Thanks for the tutorial! I got a 2004 CC Precedent with the FE290 at an auction and was disappointed (though not shocked) to find out it was leaking oil after I got it home. I had been watching your videos prior, and quickly found this one with the exact symptoms I was having. I saw the same gasket breakdown you had with much of it pulled into the crankcase. Several man-hours later, the new gasket is in and it’s running like a champ… with no leaks!
Thank you so much for this video! It saved my butt. I have a 98 CC with the FE290 and had the dreaded leaking crankcase gasket. My first time pulling and opening an engine and it went fantastic. Engine is back in the cart and running like a champ.
Kevin is my new rock star. Rather than risk missing parts and sequences I suspect you would be charging 5 hours labor and oil and gasket so this is a $500 reboot well worth the expense of getting another 10 years out of my Club Car.
Great Video, I have had a Club Car which stopped running well 10 years ago and has been on a Honey Do (way overdue list). Been wanting to strip it down completely even pulling the engine etc. This gives me some encouragement to tackle the job. Thanks.
I really like the way you explain everything you're doing. I always try to find one of your videos when I need to fix a problem with my cart. Keep up the good work! We appreciate you helping us.
@@Kevinsgolfcarts I'm trying to adjust the cable that's in the electric box that operates the cam that works the micro switches that works off the accelerator pedal that goes to the governor. I can find everything except how to adjust it. The cable is out of adjustment and the engine is hard to start and the governor isn't working right. Do you have a video on how to adjust it? If so, which one is it?
Is there a reason you put the 6 bolts/nuts that hold the engine in last instead of putting them in first as a reverse of the removal procedure? Just wondering?
Interesting to see how you got the motor out. I have changed that gasket lots of times I think it was a club car recall. I usually just remove rear body. It's easier for me. I have also heard of guys replacing that gasket without removing engine.
I like to take the engine out so I can be more thorough. Its much easier for me to just plop it on the bench and do the work instead of being hunched over the cart. It also helps keep the oil and other the mess out of the customer's cart. Removing the body on most of the carts that come into my shop would involve removing rear seat kits, tops and then the body. I find this method works best for me.
Hey Kevin, I followed these instructions and fixed my blown crankcase gasket on my club car precedent but now my oil light stays in all the time. Did I forget to connect something? Thanks for the very helpful video!!
If the top body over motor was a hinge up or removable, work on engine bay on these be much easier. Have 2000 model in Aussie needing that gasket done as well. Might mod my cart to suit.
Great video !!! Two questions please, The motor has been changed in my club car, is their any marking on the motor to tell what size & year it is?? Also, our local club car guy said the puller for the clutch assembly was $125:00 ?? (looked like a bolt to me). Thank you !!!!
It really will depend on the year, make and model of the cart. The serial number of the cart will tell you the year. This is a bar code somewhere on the body. Typically starts with 2 letters followed by 2 numbers. Those numbers are the last 2 digits of the year. No way that clutch puller is that expensive. Its a special bolt with threads only near the hex head. Some are left-hand threads.
Thank you for the great video, I just did this to my 99 Club Car DS. The gasket failed in the same spot. Once I placed the new gasket on the engine I found out why they leak in that spot. The gasket does not seal that area properly. I took some pictures of what im talking about. Either I got the wrong gasket or there is a flaw in the design.
Just a side note of my experience, the clutch was stuck on even after a few heavy taps with the impact wrench. I filled the hole with oil and wrapped the puller bolt threads with Teflon tape to seal it in. This adds extra pressure and lubricant which broke it free. Thanks again!
Question pulled engine with your help... I'm stuck at removing crankcase cover... have separated and spin loose from pillars but for some reason seems caught on the very end ... am I missing something didn't want to hammer it to hard
Sometimes the bearing gets caught on the crankshaft and causes it to stick. Using a rubber mallet, you can give the cover a few good hits and it should come off. If not, hit it back on and use Emory cloth to clean the rust off the shaft.
I really enjoy watching your videos! You do great work! I am thinking of getting into repairing golf carts, do you have any tips for a good parts supplier/wholesaler?
