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Old 07-15-2007, 04:56 PM   #1
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Default Club Car Bi-Yearly Maintenance (1992+ DS carts)

Club Car Maintenance



Like your car, your Club Car golf cart needs some maintenance once in a while too. This will ensure long life and happy operation of your Club Car.


Clean all dirt and old grease from the grease zerks with a towel or rag, there are 5. Put approximately 3-5 pumps of grease in each one or until it comes out in a visible area.

Change the oil. There is a plug on the front, bottom of the FE290 and FE350 engine blocks, use a 14mm ratchet and socket to remove this. BUT, before you do that, run the cart up to running temperature, this will allow all of the oil to run out quickly. Be sure to put a drain pan under the drain hole!!! Remove the dipstick out to allow for vacuum for quick drainage. Take off the oil filter (you may need an oil filter wrench to remove it) and replace with a Napa 4639, Super Tech 4967, or STP 4967 filter. Don't use Fram filters! Before you put the filter back, fill it half way with oil. Put the filter back on. Replace the 14mm drain plug and fill up with 1.6 quarts of SAE30 synthetic or conventional oil. 10W-30 synthetic or conventional is ok too.

Replace rear-end oil. Use a 14mm ratchet and socket to remove the lower drain plug of the transmission and differential on Upper/Lower Unit Kawasaki rear ends, only remove the lower one (6:00) on unitized transaxles. Upper/Lower Kawasaki Unit: fill top unit fill plug hole with a relatively light synthetic gear oil. Fill lower unit with 80W-90 gear oil. Unitized Kawasaki/Graziano: Fill top fill plug hole (9:00) with 80W-90 synthetic gear oil.

Adjust the valves: (This is not necessary every tune up!)
It is important that you clean all tools you will be using thoroghly before you use then, engines do NOT like dirt. Make sure the engine is COLD, do not run it any before you do this procedure.

A
Gather Materials Needed:
1. 10mm socket and ratchet
2. fairly long screw driver (optional) or dowel rod (small)
3. pliers or Club Car adjuster tool
4. feelers gauge
5. 9mm wrench
6. spark plug socket and ratchet

B
Using the 10mm ratchet and socket, remove the two bolts holding the valve cover.

C
Remove the spark plug using the spark plug socket and ratchet

D
Using the long screw driver (if comfortable with risking damaging cylinder wall when done incorrectly) or dowel rod, make sure the engine at at TDC, or top dead center. Gently put the screw driver or dowel rod into the spark plug hole until it hits the piston inside and turn the engine over with the clutch until you hear a realeasing sound and the screw driver stops moving upward, if it starts going back down, back the engine up until it stops agian.

E
After you have gotten the engine to TDC, use the feelers gauge, which you need to set to .005, and place it between the lifter and top of the valve spring.

F
Loosen the nut on top of the rocker arm with the 9mm wrench

G
While moving the feelers gauge back on forth betweent the lifter and valve spring, turn the small square adjuster on top of the rocker with the pliers or adjuster tool clockwise until the feelers gauge get fairly difficult to move.


H
While holding the adjuster exactly where you found it to start snugging up, retighten the nut tightly with the 9mm wrench


I
Recheck your adjustment

J
Make sure the nuts are tight and everything is correct, then replace the valve cover back with the two bolts.

K
Replace the spark plug and start, it will still tap because the engine has not generated enough heat within the first few minutes of running to close that .005 gap. This is the whole point of the valve clearance, to leave the metal enough room to expand when the engine gets hot.



Check your tires for dry rot and/or bald spots. Inflate to 15psi if in good condition. Replace if needed


Change fuel and air filters
Fuel filters can be ordered from Cart Parts Plus or East Coast Custom Carts, Inc..
Air Filter is the same as a 1992 Chevrolet Beretta with the 2.2L 4 cylinder engine.
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Old 10-05-2007, 03:11 PM   #2
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Default Re: Club Car Bi-Yearly Maintenance (1992+ DS carts)

Why not use fram filters?

is this a personal preference or are they not compatable??????
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Old 10-05-2007, 04:31 PM   #3
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Default Re: Club Car Bi-Yearly Maintenance (1992+ DS carts)

Fram filters have a long reputation of causing problems and not filtering properly, among being bottom-shelf quality. Their construction is rather shoddy too. I can twist them with my hands getting them off; I can't do that with any other filter. I have to stick a screwdriver through them to get them off. I just use my hands on the rest of them.
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Old 10-05-2007, 04:39 PM   #4
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Default Re: Club Car Bi-Yearly Maintenance (1992+ DS carts)

just curious, have you ever tried thier higher end filters? i have use the tough-guard on both of my vehicles since new (03 tahoe, 03 sierra) and have not had the first problem. maybe it is just thier base economy line that has problems? just a thought.

so anyway, it sounds like a personal prefernce more than a lack of compatibilyt for fram filters and kawasaki motor?
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Old 10-05-2007, 04:48 PM   #5
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Default Re: Club Car Bi-Yearly Maintenance (1992+ DS carts)

They are compatible as far as screwing on and such, but in my opinion, they're not up to par with the rest. Perhaps the higher lines of them are, but the orange ones certainly are not.

Nice to see a GM fella.

Besides, you should know you can't hurt a GM no matter what you do to it.
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Old 10-05-2007, 05:01 PM   #6
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Default Re: Club Car Bi-Yearly Maintenance (1992+ DS carts)

I always sell the "club car" brand filters, solely because my customers like seeing the name there... lol... and there is no doubt about compatibility....

No No they make a tool specifically for taking that size filter off with a ratchet...
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Old 10-05-2007, 05:23 PM   #7
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Default Re: Club Car Bi-Yearly Maintenance (1992+ DS carts)

I bought one and I can't get it on there for the black box being in the way. I have a pair of pliers now. I just never use them.
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Old 10-05-2007, 05:28 PM   #8
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Default Re: Club Car Bi-Yearly Maintenance (1992+ DS carts)

you have to put it on, then put the ratchet on it.... when i misplace it I use a pipe wrench...
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Old 10-05-2007, 05:34 PM   #9
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Default Re: Club Car Bi-Yearly Maintenance (1992+ DS carts)

I wasn't able to do it that way. The one I had was "Valvoline brand." I eventually gave it to a relative for use on their Toyota Corolla. The pliers work great, but most of the time they are easy enough to get off with my hands. I have used a pipe wrench too, as well as collapsing Frams with Channell Locks and turning them off.
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Old 10-05-2007, 05:39 PM   #10
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Default Re: Club Car Bi-Yearly Maintenance (1992+ DS carts)

LOL, I guess in the long run, whatever gets it off. You don't want to re-use it.
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