2005 gas clubcar

james dawson

this cart has only 172 hrs but has never run properly. My son bought it brand new and did not get it checked while it was under warrantee. The cart hesitates before take off and backfires and misses badly. It also runs hot [very hot]. I dumped the oil and pulled the spark plug and wire brushed it. It was not fouled at all and what I did did not improve it one iota. I need to start somewhere but I don't know where to get to the bottom of the problem. Any suggestions would help. Thanks

BGW

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nobuckbuild

Two major issues to deal with first is valve adjustment and second is the carb , to start with check the vavle lash if i remember correctly its 3-5 thousanths or .03 to.05 if the valves are not right it will cause a heat and starting problem adjust to .04 and try that , cost nothing but time unless you break the gasket on the valve cover , if that does not cure it then we move to the carb and any engine running lean will run hot , really hot. for the carb check the jets passages and float drop. since you state that it has done this since new i am inclined to believe the valve lash is where the majority of your problem lies.

lockman1

Welcome to BGW JD!

I, for one, would like a little more info on what model cart you have... DS, Precedent, XRT, Carry-all???
And what size engine that's in it... FE290?, FE350?, FE400? (the bar code tag on the engine shroud will tell you!)

Now... first things first!
No matter the model, or engine size, Club Car/Kawasaki engines are extremely finicky with their air/fuel mixture ratio,
and, with the symptoms your describing, it sounds to me like an air leak in the intake system! (speaking from experience! )

Start with the air box, open it, and make sure there's an air filter,
when closing the air box lid, make absolutely sure that it's hooked in back, and latched properly in front!
then, check the choke button to make sure that it's closing and opening properly,
Next, check the air intake tube clamps for looseness at the air box, and at the carburetor,
Then, check the carburetor mounting bolts for tightness!

If all of that seems correct and intact, put the cart in maintenance mode, click on the blue link >>> http://www.buggiesgonewild.com/gas-c...ence-mode.html
With the wheels chocked, and the shifter in neutral, run the engine, and spray carb cleaner all over the air box, air intake tube, and carburetor!
IF... the engine RPM's's change, you've found your air leak!
If the RPM's don't change, THEN... it could be your valve lash, (FE290 only) the carburetor, or something else!

whew... sorry! that was a little long-winded! but, I was kinda' bored!

It's a start, and I hope this helps!

james dawson

Don the engine is a fe350b and it's a Club Car Champions Edition..thanks for the response...I'll go back to works on the items mentioned....

james dawson

Don, if the engine is a 350 are you ruling out valve lash? You had the 290 [ ] kinda ckecked...

lockman1

Correct... FE350's and 400's have hydraulic lifters, they don't have an adjustable valve lash!

james dawson

Don thank so much for that response. Guess that puts it on carb since everything seems ok. I did not notice any adjusting screws on the carb just looking down on the engine. Is there screws that I cant see without removing the carb? Thanks.

kgsc

Lockman, I know they have hydro lifters but could it be the rocker arms are too tight ? I know a car usually has hydro lifters but you still have to adjust them initially. Are these motors the same ?

lockman1

JD,
Besides the actual idle adjustment screw (hidden under the guard plate)
there's only 1 other screw that adjusts, and it's for the low speed circuit, (idle, low rpm's)
If I remember correctly it only turns 180 degrees (12:00 to 6:00) and may not help with your symptoms.
But keep at it JD... I'm hoping it's something simple!

kgsc,
Yep I know exactly what your talking about with car rockers... you can over tighten them!
I haven't had the need to take my FE350 apart because, well... it runs flawlessly,
But, looking through the FE200-FE400 service manual, there are no torque specs for the FE350/400 rocker nuts,
and there's no initial adjustment for the for the 350/400 rockers after a rebuild, like there would be for a car.
It's just my guess that the rocker stud has a stop that won't let you over tighten the nut.

kgsc

Haven't had one apart either but glad I asked.. Learn something new every day..