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Description
This Official 1998-1999 Club Car FE290 Maintenance And Service Manual Supplement provides detailed service information, step-by-step repair instruction and maintenance specifications 1998-1999 Club Car FE290 Gasoline motors.
Club Car Kawasaki Engine Service Manual Briggs And Stratton
Please note that this supplement needs corresponding maintenance and service manual below depending on the Golf Car application:
1998-1999 DS Golf Car Maintenance And Service Manual, item# 101968401
1998-1999 Carryall Vehicle Maintenance And Service Manual, item# 101968402
1998-1999 Transportation Vehicle And Service Manual, item# 101968403
1998-1999 Club Car FE290 Maintenance And Service Manual Supplement Table of Contents
Club Car Kawasaki Engine Parts
SECTION 10 – PERIODIC MAINTENANCE
General Information
Daily Pre-Operation Safety Checklist
Periodic Service Schedule
Periodic Lubrication Schedule
Vehicle Capacities
Engine Oil
Fueling Instructions
Battery
SECTION 11 – TROUBLESHOOTING
Troubleshooting Guide
SECTION 12 – ELECTRICAL SYSTEM
General Information
FE290 Gasoline Vehicle Electrical Circuits
The Starter Circuit
The Generator Circuit
Engine Ignition Circuit
Engine Kill Circuit
Reverse Buzzer Circuit
Low Oil Warning Circuit
Neutral Lockout Circuit
Fuel Gauge and Sending Unit Circuit
Ftour Meter Circuit
Circuit Testing
Test Starter Circuit and Generator Circuit
Test Engine Ignition Circuit
Test Engine Kill Circuit
Test Reverse Buzzer Circuit
Test Low Oil Warning Circuit
Test Neutral Lockout Circuit
Test Fuel Gauge and Sending Unit Circuit
Index of Test Procedures
Test Procedures
Electrical System Components
Starter/Generator
Belt Adjustments
Electrical System, Continued:
Voltage Regulator
Key Switch
Solenoid
Fuse
Accelerator Starter Limit Switch
Kill Limit Switch
Neutral Lockout Limit Switch
Neutral Lockout Cam
Reverse Warning Buzzer
Reverse Buzzer Limit Switch
Oil Warning Light
Fuel Gauge
Fuel Gauge/Hour Meter For 1999 Model Year Vehicles
Fuel Sending Unit
RPM Limiter
Igniter
Ignition Coil
Oil Sending Unit
Battery
Ground Straps
SECTION 13 – FE290 ENGINE
General Information
Special Engine Service Tools Available from Club Car
Before Servicing
Mechanical Systems
Electrical System
Lubrication System
Spark Plug
Engine Mounting Plate
Cylinder Head
General Information
Cylinder Shroud Removal
Rocker Arms and Push Rods Removal
Cylinder Head Removal
Valve Removal
Breather Valve (Reed Valve)
Cylinder Head Cleaning and Inspection
Valve Guides
Valve Seats
Valves
Cylinder Head Installation
Installation Of Remaining Engine Components
Crankcase
Engine Removal
Crankcase Cover Removal
Camshaft and Tappets
Piston/Connecting Rod
Piston
Piston Ring
Piston Pin
Connecting Rod
Cylinder Block
Ignition Coil and Flywheel
Oil Pump
Oil Pressure Relief Valve
Crankshaft and Balancer
Counterbalance Weight
Crankshaft
Oil Screen
Ball Bearing
Oil Seals
Plain Bearing Surface
Crankshaft Installation
Piston/Connecting Rod Installation
Crankshaft Axial Play Adjustment
Camshaft Installation
Crankcase Cover Installation
Engine Assembly
Service Specifications
Specifications for Resizing Cylinder Bore
Torque Specifications
Adjustments and Settings
SECTION 14 – FUEL SYSTEM
General Information
How The Carburetor Works
Main System
Standard Jetting
Slow Speed System
Choke and Fresh Air System
Float System
Carburetor
Main Jet Elevation/Size Chart
Changing the Main Jet
Fuel System, Continued:
Engine Control Linkage
General Information
Accelerator Rod
Governor Cable
Accelerator Cable
Closed Throttle (Idle) Adjustment
Engine RPM Adjustment
Choke and Air Intake System
General Information
Choke Button Removal
Choke Button Installation
Choke Cable Removal
Choke Cable Installation
Air Box Removal
Air Box Installation
Intake Duct Removal
Intake Duct Installation
Intake Duct Repair
Air Filter
Fuel Filters
General Information
Fuel Filter Removal For 1998 Model Year Vehicles
Fuel Filter Removal For 1999 Model Year Vehicles
Installing The Fuel Filters For 1998 Model Year Vehicles
Installing The Fuel Filters For 1999 Model Year Vehicles
Fuel Pump
General Information
Fuel Pump Removal
Fuel Pump Disassembly
Fuel Pump Cleaning and Inspection
Fuel Pump Assembly
Fuel Pump Installation
Fuel Tank
General Information
Preparation for Extended Storage
Fuel Tank Removal
Fuel Tank Disposal
Fuel Tank Storage
Fuel Tank Installation
Fuel Lines
Fuel Shut-Off Valve
SECTION 15 – EXHAUST
General Information
Muffler
Muffler Removal
Muffler Installation
SECTION 16 – UNITIZED TRANSAXLE
General Information
Lubrication
Axle Shaft
Axle Shaft And Oil Seal Removal
Axle Bearing
Axle Shaft Installation
Unitized Transaxle Removal
Unitized Transaxle Disassembly
Component Disassembly
Disassemble The Governor Gear
Disassemble The Differential Gear Case Assembly
Disassemble The Shifter Fork Assembly
Disassemble The Synchronizer Gear Assembly
Disassemble The Intermediate Gear Assembly
Disassemble The Idler Shaft Assembly
Inspect Unitized Transaxle Components
Component Assembly
Idler Shaft Assembly
Intermediate Gear Assembly
Synchronizer Gear Assembly
Shifter Fork Assembly
Differential Gear Case Assembly
Governor Gear Assembly
Unitized Transaxle Assembly
Unitized Transaxle Installation
Forward/Reverse (F&R) Shifter Cable
F&R Shifter Cable Removal
F&R Shifter Cable Installation
Adjustment Of The F&R Shifter Cable
SECTION 17- TORQUE CONVERTER
General Information
Troubleshooting
Drive Belt
Torque Converter, Continued:
Drive Belt Removal
Drive Belt Installation
Drive Clutch
Drive Clutch Removal
Drive Clutch Cleaning And Inspection
Drive Clutch Disassembly
Inspection Of Drive Clutch Parts
Drive Clutch Assembly
Drive Clutch Installation
Driven Clutch
Driven Clutch Removal
Driven Clutch Disassembly
Driven Clutch Inspection
Driven Clutch Assembly
Driven Clutch Installation
Clutch Alignment