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Club Car 2005 FE290 User Manual

Club Car 2005 FE290
168 pages
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Clu
b Ca
r
MANUAL NUMBER
102680409
EDITION CODE
1204B0205A
FE290 GASOLINE VEHICLES
2005
MAINTENANCE
SERVICE
SUPPLEMENT

Table of Contents

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Club Car 2005 FE290 Specifications

General IconGeneral
BrandClub Car
Model2005 FE290
CategoryOffroad Vehicle
LanguageEnglish

Summary

FOREWORD

SECTION 10 – PERIODIC MAINTENANCE

General Safety and Warnings

General safety statements to be heeded during operation, repair, or service.

Maintenance Schedules and Procedures

Schedules for periodic service, lubrication, engine oil, fueling, and battery maintenance.

SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM

Troubleshooting Guide

Guide to identify operating difficulties, probable causes, and refer to relevant sections for checks.

Electrical System Overview

Description of the vehicle's 12-volt DC electrical system and its circuits.

Electrical System Test Procedures

List of test procedures for diagnosing electrical issues, including specific component tests.

SECTION 12 – ELECTRICAL COMPONENTS

STARTER/GENERATOR

Component responsible for starting the engine and generating electrical power.

VOLTAGE REGULATOR

Component that regulates vehicle voltage.

KEY SWITCH

Component for controlling vehicle power.

SOLENOID

Component used in the electrical system to engage the starter motor.

FUSE

Component that protects electrical circuits from overcurrent.

ACCELERATOR PEDAL LIMIT SWITCH

Switch activated by the accelerator pedal position.

KILL LIMIT SWITCH

Switch used to stop the engine under certain conditions.

NEUTRAL LOCKOUT LIMIT SWITCH

Switch that prevents starting the engine unless the transmission is in neutral.

NEUTRAL LOCKOUT CAM

Mechanical component related to the neutral lockout system.

REVERSE WARNING BUZZER

Audible warning device activated when the vehicle is in reverse.

REVERSE BUZZER LIMIT SWITCH

Switch that activates the reverse warning buzzer.

LOW OIL WARNING LIGHT

Indicator light for low engine oil level.

FUEL GAUGE/HOUR METER

Instrument displaying fuel level and engine operating hours.

FUEL LEVEL SENDING UNIT

Component in the fuel tank that measures fuel level.

RPM LIMITER

Device that prevents the engine from exceeding a set RPM.

IGNITION COIL

Component that provides high voltage for the spark plug.

OIL LEVEL SENSOR

Sensor that detects the engine oil level.

BATTERY

Information about the vehicle's battery.

GROUND CABLES

Information regarding ground cables.

SECTION 13 – FE290 ENGINE

General Engine Information

Overview of the 4-cycle, overhead valve, single-cylinder engine.

Spark Plug Service

Information on spark plug selection, gap setting, removal, and installation.

Cylinder Head and Breather Valve

Information on cylinder head compression and breather valve function.

Crankcase and Engine Removal

Procedure for removing the engine and its crankcase cover.

Oil Level Sensor and Crankcase Cover Installation

Procedures for installing the oil level sensor and crankcase cover.

Ignition Coil and Flywheel Service

Procedures for removing and installing ignition coil and flywheel.

Engine Installation and Specifications

Steps for engine installation, torque specs, and adjustments.

SECTION 14 – FUEL SYSTEM

Carburetor Service

Information and procedures for carburetor maintenance, including main jet changes.

Engine Control Linkage

System connecting throttle, governor, and pedals to the engine for proper operation.

Choke and Air Intake System

System for managing air intake and cold engine starting.

Air Filter Service

Procedures for replacing the air filter element.

Fuel Filter Service

Procedures for removing and installing fuel filters.

Fuel Pump Service

Procedures for fuel pump removal, disassembly, cleaning, and installation.

Fuel Tank Service

Procedures for fuel tank removal, disposal, storage, and installation.

Fuel Lines

Guidelines for routing and maintaining fuel lines.

Fuel Shut-Off Valve

Information on the fuel shut-off valve operation and positions.

SECTION 15 – EXHAUST SYSTEM

MUFFLER

Component that reduces exhaust noise.

MUFFLER REMOVAL

Procedure to remove the muffler.

MUFFLER INSTALLATION

Procedure to install the muffler.

SECTION 16 – UNITIZED TRANSAXLE

General Transaxle Information

Overview of the heavy-duty, fully-synchronized unitized transaxles.

Shifter Lever and Neutral Lockout

Components for gear selection and neutral safety feature.

Governor System and Lubrication

Transaxle governor system and lubricant level maintenance.

Axle Shaft and Bearing Service

Procedures for removing and installing axle shafts and bearings.

Unitized Transaxle Removal and Installation

Procedures for removing and installing the complete unitized transaxle.

Forward/Reverse Shifter Cable Service

Procedures for removing, installing, and adjusting the shifter cable.

SECTION 17 – TORQUE CONVERTER

General Information and Troubleshooting

Overview of the torque converter system and guidance for troubleshooting issues.

Drive Belt Service

Procedures for inspecting, removing, and installing the drive belt.

Drive Clutch Service

Procedures for removing, cleaning, inspecting, disassembling, assembling, and installing the drive clutch.

Driven Clutch Service

Procedures for removing, disassembling, inspecting, assembling, and installing the driven clutch.

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