Begin by raising the seat upon its hinges and lifting the cushion out of the hinge brackets. These hinges allow removal of the seat by sliding the double-eared tab out of the hinge slot.
Set the seat aside and locate the air filter box. On the 1992 – 1996 model DS Club Car with the FE290 Kawasaki engine, this is located on the driver’s side of the opening, and it is a black plastic box with two thumbscrews at the back. Turn each of these 90 degrees to unlatch and the back swings out. Note: if the box’s position in the well makes it too difficult to access the latches, remove the entire airbox by loosening the hose clamps at the front and back of the box.
Remove the Air Filter and inspect. It is supposed to be white (or as close to it as possible), not brown or black. Replace the old filter with the the brand new filter.
Remove clamps holding the hose to the air-box.
Remove old filter form airbox.
Replace the air-filter with the new one; installation is the reverse of removal.
Be sure to check the hose that connects the air-box to the carburetor and make sure no splits or cracks are allowing the air to bypass the filter and choke.
The fuel tank is on the passenger side of the engine well and has a fuel filter inline on the fuel line leading to the carburetor. If you have one of the clear plastic filters, check the color of the fuel inside it to ensure the gasoline has not gotten too old and turned to a “shellac” condition--the fuel within the filter is a dark amber color rather than a light clear color. If the fuel gets to this stage, it becomes thick and hard to pass through the filter and carburetor jets.
Note the position of the filter with the tapered end and the flat end. The fuel flow on this filter goes from tapered to flat end…Don’t get this reversed!
If the gas is too old and you have any question about its quality, pump the old gasoline out using a hand pump and replace with fresh gas. Take the old fuel filter and tap the back (the side leading to the top of the fuel tank) on a clean paper towel and see if any black sludgey deposits stain the sheet. If so, you probably have found the problem with your cart’s performance.
Sometimes there is a second filter located underneath the carburetor facing the front of the vehicle. Check to see if you have one and make sure it is also clear of deposits.
Replace the old filter with your brand new one; installation is the reverse of removal.
Locate the spark plug on the top of the engine and remove the cable,
exposing the top of the plug. Use a spark plug socket and ratchet to remove the spark plug and inspect the ceramic insulator.
This should be light brown to brown and not oily or wet. If it is black in color, you might be running too rich of a fuel mixture, requiring an adjustment to the air screw.
Check the gap with a spark plug gap tool (cheap or free at most parts counters) and set this gap to .028 – .030. Replace the spark plug and screw into place using the socket and your fingers to prevent cross-threading.
Lightly tighten with the ratchet…no need to strip it out by tightening too much (you do not want to deal with a stripped out spark plug hole on the engine’s head). Push the wire connector back on to the spark plug.