzer Limit Switch ............................................................................................................. 12-21 Low Oil Warning Light ........................................................................................................................ 12-22 Fuel Gauge/Hour Meter ..................................................................................................................... 12-22 Fuel Level Sending Unit ..................................................................................................................... 12-24 RPM Limiter ....................................................................................................................................... 12-24 Ignition Coil ........................................................................................................................................ 12-25 Oil Level Sensor ................................................................................................................................. 12-28 Relay .................................................................................................................................................. 12-28 Headlights .......................................................................................................................................... 12-29 Taillights ............................................................................................................................................. 12-30 Taillight Bulb Removal ................................................................................................................... 12-30 Voltage Limiter ................................................................................................................................... 12-31 Headlight Switch ................................................................................................................................ 12-32 Brake Light Relay ............................................................................................................................... 12-33 Park Brake Limit Switch ..................................................................................................................... 12-34 Brake Pedal Limit Switch ................................................................................................................... 12-35 Horn ................................................................................................................................................... 12-36 Horn switch ........................................................................................................................................ 12-36

2003 FE350 Gasoline Vehicle Maintenance and Service Supplement Page v Battery ............................................................................................................................................... 12-37 Ground cables ................................................................................................................................... 12-41 SECTION 13 – FE350 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 Hydraulic Lifters ............................................................................................................................. 13-4 Spark Plug ..................................................................................................................................... 13-5 Engine Mounting Plate ...................................................................................................................... 13-6 Cylinder Head .................................................................................................................................... 13-6 General Information ....................................................................................................................... 13-7 Cylinder Shroud Removal .............................................................................................................. 13-7 Rocker Arm and Push Rod Removal ............................................................................................. 13-9 Cylinder Head Removal ................................................................................................................. 13-9 Valve Removal ............................................................................................................................... 13-10 Breather Valve (Reed Valve) ......................................................................................................... 13-10 Cylinder Head Cleaning and Inspection ........................................................................................ 13-11 Valve Guides ................................................................................................................................. 13-11 Valve Seats .................................................................................................................................... 13-13 Valves ............................................................................................................................................ 13-15 Rocker Arm and Rocker Shaft inspection ...................................................................................... 13-17 Push Rod Inspection ...................................................................................................................... 13-18 Cylinder Head Installation .............................................................................................................. 13-18 Valve Clearance Check and Adjustment ....................................................................................... 13-18 Breather Valve (Reed Valve) ......................................................................................................... 13-19 Installation of Remaining Engine Components .............................................................................. 13-19 Crankcase ......................................................................................................................................... 13-21 Engine Removal ............................................................................................................................ 13-21 Crankcase Cover Removal ............................................................................................................ 13-22 Oil Level Sensor ............................................................................................................................ 13-23 Camshaft and Hydraulic Lifters ...................................................................................................... 13-23 Piston and Connecting Rod ............................................................................................................... 13-26 Cylinder Block .................................................................................................................................... 13-29 Ignition Coil and Flywheel .................................................................................................................. 13-30 Oil Pressure Relief Valve ............................................................................................................... 13-33

Page vi 2003 FE350 Gasoline Vehicle Maintenance and Service Supplement Crankshaft and Counterbalance ........................................................................................................ 13-35 Counterbalance Weight .................................................................................................................. 13-37 Oil Screen ...................................................................................................................................... 13-40 Ball Bearing .................................................................................................................................... 13-40 Oil Seals ......................................................................................................................................... 13-41 Piston and Connecting Rod Installation ......................................................................................... 13-43 Crankshaft Axial Play Adjustment ...................................................................................................... 13-44 Crankcase Cover Installation ......................................................................................................... 13-46 Engine Assembly ............................................................................................................................... 13-48 Service Specifications ........................................................................................................................ 13-50 Specifications for Resizing Cylinder Bore ...................................................................................... 13-51 Torque Specifications ..................................................................................................................... 13-51 Adjustments and Settings .............................................................................................................. 13-52 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 ...................................................................................................................... 14-8 General Information ....................................................................................................................... 14-8 Accelerator Rod ............................................................................................................................. 14-9 Governor Cable .............................................................................................................................. 14-11 Accelerator Cable ........................................................................................................................... 14-12 Closed Throttle or Idle Adjustment ................................................................................................. 14-13 Engine RPM Adjustment ................................................................................................................ 14-14 Choke and Air Intake System ............................................................................................................. 14-15 General Information ....................................................................................................................... 14-15 Choke Cable Removal ................................................................................................................... 14-15 Choke Cable Installation ................................................................................................................ 14-15 Air Box Removal ............................................................................................................................ 14-18 Air Box Installation ......................................................................................................................... 14-18 Intake Duct Removal ...................................................................................................................... 14-18 Intake Duct Installation ................................................................................................................... 14-19 Intake Duct Repair ......................................................................................................................... 14-20 Air Filter .......................................................................................................................................... 14-20

