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Old 05-31-2011, 08:16 PM   #1
hanly2
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Default Motor is revving cart barley moving maybe clutch?

Hello, I just joined here I just p/u a 2001 ds model cart today for my campsite and I need a little help getting it running right. It has a kawasaki engine in it and it looks to be in really good shape under the hood. The problem with the cart is when I put it in gear and push the pedal it will hardly move but it will move if I don't mash the gas, also it seems to move better in reverse. A few things that I have checked just to try to learn about it are. I noticed that when the cart is in N with the brake off it does not roll real easy, I am not sure if this is by design or not? I jacked up the rear end and ran the cart in both forward and reverse and the wheel spins but it sure looks like the belt is not grabbing that well. The clutch moves about 1/8 to 1/4 inch not sure how far it should go. Also noticed that the non-drive wheel is a little harder to spin then the drive wheel, but both wheels where a lot harder then the front wheels so I am guessing that is normal. 1 more thing I noticed off of the top of my head is when I step on the gas all the way and the motor will rev high and then it will pulse of and on, is this a rev limiter? I would guess it is there to keep my from blowing up the motor? I will take any help i can get. Also does anyone have a pdf of the service manual?
Thanks
Dave
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Old 05-31-2011, 11:23 PM   #2
invalidsession
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Default Re: Motor is revving cart barley moving maybe clutch?

Quote:
Originally Posted by hanly2 View Post
Hello, I just joined here I just p/u a 2001 ds model cart today for my campsite and I need a little help getting it running right. It has a kawasaki engine in it and it looks to be in really good shape under the hood. The problem with the cart is when I put it in gear and push the pedal it will hardly move but it will move if I don't mash the gas, also it seems to move better in reverse. A few things that I have checked just to try to learn about it are. I noticed that when the cart is in N with the brake off it does not roll real easy, I am not sure if this is by design or not? I jacked up the rear end and ran the cart in both forward and reverse and the wheel spins but it sure looks like the belt is not grabbing that well. The clutch moves about 1/8 to 1/4 inch not sure how far it should go. Also noticed that the non-drive wheel is a little harder to spin then the drive wheel, but both wheels where a lot harder then the front wheels so I am guessing that is normal. 1 more thing I noticed off of the top of my head is when I step on the gas all the way and the motor will rev high and then it will pulse of and on, is this a rev limiter? I would guess it is there to keep my from blowing up the motor? I will take any help i can get. Also does anyone have a pdf of the service manual?
Thanks
Dave
Sorry in advance Lockman:oops

Last edited by invalidsession; 05-31-2011 at 11:30 PM.. Reason: innaprropriate
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Old 05-31-2011, 11:50 PM   #3
invalidsession
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Default Re: Motor is revving cart barley moving maybe clutch?

Quote:
Originally Posted by hanly2 View Post
Hello, I just joined here I just p/u a 2001 ds model cart today for my campsite and I need a little help getting it running right. It has a kawasaki engine in it and it looks to be in really good shape under the hood. The problem with the cart is when I put it in gear and push the pedal it will hardly move but it will move if I don't mash the gas, also it seems to move better in reverse. A few things that I have checked just to try to learn about it are. I noticed that when the cart is in N with the brake off it does not roll real easy, I am not sure if this is by design or not? I jacked up the rear end and ran the cart in both forward and reverse and the wheel spins but it sure looks like the belt is not grabbing that well. The clutch moves about 1/8 to 1/4 inch not sure how far it should go. Also noticed that the non-drive wheel is a little harder to spin then the drive wheel, but both wheels where a lot harder then the front wheels so I am guessing that is normal. 1 more thing I noticed off of the top of my head is when I step on the gas all the way and the motor will rev high and then it will pulse of and on, is this a rev limiter? I would guess it is there to keep my from blowing up the motor? I will take any help i can get. Also does anyone have a pdf of the service manual?
Thanks
Dave
You need to slow down Dave, 1st off, you have two clutches; 1 drive and the 2nd driven. These are connected by your drive belt. What you need to do is flip the yellow switch behind the F / R lever 180 degrees (under the seat). This will give you full operation of the motor and clutches without the vehicle moving or the need to jack her up. Observe the operation of the belt while giving her some gas, it should transition smoothly between open and closed clutches. A staggering movement would indicate a worn clutch or belt. Replace the belt first, cheapest option and likely required anyway. If one or the other clutches is "stuttering" Strip, re-build it or replace it as your budget allows.
Hope that helps and let us know the outcome.

Chris.
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Old 06-01-2011, 08:11 AM   #4
shadowman
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Default Re: Motor is revving cart barley moving maybe clutch?

take your time and follow the advice ginen and post results.......oh and welcome.......................
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Old 06-01-2011, 01:33 PM   #5
PIB-My-Ride
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Default Re: Motor is revving cart barley moving maybe clutch?

This video shows my drive clutch BEFORE it was rebuilt. I sent it to a site sponsor because I was unhappy with the top speed. When it was returned, the "ding ding" sound heard in the video was gone, the belt reached the top, and my speed DOUBLED.

If your drive clutch is only closing 1/4", you must have one slow cart!


One note about the "maintenance mode" Chris described:

Gently pull the yellow knob out, then rotate 180º and let it go back in. While in maintenance mode, the cart will run in neutral, but not while in gear.

My cart is the same year and model as yours, and it rolls easily in neutral. I wouldn't rule out sticking brake shoes.
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Old 06-01-2011, 04:49 PM   #6
hanly2
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Default Re: Motor is revving cart barley moving maybe clutch?

ok great thanks for the help. I put in in maint. mode and gassed it and found out that the belt does not move up at all in the drive clutch, and the drive clutch doesn't even come close to moving as far as the one in that video. I made a quick video and pulled the belt off to take a pic of the clutch, turns out the whole side that moves in/out is worn all the way through looks like swiss cheese. Can I get a new plate and replace the springs to make it work again? Also belt is about 13/16 wide.

Last edited by hanly2; 06-01-2011 at 04:50 PM.. Reason: tried to embed video
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Old 06-01-2011, 04:52 PM   #7
hanly2
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Default Re: Motor is revving cart barley moving maybe clutch?

Ok here is the link to the video and to a pic of the clutch.


[IMG][/IMG]
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Old 06-01-2011, 05:11 PM   #8
shadowman
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Default Re: Motor is revving cart barley moving maybe clutch?

dude........you need a new clutch.............i don,t think you can replace just that peice and new one isn,t cheap but you might be able to find a used one................wow now that clutch saw some use...................
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Old 06-01-2011, 05:37 PM   #9
hanly2
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Default Re: Motor is revving cart barley moving maybe clutch?

haha, ok I found some good deals on clutches how does $150 sound? Also can you tell me how I can check the driven clutch? And do you know the guy that was selling the homemade puller tool?
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Old 06-01-2011, 10:38 PM   #10
invalidsession
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Default Re: Motor is revving cart barley moving maybe clutch?

Quote:
Originally Posted by hanly2 View Post
Ok here is the link to the video and to a pic of the clutch.

YouTube - ‪club car clutch‬‏

[IMG][/IMG]


That clutch has issues the like of which I never saw before lol. I dread to think what the rest of the drive train is like. I do have that inner section on the bench, though it doesn't have the vent slots Let me know if you decide to rebuild it.

Chris.
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