Wonderful video helped me a ton. Only very minor critique is.. why didn't you replace the crankshaft seal while you were in there? That is what was bad on mine. Regardless, you showed me how to get to it and saved me $400 that the shop wanted to charge me. Plus loading the cart on the trailer, going to pick it up and calling them to ask them when my darn cart will be finished.
The seal was still in good shape and wasn't leaking. At the time, the seals were on backorder for a few weeks and the customer didn't want to wait that long. They made the call to move forward without replacing it.
Ive got a 06 club car with the fe290d engine and i cant figure out whats wrong with it. I put a new carburetor and fuel punp on it hoping that would fix it but it didnt. It will spin over but cant seem to get enough power to move. Its also spitting alot of gas out of the intake on the carburetor. Any ideas what it could be?
Yeah, its possible. Its a bit of a dance with a floor jack and jack stands. I use the jack under the rear driver's side tire to compress the suspension. You have to get the clutch bolt lined up with enough room to remove it and install the clutch puller.
One of the things that happen when most people have an engine oil leak is that thought that if they overfill it, they won't have to check the oil as often. That leads exactly to the problem you see here.
Another reason which is more common in my experience, people overfill them due to not knowing the total capacity. This engine had a whole US quart of oil added when the level was below the knurled section. As long as the oil is within the knurled section of the dipstick, its within its operating capacity.
Quick question. Does the size of the fuel filter determine the amount of fuel the carburetor gets. You cant use a fuel filter from a snowblower on a golf cart ?
Yes it does, to a point. The fuel pump can only pump so much fuel but if its restricted by a much smaller fuel filter, it could cause issues at higher engine RPM. The carburetor can only deliver as much fuel as the engine needs. The fuel pump can only deliver as much fuel as the carburetor needs. The fuel pump can only push as much fuel through the fuel lines as allowed by the capacity of the lines and filter. I wouldn't use anything too small since it will become blocked up faster and has less surface area to provide filtering.
I believe it was a problem that started from being overfilled multiple times. Others have said its a design flaw of this engine. I don't know the history of this cart so I can't say with absolute certainty. These engines do not like to be overfilled regardless. They will smoke real bad and cause other issues. Oil and a filter are cheap, engine rebuilds are not.
@@Kevinsgolfcarts thank you for the quick response! You rock! Is the cross bar under the seat/over the motor going to be an issue? I know that the body has to be lifted up some to get the front of that out. Thanks again!
@@Kevinsgolfcarts thanks for all the great information! I have the engine out and the front cover off. The crank seal is not leaking (I did get a replacement) and I see you did not change it in this cover. Am I okay not replacing the front seal? It looks like changing the seal requires removing the bearing?
That's your opinion. There's a rear seat on this cart and it still is difficult to access. I have better access the way I do it. You are free to do it how you wish.
Thanks for the tutorial! I got a 2004 CC Precedent with the FE290 at an auction and was disappointed (though not shocked) to find out it was leaking oil after I got it home. I had been watching your videos prior, and quickly found this one with the exact symptoms I was having. I saw the same gasket breakdown you had with much of it pulled into the crankcase. Several man-hours later, the new gasket is in and it’s running like a champ… with no leaks!
Major surgery on a golf club car, been waiting for this one! Great job Kevin.
Thank you so much for this video! It saved my butt. I have a 98 CC with the FE290 and had the dreaded leaking crankcase gasket. My first time pulling and opening an engine and it went fantastic. Engine is back in the cart and running like a champ.
That's awesome!!
Kevin is my new rock star. Rather than risk missing parts and sequences I suspect you would be charging 5 hours labor and
oil and gasket so this is a $500 reboot well worth the expense of getting another 10 years out of my Club Car.
Thanks for the video Kevin !!! I getting ready to change crankcase gasket on my 2006 DS. Perfect timing !!!
Nice work Kevin, thanks for taking the time to make this video.
Great Video, I have had a Club Car which stopped running well 10 years ago and has been on a Honey Do (way overdue list). Been wanting to strip it down completely even pulling the engine etc. This gives me some encouragement to tackle the job. Thanks.
I really like the way you explain everything you're doing. I always try to find one of your videos when I need to fix a problem with my cart. Keep up the good work! We appreciate you helping us.
Great to hear!
