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Unread 07-10-2019, 08:51 AM   #1
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Join Date: Jul 2019
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Default Cart cutting out pass 1/4 throttle

Hello, I'm new to the site and have read through a lot of the threads but have not been able to find a solution or another person with the same exact issue I am having.

Cart is a 2006 Club Car Precedent with Kawasaki Gas Engine.

I bought the cart back in May, and it has been running fine up until about three weeks ago. At first it would start and run for about 5 to 10 minutes as normal, but then would start to cut out if the throttle was pushed more than 1/4 of the way in.

It has gotten worse now, where you can only push it in about an 1/8th of the way to start it, and it will run fine as long as you don't go past an 1/8 to 1/4 throttle, anything further it starts cutting out / backfiring, almost as if the choke was still stuck on or something.

As I've been looking at it, it appears someone has hacked the Rev Limiter. Brown Wire is still grounded, but the black wire that comes off is cut in 1/2, and the connector was removed. And there is another black wire coming off from under then engine to the right (if looking at the head), and it is cut. So I have a total of 4 cut black wires dangling by the rev limiter. I've tried finding wiring diagrams, and have tried connecting them at different points but no luck. The one wire (to the right of the rev limiter) if grounded or touches another wire will kill then engine.

Also, as I've had it in repair mode to be able to start in neutral, sometimes it will keep running even after the cart key is turned off.

Engine will idle, and run at 1/8 to 1/4 throttle but cuts out at anything past that. If you try to start with throttle greater than 1/4 it will not start, have to barely engage throttle to start.

Do you think its with the wires / rev limiter? I'm not even sure how its running with those wires all cut. I can take a picture tonight if that will help.

We live in the country and I'm guessing that they may have had those wires taped up, and with my sons driving the cart they may have came disconnected.

Local shop is 40 minutes away, and backed up for 2 weeks, so would like to see what I can do before taking it in.

On a side note, when I bought it, the owner gave me some extra micro switches, fuel pump, and carb. I cannot seem to find where these micro switches are located, I've looked everywhere. I have changed the fuel pump out, and that did not change anything either.

Sorry for the long post, but was trying to be as thorough as possible up front, to keep the thread count down from all the questions I'm sure I'll get asked. Thanks in advance and appreciate all your expert advise, as this is my first cart.
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Unread 07-10-2019, 10:25 AM   #2
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Default Re: Cart cutting out pass 1/4 throttle

The wiring by the rev limiter needs to be fixed/connected together. That's the wiring for the ignition kill circuit so the engine shuts off when you take your foot off the pedal. Black wires connect together, and there should be a white with black stripe wire that meets those near the base of the oil fill/dipstick tube. Of course its possible there's some other redneck engineering going on in other places so if you connect those together and the engine doesn't run at all, then leave them disconnected temporarily and we can narrow down that issue later.

The carb probably needs to be removed and cleaned very thoroughly to fix the power issue. You shouldn't need a kit or any gaskets unless they've been damaged previously. If any gasket wan't to stay stuck to the carb just leave it on there. Remove the bowl, the float and needle, and the main jet. There's a pilot tube in the center of the carb above the main jet, use a screwdriver to reach into the venturi and push down on the top of the pilot tube and it should drop out with a few taps of the carb on the bench.
Clean all that and make sure all the holes are clean as well as the bowl vent port a the top of the carb.
Remove the idle pilot screw on the side (brass screw) and make sure the holes in that are clean, use cleaner and compressed air if you have it to make sure the supply openings for that are clean and make sure the idle mixture ports inside the carb bore are clean and you can see cleaner spraying out of them. The idle mixture screw is not removeable, but usually does not need any attention other than some cleaner and air blasted through. The mixture screw is supplied by the same ports as the idle pilot screw. When re-installing the pilot screw do not over tighten the screw or you can crush the screw and block the openings in the screw and in the carb.


Also, Thank You for being thorough in your post! The more details the better!
Many people post a single question and simply ask "why its broke?", as if we're magicians, and then we have to ask for more details anyway. Much appreciated to have most or all relevant info supplied up front!

Also, Welcome to the BGW!
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Unread 07-10-2019, 11:37 AM   #3
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Default Re: Cart cutting out pass 1/4 throttle

I'll wire all four black wires together tonight and see what it does. If it still runs after that, I'll disconnect ground on rev limiter to see if that bypass has any affect.

As far as redneck engineering, I'm think that might be the case. I noticed a couple other wires by battery / solenoid that are disconnected. Smaller orange wire and a blue wire are both not connected, and have quick connects on them.

