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Unread 07-04-2011, 08:50 PM   #1
Not Yet Wild
Club Car
 
Join Date: Jul 2011
Location: Paxinos, PA
Posts: 9
Default Gas Club Car does not move, engine works fine... Electrical problem...

I have a Club Car AG9527. I don't know what year it is.
The thing always worked perfect until just recently.
It's a gas powered Club Car, Kawasaki engine.
As soon as you press the gas pedal it starts the engine but doens't move.

If I play around with some wiring around the bottom of the engine where there is a little black box, it'll start until it's shut off again. There are three wires going to this little box. Two look like they simply go to ground(body) and one white wire, black stripe, goes back the wiring harness to somewhere. I think to one of the switches on the gear selector(forward/neutral/reverse).

This little black box seems to kill the engine. One wire goes up into the engine. If I disconnect it the engine wont shut off, but at least it'll move.

It acts almost as if it's an electric clutch or something. Again, the engine works fine but it doesn't move. If I wiggle wires around this little box(that's sealed and bolted to the engine bottom) it'll start moving.

Any ideas would be greatly appreciated.

Thanks,
Dave.
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Unread 07-04-2011, 09:03 PM   #2
Not Yet Wild
Club Car
 
Join Date: Jan 2010
Location: Ruffsdale,PA
Posts: 47
Default Re: Gas Club Car does not move, engine works fine... Electrical problem...

Looks like your cart is a 95' and the little black box you are referring to is the rev limiter I'm not an expert by any means but I would disconnect the ground wire and see if it goes. The rev limiter purpose is to control the engine for reaching top end (i.e. blowing your engine) if you dont control the rpm's.
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Unread 07-04-2011, 09:37 PM   #3
Not Yet Wild
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Default Re: Gas Club Car does not move, engine works fine... Electrical problem...

Hey, thanks for writing back.
I did pull the one wire that leads back to the control box.

This doesn't do the trick though. There is still something wrong.

The engine works fine but it just does not move unless I wiggle wires around then it'll start moving. There is another wire that goes back to the rear of the engine, goes into the transmission it looks like. If you take a look at ClubCarDudes Engine picture #5 it shows part #1 and Part #14. Almost as if there is something in the transmission that engages or something to put power to the drive. Is this possible?

I've been messing around with this thing for about a week now on and off. I can get it to run if I just wiggle wires, then it runs until I shut it off again.
The engine works fine, when I say 'run' I mean that it moves... The thing will move until I stop the engine.

Do you know of a manual that'll match up the parts listed on the pictures?

I'll try to attach a file so you know what I'm talking about.

Thanks!
Attached Images
File Type: jpg c8enginepart5mh1.jpg (79.5 KB, 15 views)
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Unread 07-04-2011, 09:49 PM   #4
Not Yet Wild
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Location: Ruffsdale,PA
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Default Re: Gas Club Car does not move, engine works fine... Electrical problem...

I'm not sure what that is. If is just a wire coming off the engine ( which I cant tell from the picture) mine is yellow and it goes to an oil indicater light.
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Unread 07-04-2011, 10:01 PM   #5
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Default Re: Gas Club Car does not move, engine works fine... Electrical problem...

As far as I know club cars have never had and electronic clutch. The box you are talking about is the RPM limiter. Jack the cart up and put on jackstands put in maint mode and start checking connections at the limiter. If still doesn"t run disconnect the black ground wire that is bloted at the limiter bracket. Let us know what you figure out. My best guess is one of the bullet connectors has a bad connection.
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Unread 07-04-2011, 10:02 PM   #6
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Default Re: Gas Club Car does not move, engine works fine... Electrical problem...

Did you check the wiring diagram in the #7 post of that sticky I just fixed my cart which had a dead short and I've been up and down every wire just about to find that it was my radio antenna grounding out.
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Unread 07-04-2011, 10:17 PM   #7
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Default Re: Gas Club Car does not move, engine works fine... Electrical problem...

Thanks everyone for helping. Yes, I know that Club Cars dont have electric clutches... but what I'm wondering is what is the little device that seems to be in the Engine picture #5, part #14. I guess it would't be a solenoid or electromechanical device being in the engine. If it had to do with the drive/transmission, I guess it would be in there.

I'll do what you said G2Rebel and pull the ground. I pulled the wire from the harness out of the bullet connector and it kept the engine running even in park and with the key off.
Maybe pulling the ground would do something different?

Mellow Buggie... What do you mean by wiring diagram #7? Are you talking about the file that I've attached? The wiring seems very simple and is missing a few items that go to the engine such as the device that's on the Engine#5, part #1 & #14. The schematic seems as if it's only external to the engine. No cut off or heat/oil detectors.

Does anyone know where I could find the manual that matches the parts to the schematics that are online? Any idea where I could get that little RPM limiter? I wouldn't mind taking it off line but I'm not the only one that'll drive the thing. I'd love not having a limit but I don't want to blow the engine. I'd be worried about my kids taking it too fast for too long :)

Thanks everyone!
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Unread 07-05-2011, 08:40 AM   #8
The Last Moja Morani
 
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Default Re: Gas Club Car does not move, engine works fine... Electrical problem...

1st thing you need to do is when it won,t run check to see if you have spark........if not that small black box is the rpm limitor and you can pull the brown wire off and see if it than runs.........also on the back side of the bracket that holds the rpm limitor on there is an ignitor mounted......a small bitty silver thing with one spade terminal.....in a lot of cases when that year cart has an intermittant spark issue its either the rpm limitor or ignitor or both...........theres no real way to bench test them other than just replacing them.............................but 1st things 1st check it for spark.............................
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Unread 07-05-2011, 10:47 AM   #9
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Default Re: Gas Club Car does not move, engine works fine... Electrical problem...

If I'm reading this correctly, Neuro is saying "the cart is running but not moving". When he wiggles the wires, off he goes. Sounds like what he is getting is the starter running but no spark to the engine to fire it up. If this is indeed the case; disconnect the ground wire to the RPM limiter, insulate it and test. This will eliminate the limiter as a problem. Next, check and clean all the terminals and wire connections from the limiter to the igniter and ignition coil, heck, replace the connectors if you like, it's cheap and easy. If that doesn't cure it I'd replace the igniter and coil with the newer combination unit.
There really isn't any more to it than that.
Good luck and keep us posted

Chris.
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Unread 07-05-2011, 04:48 PM   #10
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Default Re: Gas Club Car does not move, engine works fine... Electrical problem...

Yes, that's exactly it. The starter moves but the engine does not start.
There is spark at the plug, tested it by hand(zap test). I thought though that the system would short out the spark if this was the issue. Nonetheless, I'll do what you all are saying to do, disconnect the RPM limiter
and see if that'll work. I did it already and it works but the engine keeps running and never shuts off.

Thanks!
Dave.




Quote:
Originally Posted by invalidsession View Post
If I'm reading this correctly, Neuro is saying "the cart is running but not moving". When he wiggles the wires, off he goes. Sounds like what he is getting is the starter running but no spark to the engine to fire it up. If this is indeed the case; disconnect the ground wire to the RPM limiter, insulate it and test. This will eliminate the limiter as a problem. Next, check and clean all the terminals and wire connections from the limiter to the igniter and ignition coil, heck, replace the connectors if you like, it's cheap and easy. If that doesn't cure it I'd replace the igniter and coil with the newer combination unit.
There really isn't any more to it than that.
Good luck and keep us posted

Chris.
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