Tune up and speeding up a 02 DS with FE350

ClubHumvee

THIS IS LONG, SORRY.

So got my 02 DS about two years ago and when I got it the previous owner had really neglected it. They went as far as running diesel fuel. Oils leaks clogged filter, you name it.

I cleaned the fuel, stopped the oil leaks, changed the oil, fuel and air filter, spark plug. Got it running smooth.

The thing was fast. I noticed there was zip tie on what I believe is the governor, but I didn't​ give it much thought. Many times we took the cart to the community pool a block away, or took the kids around the block.

I slowly started to notice that it would back fire every now and then. But again, we didn't use it much.

We have four kids and this year we bought a Yukon for the space, but quickly realized that we can tow easily with it.

We take trips to beach a few times a year and decided we'd​ start taking the golf cart. So we did. We took that cart to the island and use it for everything. Loved it. But now we are using it a full day and going a few miles, not a few blocks any more.

I quickly realized that the cart would top out on speed and the cut out. Then start again, then cut out. The back fire loud , regularly. I also noticed that back side was hot. Hotter than normal.

The back firing scares the crap out my 3 year olds.

I called the local Club Car dealer and they asked about the rev limiter and said that was what was causing the back firing and cutting out. They asked about the governor and I told them it was zipped tied from before I had it.

So my wife and I decided that since we're going to use that cart regularly and would like it to last, that we'd take it in for service.

SO HERE'S THE ACTUALLY POINT.
THE TOO LONG DIDN'T READ PORTION.

Club Car came back and said bushing were shot and the drive belts were frayed. So I had them so that. And they said that the rpms were completely maxed out. And this would eventually blow the engine.

I had them fix the governor and adjust the top end speed as far as they could without damaging the engine. And Rev limiter wouldn't kick in, and the cart wouldn't back fire.

They did. And now the cart is SLOW. painfully slow. The dealer says it set to 15 mph. But man it feels like 3mph. I don't know how fast I was going before, but I was happy to blow past the high end electric carts.

SO MY QUESTION.

What can I do to speed this this back up, without the rev limiter cutting out and back firing and over heating?

I HAVE ordered a DS Kawasaki performance​ tuning kit. Which gives you gears and new springs and belt and a couple other stuff such as a KN filter.

The site says it should put me over 20. 21mph ish.

Has anyone tried this. You all are the experts, any advice would be appreciated.

Sorry again for the long post.

BGW

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ClubHumvee

Any recommendations for speed up a cart without adjust the governor or rev limiter?

Anyone have experience with the buggies unlimited performance kit?

cruisinkruty

put a tachometer on it.Adjust governor spring tension to about 200 rpms before rev limiter causes cutout. Run a taller tire.

Golf cart guy

Put High speed gears in it.
This will bring engine RPMs back down to a very close to what stock gears run the cart at 15 MPH.
Adjust the linkage correctly and you will have a 25+ MPH cart that doesn't backfire and is enjoyable to travel in.

ClubHumvee

Is there a tachometer that everyone is using or one you recommend?

What RPM does the rev limiter cut out at?

ClubHumvee

The DS Kawasaki performance kit I ordered includes new clutch springs and new gears and couple other things. Any experience with the kit from buggies unlimited?

https://m.buggiesunlimited.com/golf-...1997-up)/30926

lockman1

In response to your PM... Like I said, I don't have experience with this kit, just the company!

There are only 3 out of 5 things that come with this kit that I would consider using,

The K&N air filter... a great filter!
I have one, BUT... I had to install a slightly larger main jet in my carb to get it to run right.

8:1 high speed gears...
They should work really well being that you want to keep your rev limiter intact!

I've always wanted them, but I'm too cheap and lazy to put them in,
so I opted to add additional lift with 25" tires, disable the rev limiter, and zip tie the governor spring,
it got me to around 30 mph before the valves float!


Clutch Tuning Kit...
Driven (rear) Clutch torque spring... It's always a good idea when adding high speed gears, or larger tires!
My cart has a torque spring from the factory due to it's original design as a "Lynx Hunting Vehicle"

The 200 rpm Drive (front) Clutch spring... see "Power kit" below.

The Power Kit....
A relay and wire harness to get your cart to pedal start and idle, and the drive clutch spring keeps the clutch from engaging just above idle.
(that is... IF... you want it to idle.)
Personally? I feel it's a lot of extra work, and kind of useless when all it takes is disconnecting 1 wire in the components box,
and with a proper idle, you don't really need the drive clutch spring!

(reference link)>>> http://www.buggiesgonewild.com/gas-c...dle-setup.html

Single cogged drive belt... it's better than the standard belt,
but I opted for Cart Parts Plus "Severe Duty" double cogged belt, and I won't use any other drive belt now!

Granted, the kit is reasonably priced, but... had you waited just a little longer for more responses before ordering it,
I/We could have saved you about $100 for better stuff without the unneeded stuff!
That being said... I'll guess that you already have it by now, so you might as well use it!
"Why?" ... because, returning it might prove to be a difficult experience!

.02

ClubHumvee

Thank you Lockman. Thanks for taking the time to help this complete newbie.

I'm not against adjusting the governor, I just didn't want to max it out. The Club Car dealer made it sound like the cart was going to explode if I did.

I thought that this kit would bring me to the low 20s and just some minor governor adjustments would take me to upper 20s.

I don't know what stock rpms are. I think the dealership reset it to 3100? Stock? I read on here that max is 4600. I'd probably just bring it up a 1000 to 4100?

Since my wife and mother in law uses the cart to take my triplets to and from the beach and pool, I'd like more speed, but as safe as possible.

With that said, I saved 10% and free shipping. So the kit was just over $400 shipped.

The Performance kit arrives today. The box has not been opened. So I'm confident I can return it. I read the reviews and I see returns may be difficult, but worst case, I'll let my credit card company handle the fight.

So what components do you and the experts here recommend?

DannyAbear

This 'power kit' explains to me where the elusive relay that was discussed in my other thread came from.

lockman1

It's possible