I've been trying to find a manual for the 06, but only was able to find 01/02, but would think they are close to being the same.

I'll take pics tonight and post tomorrow my results. Thanks again for the feedback, greatly appreciated.
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Unread 07-10-2019, 11:41 AM   #4
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Default Re: Cart cutting out pass 1/4 throttle

Quote:
Originally Posted by Fairtax4me View Post


Also, Thank You for being thorough in your post! The more details the better!
Many people post a single question and simply ask "why its broke?", as if we're magicians, and then we have to ask for more details anyway. Much appreciated to have most or all relevant info supplied up front!

Also, Welcome to the BGW!


Agreed!

like going to a doctor, saying "I'm sick. Fix me".



I would suggest, even before trying to diagnose or replace ANY parts...

first thing you need make everything back to "stock" as you possibly can. Especially wiring. Club Car is pretty good about nice connections. If you see something with a butt connector, electrical tape, etc. Chances are it didn't come that way from the factory so I would look closer into anything that looks like it's been modified. It will save you a lot of headache in the end, and if you end up taking it to the shop will save you a lot of money as well because the first thing they're going to do is fix all of the wiring/routing/etc and put it back the way it should be from the factory before trying to diagnose anything. Otherwise it's about equivalent to a "Where's Waldo" book. Sure eventually you'll find him, but it's a lot easier if there are only 10 people on the page with him instead of 1000.
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Unread 07-10-2019, 09:18 PM   #5
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Default Re: Cart cutting out pass 1/4 throttle

Troubleshooting procedure I followed per feedback:

1) I connected all four black wires together, cart would start but would still cut out.

2) Left all four black wires together, disconnected brown ground wire to rev limiter, cart would start but would still cut out.

3) Reconnected brown ground wire to rev limiter.

4) Removed Carb, replaced with new carb, same result, cart would start but would still cut out.

5) Pulled Spark Plug, checked for spark, all is good there. Consistent good spark.

To add to the excitment my central air conditioning system is not working, something else to fix :)

Any other suggestions / thoughts?
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Unread 07-10-2019, 09:23 PM   #6
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Default Re: Cart cutting out pass 1/4 throttle

I've attached pics to try and help aid in the discovery process.

Pic 1: The blue and orange wires appear to be coming off the solenoiod side posts to the main wiring harness.

1.jpg

Pic 2: Solenoid Pic with Orange / Blue Wires on post.

2.jpg

Pic 3, 4, 5: Rev Limiter - I posted questions in the pics.

3.jpg

4.jpg

5.jpg
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Unread 07-10-2019, 09:26 PM   #7
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Default Re: Cart cutting out pass 1/4 throttle

Pic 6: Rev Limiter - I posted questions in the pics.
6.jpg

Pic 7: Fuel Filter - Posted Question in Pic.
7.jpg

Pic 8: Plug Picture
8.jpg
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Unread 07-10-2019, 09:37 PM   #8
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Default Re: Cart cutting out pass 1/4 throttle

The wire in the last pic in the lower right goes to the coil. Thags the kill wire that kills spark and shuts the motor down when it is grounded.

The other wire in that picture I dont know what it is. It shouldnt be there.

All those bare wires in there are bad news. If any of them touch anything metal, it's going to kill spark and kill the cart.

The wiring should go from the white/black wire that runs alongside the cable, to the bullet connector behind the rev limiter. From there it goes to the coil.

All the black wires back there are essentially all hooked together. The kill wire coming from the microswitches connects with the kill wire from the rev limiter and feeds to the ignition coil.

That's also not the correct solenoid. It probably works (functionally) but doesnt mount correctly and with it bouncing around inside the black box like that could lead to trouble.

How long does it drive before it cuts out? When it cuts out will it instantly start back up again or do you have to wait a bit?

Theres a wire that goes behind the fan shroud behind the rev limiter (kill wire). It is one of those wires you're messing with. For giggles, disconnect that wire and insulate it so it cant touch metal. Try that and let us know if it still cuts out
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Unread 07-10-2019, 09:39 PM   #9
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Default Re: Cart cutting out pass 1/4 throttle

That's also probably not the right spark plug. I would get a NGK BP4ES or BP5ES any auto parts store should carry it. NGK are the only spark plugs I ever use, because they work
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Unread 07-10-2019, 09:48 PM   #10
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Default Re: Cart cutting out pass 1/4 throttle

Here is a video of it running, from start, then i barely idle it out with low throttle then rev again to here it cut out.

Hope Video Link works:

https://onedrive.live.com/embed?cid=...C9CK8lwiA3TOpc
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