2003 FE350 Gasoline Vehicle Maintenance and Service Supplement Page vii Fuel Filters ......................................................................................................................................... 14-21 General Information ....................................................................................................................... 14-21 Fuel Filter Removal ........................................................................................................................ 14-21 Fuel Filter Installation ..................................................................................................................... 14-21 Fuel Pump ......................................................................................................................................... 14-23 General Information ....................................................................................................................... 14-23 Fuel Pump Removal ...................................................................................................................... 14-23 Fuel Pump Disassembly ................................................................................................................ 14-23 Fuel Pump Cleaning and Inspection .............................................................................................. 14-24 Fuel Pump Assembly ..................................................................................................................... 14-24 Fuel Pump Installation ................................................................................................................... 14-25 Fuel Tank ........................................................................................................................................... 14-26 General Information ....................................................................................................................... 14-26 Fuel Tank Removal ........................................................................................................................ 14-26 Fuel Tank Disposal ........................................................................................................................ 14-27 Fuel Tank Storage ......................................................................................................................... 14-28 Fuel Tank Installation ..................................................................................................................... 14-28 Fuel Lines .......................................................................................................................................... 14-29 Fuel Shut-Off Valve ........................................................................................................................... 14-30 SECTION 15 – EXHAUST SYSTEM General Information ........................................................................................................................... 15-1 Muffler ................................................................................................................................................ 15-1 Muffler Removal ............................................................................................................................. 15-1 Muffler Installation .......................................................................................................................... 15-1 SECTION 16 – UNITIZED TRANSAXLE General Information ........................................................................................................................... 16-1 Lubrication ..................................................................................................................................... 16-3 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 Disassembly ........................................................................................................ 16-15

Page viii 2003 FE350 Gasoline Vehicle Maintenance and Service Supplement Component Disassembly ................................................................................................................... 16-18 Governor Gear Disassembly .......................................................................................................... 16-18 Differential Gear Case Disassembly .............................................................................................. 16-20 Shifter Fork Disassembly ............................................................................................................... 16-21 Synchronizer Gear Disassembly .................................................................................................... 16-22 Intermediate Gear Disassembly ..................................................................................................... 16-23 Idler Shaft Disassembly ................................................................................................................. 16-23 Unitized Transaxle Component Inspection ........................................................................................ 16-24 Component Assembly ........................................................................................................................ 16-25 Idler Shaft Assembly ...................................................................................................................... 16-25 Intermediate Gear Assembly .......................................................................................................... 16-25 Synchronizer Gear Assembly ......................................................................................................... 16-25 Shifter Fork Assembly .................................................................................................................... 16-27 Differential Gear Case Assembly ................................................................................................... 16-27 Governor Gear Assembly ............................................................................................................... 16-30 Unitized Transaxle Assembly ............................................................................................................. 16-30 Unitized Transaxle Installation ........................................................................................................... 16-37 Forward/Reverse Shifter Cable .......................................................................................................... 16-43 Forward/Reverse Shifter Cable Removal ....................................................................................... 16-43 Forward/Reverse Shifter Cable Installation .................................................................................... 16-43 Forward/Reverse Shifter Cable Adjustment ................................................................................... 16-45 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 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

2003 Club Car Turf 2 (Gas) OEM Service & Repair Manual

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