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Gas Club Car Gas DS, and Precedent golf cars



 
 
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Old 07-15-2007, 04:56 PM   #1
NO NO NO E-Z-GO!
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Join Date: Dec 2006
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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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