@@Kevinsgolfcarts I'm trying to adjust the cable that's in the electric box that operates the cam that works the micro switches that works off the accelerator pedal that goes to the governor. I can find everything except how to adjust it. The cable is out of adjustment and the engine is hard to start and the governor isn't working right. Do you have a video on how to adjust it? If so, which one is it?
Really a lot of work! Very good work Kevin! Keep it up. You help me a lot as I work on my Cart, and refer back to you.
Your awesome! 👏
Thanks for this video! I used it as a guide for replacing the side cover gasket on my 2005 DS this weekend!
Great video Kevin, can you please share where you bought the bolt to remove the clutch pull it would be very helpful to me thanks
Your videos are very good. Not alot of useless chatter . Just good info thanks for making these.
Glad you like them!
Is there a reason you put the 6 bolts/nuts that hold the engine in last instead of putting them in first as a reverse of the removal procedure? Just wondering?
Interesting to see how you got the motor out. I have changed that gasket lots of times I think it was a club car recall. I usually just remove rear body. It's easier for me. I have also heard of guys replacing that gasket without removing engine.
I like to take the engine out so I can be more thorough. Its much easier for me to just plop it on the bench and do the work instead of being hunched over the cart. It also helps keep the oil and other the mess out of the customer's cart. Removing the body on most of the carts that come into my shop would involve removing rear seat kits, tops and then the body. I find this method works best for me.
Hey Kevin, I followed these instructions and fixed my blown crankcase gasket on my club car precedent but now my oil light stays in all the time. Did I forget to connect something? Thanks for the very helpful video!!
Thanks for convincing me to have a pro rebuild mine. Wish I could hire Kevin!
If the top body over motor was a hinge up or removable, work on engine bay on these be much easier. Have 2000 model in Aussie needing that gasket done as well. Might mod my cart to suit.
Great video !!! Two questions please,
The motor has been changed in my club car, is their any marking on the motor to tell what size & year it is??
Also, our local club car guy said the puller for the clutch assembly was $125:00 ??
(looked like a bolt to me).
Thank you !!!!
It really will depend on the year, make and model of the cart. The serial number of the cart will tell you the year. This is a bar code somewhere on the body. Typically starts with 2 letters followed by 2 numbers. Those numbers are the last 2 digits of the year. No way that clutch puller is that expensive. Its a special bolt with threads only near the hex head. Some are left-hand threads.
@@Kevinsgolfcarts thank you !!!!
Damn, I'm exhausted just watching this video but nice job man.
Thank you for the great video, I just did this to my 99 Club Car DS. The gasket failed in the same spot. Once I placed the new gasket on the engine I found out why they leak in that spot. The gasket does not seal that area properly. I took some pictures of what im talking about. Either I got the wrong gasket or there is a flaw in the design.
Great Video.. i have to make the same repair to my g14. Can it be done in the frame with the body off or should the engine come out?
Incredible video, very thorough!
Glad you liked it!
Just a side note of my experience, the clutch was stuck on even after a few heavy taps with the impact wrench. I filled the hole with oil and wrapped the puller bolt threads with Teflon tape to seal it in. This adds extra pressure and lubricant which broke it free. Thanks again!
Question pulled engine with your help...
I'm stuck at removing crankcase cover... have separated and spin loose from pillars but for some reason seems caught on the very end ... am I missing something didn't want to hammer it to hard
Sometimes the bearing gets caught on the crankshaft and causes it to stick. Using a rubber mallet, you can give the cover a few good hits and it should come off. If not, hit it back on and use Emory cloth to clean the rust off the shaft.
I really enjoy watching your videos! You do great work! I am thinking of getting into repairing golf carts, do you have any tips for a good parts supplier/wholesaler?
Wonderful video helped me a ton. Only very minor critique is.. why didn't you replace the crankshaft seal while you were in there? That is what was bad on mine. Regardless, you showed me how to get to it and saved me $400 that the shop wanted to charge me. Plus loading the cart on the trailer, going to pick it up and calling them to ask them when my darn cart will be finished.
The seal was still in good shape and wasn't leaking. At the time, the seals were on backorder for a few weeks and the customer didn't want to wait that long. They made the call to move forward without replacing it.
