Contents
Club Car Engine Manual
Introduction
This manual provides instructions on how to maintain and repair the engine of a Club Car golf cart. It includes information on the following topics:
- Engine specifications
- Engine troubleshooting
- Engine maintenance
- Engine repair
Engine Specifications
The following table lists the specifications for the Club Car engine.
| Specification | Value |
|---|---|
| Engine type | Single-cylinder, air-cooled, 4-stroke |
| Displacement | 357 cc |
| Bore | 70 mm |
| Stroke | 60 mm |
| Compression ratio | 8.5:1 |
| Maximum power | 11.5 hp at 3,600 rpm |
| Maximum torque | 18.5 lb-ft at 2,500 rpm |
Engine Troubleshooting
The following table lists common engine problems and their possible causes.
| Problem | Possible Cause |
|---|---|
| Engine won’t start |
|
| Engine runs rough |
|
| Engine overheats |
|
| Engine loses power |
|
Engine Maintenance
The following is a schedule of recommended engine maintenance tasks.
- Every 25 hours: Check engine oil level and add oil if necessary.
- Every 50 hours: Change engine oil and oil filter.
- Every 100 hours: Clean air filter.
- Every 200 hours: Change spark plug.
- Every 500 hours: Adjust valve clearance.
Engine Repair
The following are instructions on how to repair common engine problems.
Replacing the engine oil and oil filter
- Place the golf cart on a level surface.
- Allow the engine to cool down.
- Locate the engine oil drain plug and remove it.
- Allow the oil to drain into a drain pan.
- Replace the oil drain plug.
- Locate the engine oil filter and remove it.
- Apply a thin coat of oil to the gasket of the new oil filter.
- Screw the new oil filter onto the engine.
- Add new oil to the engine. The amount of oil required will vary depending on the model of golf cart. Please refer to your owner’s manual for specific instructions.
Replacing the spark plug
- Locate the spark plug and remove the spark plug wire.
- Use a spark plug wrench to unscrew the spark plug.
- Inspect the spark plug and replace it if it is fouled or damaged.
- Apply a small amount of anti-seize compound to the threads of the new spark plug.
- Screw the new spark plug into the engine.
- Tighten the spark plug to the specified torque.
- Replace the spark plug wire.
Adjusting the valve clearance
- Locate the valve cover and remove it.
- Rotate the crankshaft until the piston is at top dead center (TDC) on the compression stroke.
- Use a feeler gauge to measure the clearance between the valve and the rocker arm.
- Adjust the valve clearance by loosening the locknut on the rocker arm and turning the adjusting screw.
- Tighten the locknut and recheck the valve clearance.
- Repeat this process for the other valve.
Conclusion
This manual provides basic instructions on how to maintain and repair the engine of a Club Car golf cart. If you are not comfortable performing any of the tasks described in this manual, please consult a qualified mechanic.
