Club Car Engine & Drivetrain Repair and Rebuild Manual

$14.99

Category:

Covers: Club Car Engine and Drivetrain Repair & Rebuild (see list below)
Format: PDF file
Compatibility: Windows/Mac computers
File details: Bookmarked: Yes, Searchable: Yes, Printable: Yes
File size: 44mb

Topics in this manual:

  • FE290 Engine rebuild
  • FE350 Engine rebuild
  • FE400 Engine rebuild
  • MC008C-ES00 and MC008C-FS00 Unitized Transaxle
  • MC010C-BS00 Unitized Transaxle with Differential Lock
  • MC012C-AS00 and MC012C-BS00 Unitized Transaxle with Differential Lock
  • Transmission Models 420317 and 420682
  • Front Differential Models 6203-01-139-S and 6203-01-189-S
  • Rear Differential Models 420366 and 420851

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FE290 ENGINE
General Information
Special Engine Service Tools Available from Club Car
Recommended Replacement Parts for Engine Teardown
Before Servicing
Mechanical Systems
Cylinder Components
Cylinder Head
General Information
Cylinder Shroud Removal
Rocker Arm and Push Rod Removal
Cylinder Head Removal
Valve Removal
Breather Valve (Reed Valve)
Cylinder Head Cleaning and Inspection
Valve Guides
Valve Seats
Valves
Rocker Arm and Rocker Shaft Inspection
Push Rod Inspection
Cylinder Head Installation
Valve Clearance Check and Adjustment
Breather Valve (Reed Valve)
Installation Of Remaining Engine Components
Crankcase Components
Crankcase Cover Removal
Camshaft and Tappets
Piston and Connecting Rod
Cylinder Block
Ignition Coil and Flywheel
Oil Pump
Oil Pressure Relief Valve
Page iv Repair and Rebuild Manual – Engines and Drivetrain Components
Crankshaft and Counterbalance
Counterbalance Weight
Oil Screen
Ball Bearing
Oil Seals
Piston and Connecting Rod Installation
Crankshaft Axial Play Adjustment
Crankcase Cover Installation
Engine Assembly
Engine Installation
Service Specifications
Specifications for Resizing Cylinder Bore
Torque Specifications
Adjustments and Settings
SECTION 3 – FE350 ENGINE
General Information
Special Engine Service Tools Available From Club Car
Recommended Replacement Parts For Engine Teardown
Before Servicing
Mechanical Systems
Cylinder Components
Cylinder Head
General Information
Cylinder Shroud Removal
Rocker Arm and Push Rod Removal
Cylinder Head Removal
Valve Removal
Breather Valve (Reed Valve)
Cylinder Head Cleaning and Inspection
Valve Guides
Valve Seats
Valves
Rocker Arm and Rocker Shaft inspection
Push Rod Inspection
Cylinder Head Installation
Valve Clearance Check and Adjustment
Breather Valve (Reed Valve)
Installation of Remaining Engine Components
Repair and Rebuild Manual – Engines and Drivetrain Components Page v
Crankcase Components
Crankcase Cover Removal
Camshaft and Hydraulic Lifters
Piston and Connecting Rod
Cylinder Block
Ignition Coil and Flywheel
Oil Pump
Oil Pressure Relief Valve
Crankshaft and Counterbalance
Counterbalance Weight
Oil Screen
Ball Bearing
Oil Seals
Piston and Connecting Rod Installation
Crankshaft Axial Play Adjustment
Camshaft Axial Play Adjustment
Crankcase Cover Installation
Engine Assembly
Engine Installation
Service Specifications
Specifications for Resizing Cylinder Bore
Torque Specifications
Adjustment and Settings
SECTION 4 – FE400 ENGINE
General Information
Special Engine Service Tools Available From Club Car
Recommended Replacement Parts For Engine Teardown
Before Servicing
Cylinder Head
General Information
Muffler Removal and Installation
Cylinder Block
Engine Installation
Service Specifications
Specifications for Resizing Cylinder Bore
Torque Specifications
Adjustment and Settings
Page vi Repair and Rebuild Manual – Engines and Drivetrain Components
SECTION 5 – MC008C-ES00 AND MC008C-FS00 UNITIZED TRANSAXLES