I needed to see the starter generator video. Why did you not polarize the generator'?
Ive got a 06 club car with the fe290d engine and i cant figure out whats wrong with it. I put a new carburetor and fuel punp on it hoping that would fix it but it didnt. It will spin over but cant seem to get enough power to move. Its also spitting alot of gas out of the intake on the carburetor. Any ideas what it could be?
Have any videos on replacing valve seals ?
Also I see no jack stands........I would like to have a lift for doing things, can u recommend one? Great helpful videos, thank you...
No need for jack stands (for me), the front tires are on truck ramps. I don't own a lift so I cannot recommend one.
Kevin is it possible to replace the driven clutch with out removing the engine i was looking for a vid but could not find one (club car DS)
Yeah, its possible. Its a bit of a dance with a floor jack and jack stands. I use the jack under the rear driver's side tire to compress the suspension. You have to get the clutch bolt lined up with enough room to remove it and install the clutch puller.
Where can I find the clutch puller bolt?
I'm looking too
Thank you so much! I followed your video and did it myself!
One of the things that happen when most people have an engine oil leak is that thought that if they overfill it, they won't have to check the oil as often. That leads exactly to the problem you see here.
Another reason which is more common in my experience, people overfill them due to not knowing the total capacity. This engine had a whole US quart of oil added when the level was below the knurled section. As long as the oil is within the knurled section of the dipstick, its within its operating capacity.
Quick question. Does the size of the fuel filter determine the amount of fuel the carburetor gets. You cant use a fuel filter from a snowblower on a golf cart ?
Yes it does, to a point. The fuel pump can only pump so much fuel but if its restricted by a much smaller fuel filter, it could cause issues at higher engine RPM. The carburetor can only deliver as much fuel as the engine needs. The fuel pump can only deliver as much fuel as the carburetor needs. The fuel pump can only push as much fuel through the fuel lines as allowed by the capacity of the lines and filter. I wouldn't use anything too small since it will become blocked up faster and has less surface area to provide filtering.
@@Kevinsgolfcarts
Thank you for such a quick response. Just enjoy your channel and videos. Thanks again
Im in Winnipeg Manitoba Canada
Where can i find the clutch puller bolt
What would someone except to pay for this job?
Can you tell me did they just over fill it that blew that gasket? I bought one today with this exact same leak.
I believe it was a problem that started from being overfilled multiple times. Others have said its a design flaw of this engine. I don't know the history of this cart so I can't say with absolute certainty. These engines do not like to be overfilled regardless. They will smoke real bad and cause other issues. Oil and a filter are cheap, engine rebuilds are not.
With a fuel issue to start is it possible fuel leaked by the carb and into the oil? I believe that may have been my problem!
Do you have the same video for a precedent?
Its basically the same procedure. They used the FE350 in the Precedent. Its just a different body.
@@Kevinsgolfcarts thank you for the quick response! You rock! Is the cross bar under the seat/over the motor going to be an issue? I know that the body has to be lifted up some to get the front of that out.
Thanks again!
That bar comes off. Its a bit tricky but its removable.
@@Kevinsgolfcarts thanks for all the great information! I have the engine out and the front cover off. The crank seal is not leaking (I did get a replacement) and I see you did not change it in this cover. Am I okay not replacing the front seal? It looks like changing the seal requires removing the bearing?
Great job my friend .....
Thanks 👍
Where can I get a free service manual for a 2008 Club Car DS? Thanks,
You'll have to do some digging on google. Most sites are charging for a PDF now.
This is a typical failure of the case cover gasket on this engine. That is, the gasket being sucked into the crankcase, rather than being blown out.
how about an engine overhaul?
I don't rebuild engines anymore. I send them out.
Great video, just amazes me how many you can't hear, I have never had one I had to turn down...
I'm not sure what you are referring to.
Great job.
Nice video
No jack stands! Very dangerous to get under that cart like you did.
Its on ramps as well.
Remove the rear service panel to access the muffler clamp, belt, generator starter. You make the job a lot harder than what it actually is.
That's your opinion. There's a rear seat on this cart and it still is difficult to access. I have better access the way I do it. You are free to do it how you wish.
Excellent how to vifelo with very little editing nice job