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Club Car MC008C-ES00 User Manual

Club Car MC008C-ES00
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 MC008C-ES00 Specifications

General IconGeneral
BrandClub Car
ModelMC008C-ES00
CategoryEngine
LanguageEnglish

Summary

SECTION 1 – SAFETY

General Warning

General warnings for vehicle operation, repair, and service.

DANGER Hazard Definition

Definition of DANGER hazard.

WARNING Hazard Definition

Definition of WARNING hazard.

General Safety Statements

General safety statements for operation, repair, and service.

SECTION 2 – FE290 ENGINE

FE290 Engine Before Servicing

Information and instructions before beginning engine service.

FE290 Cylinder Head

Information and procedures for the cylinder head.

FE290 Cylinder Head Removal

Steps for removing the cylinder head assembly.

FE290 Cylinder Head Cleaning and Inspection

Procedures for cleaning and inspecting the cylinder head.

FE290 Valve Seats

Inspection and repair of valve seats.

FE290 Valve Seat Repair

Procedures for resurfacing and lapping valve seats.

FE290 Cylinder Head Installation

Procedures for installing the cylinder head.

FE290 Valve Clearance Check and Adjustment

Checking and adjusting valve clearance when engine is cold.

FE290 Ignition Coil and Flywheel

Removal and installation of ignition coil and flywheel.

FE290 Crankshaft and Counterbalance

Removal and disassembly of crankshaft and counterbalance.

FE290 Crankshaft Inspection

Inspecting crankshaft journals and alignment.

FE290 Crankshaft Installation

Procedures for installing the crankshaft.

FE290 Crankshaft Axial Play Adjustment

Adjusting crankshaft axial play using shims.

FE290 Engine Assembly

General information and procedures for engine assembly.

FE290 Engine Installation

General information on engine installation.

FE290 Service Specifications

Technical service limits for FE290 engine components.

FE290 Resizing Cylinder Bore Specs

Specifications for resizing cylinder bore.

FE290 Torque Specifications

Torque values for various fasteners.

FE290 Adjustments and Settings

Specifications for engine adjustments and settings.

SECTION 3 – FE350 ENGINE

FE350 Engine Before Servicing

Information and instructions before beginning engine service.

FE350 Cylinder Head

Information and procedures for the cylinder head.

FE350 Cylinder Head Removal

Steps for removing the cylinder head assembly.

FE350 Cylinder Head Cleaning and Inspection

Procedures for cleaning and inspecting the cylinder head.

FE350 Valve Seats

Inspection and repair of valve seats.

FE350 Valve Seat Repair

Procedures for resurfacing and lapping valve seats.

FE350 Cylinder Head Installation

Procedures for installing the cylinder head.

FE350 Automatic Compression Release Valve (ACR) Inspection

Inspecting the automatic compression release valve.

FE350 Ignition Coil and Flywheel

Removal and installation of ignition coil and flywheel.

FE350 Crankshaft and Counterbalance

Removal and disassembly of crankshaft and counterbalance.

FE350 Crankshaft Inspection

Inspecting crankshaft journals and alignment.

FE350 Crankshaft Axial Play Adjustment

Adjusting crankshaft axial play using shims.

FE350 Engine Assembly

General information and procedures for engine assembly.

FE350 Engine Installation

General information on engine installation.

FE350 Service Specifications

Technical service limits for FE350 engine components.

FE350 Resizing Cylinder Bore Specs

Specifications for resizing cylinder bore.

FE350 Torque Specifications

Torque values for various fasteners.

FE350 Adjustments and Settings

Specifications for engine adjustments and settings.

SECTION 4 – FE400 ENGINE

FE400 Engine Before Servicing

Information and instructions before beginning engine service.

FE400 Cylinder Head

Information and procedures for the cylinder head.

FE400 Engine Installation

General information on engine installation.

FE400 Service Specifications

Technical service limits for FE400 engine components.

FE400 Resizing Cylinder Bore Specs

Specifications for resizing cylinder bore.

FE400 Torque Specifications

Torque values for various fasteners.

FE400 Adjustments and Settings

Specifications for engine adjustments and settings.

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

Unitized Transaxle Removal

Procedures for removing the unitized transaxle.

Unitized Transaxle Disassembly

Steps for disassembling the unitized transaxle.

Unitized Transaxle Differential Gear Case Disassembly

Steps for disassembling the differential gear case.

Unitized Transaxle Synchronizer Gear Disassembly

Steps for disassembling the synchronizer gear.

Unitized Transaxle Component Inspection

Inspecting transaxle components for wear or damage.

Unitized Transaxle Synchronizer Gear Assembly

Steps for assembling the synchronizer gear.

Unitized Transaxle Differential Gear Case Assembly

Steps for assembling the differential gear case.

Unitized Transaxle Assembly

General information and procedures for transaxle assembly.

SECTION 8 – TRANSMISSION MODELS 420317 AND 420682

Transmission Removal

Procedures for removing the transmission.

Transmission Disassembly

Steps for disassembling the transmission.

Input Shaft, Gear and Governor Assembly Removal

Removing the input shaft, gear, and governor assembly.

Transmission Assembly

General information and procedures for transmission assembly.

Transmission Installation

General information on transmission installation.

SECTION 9 – FRONT DIFFERENTIAL MODELS 6203-01-139-S AND 6203-01-189-S

Front Differential Removal

Procedures for removing the front differential.

Front Differential Disassembly

Steps for disassembling the front differential.

Front Differential Installation

General information on front differential installation.

Front Differential Axle Half Shaft Installation

Procedures for installing axle half shafts.

SECTION 10 – REAR DIFFERENTIAL MODELS 420366 AND 420851

Rear Differential Axle Shafts and Differential Removal

Procedures for removing axle shafts and rear differential.

Rear Differential Disassembly

Steps for disassembling the rear differential.

Rear Differential Axle Shafts and Differential Installation

Procedures for installing axle shafts and differential.

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