General Information
Transaxle Models and Identification
Axle Shaft
Unitized Transaxle Removal
Unitized Transaxle Disassembly
Component Disassembly
Governor Gear Disassembly
Differential Gear Case Disassembly
Shifter Fork Disassembly
Synchronizer Gear Disassembly
Intermediate Gear Disassembly
Idler Shaft Disassembly
Unitized Transaxle Component Inspection
Component Assembly
Idler Shaft Assembly
Intermediate Gear Assembly
Synchronizer Gear Assembly
Shifter Fork Assembly
Differential Gear Case Assembly
Governor Gear Assembly
Unitized Transaxle Assembly
Axle Tubes
Unitized Transaxle Installation
Lubrication
SECTION 6 – MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
General Information
Transaxle Models And Identification
Axle Shaft
Unitized Transaxle Removal
Unitized Transaxle Disassembly
Component Disassembly
Differential Gear Lock Housing Disassembly
Governor Gear Disassembly
Differential Gear Case Disassembly
Shifter Fork Disassembly
Synchronizer Gear Disassembly
Intermediate Gear Disassembly
Idler Shaft Disassembly
Repair and Rebuild Manual – Engines and Drivetrain Components Page vii
Unitized Transaxle Component Inspection
Component Assembly
Idler Shaft Assembly
Intermediate Gear Assembly
Synchronizer Gear Assembly
Shifter Fork Assembly
Differential Gear Case Assembly
Governor Gear Assembly
Differential Gear Lock Housing Assembly
Unitized Transaxle Assembly
Axle Tubes
Unitized Transaxle Installation
Lubrication
SECTION 7 – MC012C-AS00 AND MC012C-BS00 UNITIZED TRANSAXLES WITH DIFFERENTIAL
LOCKS
General Information
Transaxle Models and Identification
Axle Shaft
Unitized Transaxle Removal
Unitized Transaxle Disassembly
Component Disassembly
Differential Gear Lock Housing Disassembly
Governor Gear Disassembly
Differential Gear Case Disassembly
Shifter Fork Disassembly
Synchronizer Gear Disassembly
Intermediate Gear Disassembly
Idler Shaft Disassembly
Unitized Transaxle Component Inspection
Component Assembly
Idler Shaft Assembly
Intermediate Gear Assembly
Synchronizer Gear Assembly
Shifter Fork Assembly
Differential Gear Case Assembly
Governor Gear Assembly
Differential Gear Lock Housing Assembly
Unitized Transaxle Assembly
Axle Tubes
Unitized Transaxle Installation
Page viii Repair and Rebuild Manual – Engines and Drivetrain Components
Lubrication
SECTION 8 – TRANSMISSION MODELS 420317 AND 420682
General Information
Model Identification
Service Fixture
Transmission Removal
Transmission Disassembly
Input Shaft Disassembly
Input Shaft Assembly
Intermediate Shaft Disassembly
Output Shaft Disassembly
Shifter Shaft Removal
Shifter Shaft Installation
Case Inspection
Shaft Seal Removal
Shaft Seal Installation
Output Shaft Assembly
Intermediate Shaft Assembly
Intermediate and Output Shaft Assembly
Transmission Assembly
Transmission Installation
SECTION 9 – FRONT DIFFERENTIAL MODELS 6203-01-139-S AND 6203-01-189-S
General Information
Axle Half Shaft Removal
Front Differential Removal
Tools Required For This Section
Front Differential Coil And Output Cover
Coil and Output Cover Removal
Coil and Output Cover Installation
Front Differential
Front Differential Disassembly
Front Differential Assembly
Front Differential Installation
Axle Half Shaft Installation
SECTION 10 – REAR DIFFERENTIAL MODELS 420366 AND 420851
General Information
Axle Shafts and Differential Removal
Repair and Rebuild Manual – Engines and Drivetrain Components Page ix
Rear Differential Disassembly
Pinion Gear Removal
Ring Gear Removal
Clutch Carrier Assembly
Ring Gear Installation
Pinion Gear Installation
Rear Differential Assembly
Axle Shafts and Differential Installation

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