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Unread 11-03-2012, 03:38 PM   #1
Not Yet Wild
Club Car
Join Date: Nov 2012
Location: Cambridge, UK
Posts: 3
Default 1999 Club Car DS only idles fault fixed, but having trouble setting mixture


My first post as I just joined.

Last week I bought a Club Car DS (1999) for the gliding club I'm a member of. We have a 2000 4 seat DS that we lease but an extra buggy is always helpful.

When I bought the DS I knew it was a non-runner but it Had run a few days prior to the sale. The fault seemed to be carb related, and given it had been standing for some years this made sense.

Friday afternoon I cleaned the carb out, both jets were blocked and the float chamber was full of crud; however the original symptoms persisted.

It would start and run at a low idle - just cutting out the starter *just*, but as soon as you hit the gas it would die. Messing with the choke had an effect and it would run just fine then stop again.

So, totally clean carb, fuel pump working but still no go.

Today I stripped the carb again, found some more crud in the float chamber, blew the carb through with the jets out, cleaned the jets again.

This time I also removed the plastic/rubber spacer that goes between the carb and the inlet on the engine, stripped off the cruddy gasket and reassembled the lot using blue instant gasket guff - in the absence of new gaskets.

I also changed the spark plug - NGK BP5ES with a 0.28 gap.

Result... nothing. No difference.

I then tried messing with the external slow running jet a little in case there was a missing washer or something - it made a difference - hmmm.
I whipped off the inlet pipe and bringing my 80s go kart choke skills into practice I found that the engine would run nicely - but there was an air issue.

So I took the air filter box off and cleaned it up.
Re-attached the air filter box to the engine and it ran! Result.

Then I did the best I could to clean up the inlet pipe that goes to the air filter box.

I still don't know for sure what fixed it, a combination of the carb sucking air, a blockage in the air intake, crud in the carb - who knows.

Anyway, the other DS we have will start even if you just floor it.
This one, I can make run that way but it seems to run better a little leaner which means that you have to nurse it along to start.

Setting the mixture was a bit hit and miss, I put it in neutral and turned the service mode on - then tried different engine speeds and twiddled the mixture screw ( just under 180 degrees of movement on it).

So - some questions for the experts out there from a girl struggling with a very unfamiliar engine.

What process/rule of thumb do you guys use for setting the mixture?
When warm or cold would you expect a club car DS to respond to being floored from engine stopped state? Or would it just sit there running the starter until you back off the gas? (it starts fine if you go gently at it)
Anything to pay attention to in a little used but long stored ( 6 years) Club Car DS?

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Unread 11-03-2012, 06:45 PM   #2
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Join Date: Sep 2012
Location: Michigan
Posts: 351
Default Re: 1999 Club Car DS only idles fault fixed, but having trouble setting mixture

Normally they will not start when cold by flooring it, choke is required when cold. Nice job fixing your running problem
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air leak, carburettor, mixture
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