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Unread 03-19-2017, 08:12 PM   #1
Not Yet Wild
 
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Location: Mechanicsville Va
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Default 1990 CC gas knocking

Knocking. more gas you give, the louder it gets. It's been rebuilt several years ago and has knocked for the last 10 yrs. my buddy acquired it a year ago and we have fixed most of the gremlins. He was told it was the clutch. I said it wasn't, but I rebuilt the clutch, no difference, swapped with another clutch, no difference. decided to pull motor down. rod bolts were tight, removed rod cap and it has score marks in it. crank appears to have a little score. Is this a known problem? looks like we need a complete rebuild kit along with a crank? The part I don't understand is that there is a little play side to side on the rod at the crank. Can that be causing the knock? it looks like the rod has potential to float side to side making knocking noises?

Anyone have advice? a good flathead crank cheap? Is he better to try and find a clone? My buddy is on an extremely tight budget and I'm trying to help him out the best that I can.

Thanks, Troy
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Unread 03-19-2017, 09:43 PM   #2
Gone Wild
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Default Re: 1990 CC gas knocking

I have the same year cart and the flat head engine is a turd...
I'd swap it out with a clone
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Unread 03-20-2017, 06:00 AM   #3
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Default Re: 1990 CC gas knocking

Your issue is a common one with these old motors as they age. It's not to say that these motors are bad motors (I run one), but over a period of time (usually decades), the crankshaft journal begins to get egged-out and the knocking begins. Yeah, your rod bolts will still be tight, but that doesn't mean anything in this situation. Once the rod gets loose enough, it begins banging against the inside of the crankcase at the back side of the motor below the starter/generator until it finally breaks from the crank.

When I got my cart it had a blown KF82 engine after knocking for awhile. Here's my thread that has pics of the carnage:
Engine Block Pulley Removal - KF82

And here's a relatively inexpensive option for rebuilding that I explored at one point:
http://www.buggiesgonewild.com/gener...s-georgia.html

(I didn't end up having my motor rebuilt because I found someone locally with a running KF82 motor which solved my problems)
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Unread 03-20-2017, 12:54 PM   #4
Gone Wild
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Default Re: 1990 CC gas knocking

check it with a strip of plastigauge material,available at any good auto parts store.That will tell you your clearance
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Unread 03-20-2017, 09:48 PM   #5
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Default Re: 1990 CC gas knocking

Taking Springbok's advice, I called J&M carts in Georgia. For 165.00 they will machine the crank and rod. Boxing them up tomorrow to send to them. I'll also buy a gasket set and piston and rings. That should take care of it.

Thanks !!!!

Troy
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Unread 03-21-2017, 05:54 AM   #6
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Default Re: 1990 CC gas knocking

Awesome! Please let me know how it works out and maybe even post some pics of the parts when you get them back. I still have my old original motor and may have that work done at some point.
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