Club Car FE290 User Manual (English)

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MANUAL NUMBER

102396501

EDITION CODE 0904A00000

Engine Models:

• FE290

• FE350

• FE400

Unitized Transaxle Models:

• MC008C-ES00

• MC008C-FS00

• MC010C-BS00 (with Differential Lock)

• MC012C-AS00 (with Differential Lock)

• MC012C-BS00 (with Differential Lock)

All-Wheel Drive:

• Transmission

• Front Differential

• Rear Differential

Engines

and

Drivetrain

Components

REPAIR

AND

REBUILD

MANUAL

Gasoline and Diesel

Vehicles

Table of Contents5
Section 1 - Safety13
General Warning13
Section 2 - Fe290 Engine17
General Information17
Special Engine Service Tools Available from Club Car17
Recommended Replacement Parts for Engine Teardown18
Before Servicing18
Mechanical Systems18
Cylinder Components20
Cylinder Head20
General Information20
Cylinder Shroud Removal20
Rocker Arm and Push Rod Removal23
Cylinder Head Removal23
Valve Removal24
Breather Valve (Reed Valve)24
Cylinder Head Cleaning and Inspection25
Valve Guides25
Valve Seats27
Valves29
Rocker Arm and Rocker Shaft Inspection31
Push Rod Inspection32
Cylinder Head Installation32
Valve Clearance Check and Adjustment34
Breather Valve (Reed Valve)34
Installation of Remaining Engine Components35
Crankcase Components36
Crankcase Cover Removal36
Camshaft and Tappets38
Piston and Connecting Rod38
Cylinder Block41
Ignition Coil and Flywheel43
Oil Pump45
Oil Pressure Relief Valve46
Crankshaft and Counterbalance47
Counterbalance Weight50
Oil Screen52
Ball Bearing53
Oil Seals53
Piston and Connecting Rod Installation55
Crankshaft Axial Play Adjustment56
Crankcase Cover Installation58
Engine Assembly59
Engine Installation60
Service Specifications61
Specifications for Resizing Cylinder Bore62
Torque Specifications62
Adjustments and Settings63
Section 3 - Fe350 Engine65
General Information65
Special Engine Service Tools Available from Club Car65
Recommended Replacement Parts for Engine Teardown66
Before Servicing66
Mechanical Systems66
Cylinder Components68
Cylinder Head68
General Information68
Cylinder Shroud Removal68
Rocker Arm and Push Rod Removal71
Cylinder Head Removal71
Valve Removal72
Breather Valve (Reed Valve)72
Cylinder Head Cleaning and Inspection73
Valve Guides74
Valve Seats75
Valves77
Rocker Arm and Rocker Shaft Inspection79
Push Rod Inspection80
Cylinder Head Installation80
Valve Clearance Check and Adjustment81
Breather Valve (Reed Valve)81
Installation of Remaining Engine Components82
Crankcase Components84
Crankcase Cover Removal84
Camshaft and Hydraulic Lifters85
Piston and Connecting Rod87
Cylinder Block90
Ignition Coil and Flywheel92
Oil Pump93
Oil Pressure Relief Valve95
Crankshaft and Counterbalance96
Counterbalance Weight99
Oil Screen102
Ball Bearing102
Oil Seals103
Piston and Connecting Rod Installation105
Crankshaft Axial Play Adjustment106
Camshaft Axial Play Adjustment107
Crankcase Cover Installation108
Engine Assembly109
Engine Installation110
Service Specifications111
Specifications for Resizing Cylinder Bore112
Torque Specifications112
Adjustment and Settings113
Section 4 - Fe400 Engine115
General Information115
Special Engine Service Tools Available from Club Car115
Recommended Replacement Parts for Engine Teardown116
Before Servicing116
Cylinder Head116
General Information116
Muffler Removal and Installation117
Cylinder Block117
Engine Installation120
Service Specifications120
Specifications for Resizing Cylinder Bore120
Torque Specifications120
Adjustment and Settings120
Section 5 - Mc008C-Es00 and Mc008C-Fs00 Unitized Transaxles121
General Information121
Transaxle Models and Identification121
Axle Shaft122
Unitized Transaxle Removal122
Unitized Transaxle Disassembly122
Component Disassembly126
Governor Gear Disassembly126
Differential Gear Case Disassembly129
Shifter Fork Disassembly131
Synchronizer Gear Disassembly131
Intermediate Gear Disassembly132
Idler Shaft Disassembly133
Unitized Transaxle Component Inspection134
Component Assembly134
Idler Shaft Assembly134
Intermediate Gear Assembly134
Synchronizer Gear Assembly135
Shifter Fork Assembly138
Differential Gear Case Assembly139
Governor Gear Assembly141
Unitized Transaxle Assembly141
Axle Tubes146
Unitized Transaxle Installation146
Lubrication146
Section 6 - Mc010C-Bs00 Unitized Transaxle with Differential Lock147
General Information147
Transaxle Models and Identification147
Axle Shaft148
Unitized Transaxle Removal148
Unitized Transaxle Disassembly148
Component Disassembly153
Differential Gear Lock Housing Disassembly153
Governor Gear Disassembly153
Differential Gear Case Disassembly154
Shifter Fork Disassembly156
Synchronizer Gear Disassembly156
Intermediate Gear Disassembly158
Idler Shaft Disassembly158

Club Car FE290 User Manual

Table of Contents

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Brand	Club Car
Model	FE290
Category	Utility Vehicle
Language	English