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Club Car FE400 User Manual

Club Car FE400
264 pages
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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 Contents

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Club Car FE400 Specifications

General IconGeneral
Horsepower14 hp
Cooling SystemAir-cooled
Fuel SystemCarburetor
Fuel TypeUnleaded gasoline
Displacement404 cc
Engine Type4-cycle, single cylinder, air-cooled

Summary

Section 1 - Safety

General Warning

Details essential safety precautions for servicing Club Car vehicles.

Safety Alert Definitions

Explains the meaning of DANGER, WARNING, and CAUTION statements.

Section 2 - FE290 Engine

Valve Guide Inspection

Procedure for inspecting FE290 engine valve guides for wear and proper diameter.

Valve Seat Inspection

Procedure for inspecting FE290 engine valve seats for damage and proper contact.

Valve Clearance Check and Adjustment

Procedure for checking and adjusting valve clearance on a cold FE290 engine.

Valve Seat Repair

Instructions for reconditioning and resurfacing FE290 engine valve seats.

Installation of Remaining Engine Components

Steps for installing remaining components after FE290 engine assembly.

Section 2 - FE290 Engine

Section 3 - FE350 Engine

Rocker Arm and Push Rod Removal

Instructions for removing rocker arms and push rods from the FE350 engine.

Valve Removal

Procedure for removing valves, springs, and seals from the FE350 engine.

Valve Stem Diameter

Measurement procedure for FE350 engine valve stem diameter and service limits.

Push Rod Inspection

Procedure for inspecting FE350 engine push rods for bend.

Crankcase Components

General information and procedures for FE350 engine crankcase components.

Cylinder Head Removal

Procedure for removing the FE350 engine cylinder head assembly and head gasket.

Cylinder Head Cleaning and Inspection

Steps for cleaning and inspecting the FE350 engine cylinder head for flatness and damage.

Valve Guide Replacement

Detailed steps for replacing valve guides in the FE350 engine cylinder head.

Rocker Arm and Rocker Shaft Inspection

Procedure for inspecting rocker arm bearing and rocker shaft dimensions on FE350 engine.

Cylinder Head Installation

Detailed steps for installing the FE350 engine cylinder head assembly.

Section 3 - FE350 Engine

Crankshaft Inspection

Procedure for inspecting FE350 engine crankshaft journals, gear, alignment, and run-out.

Crankshaft Installation

Detailed steps for installing the FE350 engine crankshaft and counterbalance weight.

Piston and Connecting Rod Installation

Detailed steps for installing the piston and connecting rod assembly into the FE350 engine cylinder.

Engine Assembly

Steps for assembling the FE350 engine, including cylinder head, flywheel, and ignition coil.

Section 4 - FE400 Engine

To Resize Bore to Next Oversize

Instructions for resizing the FE400 engine cylinder bore to the next oversize diameter.

Cylinder Head

Covers general information and inspection of the FE400 cylinder head.

Section 5 - MC008C-ES00 and MC008C-FS00 Unitized Transaxles

Section 6 - MC010C-BS00 Unitized Transaxle with Differential Lock

Section 7 - MC012C-AS00 and MC012C-BS00 Unitized Transaxles with Differential Locks

Section 8 - Transmission Models 420317 and 420682

Section 9 - Front Differential Models 6203-01-139-S and 6203-01-189-S

Section 10 - Rear Differential Models 420366 and 420851

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