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Old 10-17-2014, 09:06 PM   #1
mdc
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Exclamation 06 gas club car turns over (sometimes)

My 06 Club Car with Kawasaki fe350 gas motor runs great when it starts. Approximately 50% of the time it attempts to start but the the starter cannot turn it over. You can watch the flywheel trying to spin as the starter is trying to turn over the motor. The motor is fully functional when it runs and never fails to start as long as it turns over.

When this happens I have to depress and release the gas pedal up to 10 times quickly (or slowly) to get it to start, whatever works. I can hear it trying to turn over but it just has a hard time on some starts. Happens if the engine is cold or hot, with or without choke. The drive belt is not binding or is not too tight to prevent the starter from turning over the engine. Starts immediately as long as it turns over at least once. Good spark and fuel pump functioning properly.

Otherwise there are no mechanical problems with the engine. Already replaced battery, fuel lines, fuel filter, air filter, oil, spark plug and GOCR after purchasing.

Hoping to find some good buggy wisdom,
Mark

Last edited by mdc; 10-17-2014 at 09:39 PM.. Reason: typo
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Old 10-18-2014, 06:10 AM   #2
Rodriguezmf1250
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Default Re: 06 gas club car turns over (sometimes)

Remove Rev limiter, see if there is a change.
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Old 10-18-2014, 07:08 AM   #3
lockman1
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Default Re: 06 gas club car turns over (sometimes)

The rev limiter has nothing to do with the engine not "turning over" Rod!

Welcome to BGW mdc

I have an 07 CC DS with an FE350, and have had the same situation!
(I've also replaced the battery thinking that might be it!)
When I replaced the S/G belt a couple years ago, I tightened it SO tight,
the engine wouldn't turn over beyond the compression stroke,
I blew the 10 amp fuse (3X's) in the electrical component box just trying to start it!

Most here will say... "crank that sucker as tight as you can get it!"
But, I disagree... I found that there is a "sweet spot" for tightening the S/G belt...
Not too tight when the engine has difficulties turning over, and not too loose so the S/G slips on the belt.

My suggestion???
readjust your S/G belt whether you think it needs it, or not!
It'll take a few tries to find the "sweet spot", but when you find it...
it'll turn over the first time, every time!

.02
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Old 10-18-2014, 08:33 AM   #4
mdc
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Exclamation Re: 06 gas club car turns over (sometimes)

Thanks for the welcome and the wisdom lockman1. Great suggestion. My belt is rather loose, though, I can move it by hand when the motor is off. I will definately take your advice and retension it to spec and try again. You never know.

Markus:
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Old 10-18-2014, 08:38 AM   #5
mdc
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Exclamation Re: 06 gas club car turns over (sometimes)

Thanks for the technical input Rodríguez. I will check the service manual to figure out how to do this and try again. I assume I can just disconnect a wire?

Markus
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Old 10-18-2014, 09:17 AM   #6
lockman1
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Default Re: 06 gas club car turns over (sometimes)

That's what BGW is here for Markus!
The rev limiter ground is mounted to the left mounting bolt of the limiter itself, (on the lower, front of the engine)
remove the bolt. and the eye loop, tape up the eye loop (to prevent grounding) and reinstall the bolt.

But, I can 100% guarantee that... that's not your fix!



I'm curious though... Which belt are you thinking of?
The 1" wide belt is the drive belt... it's supposed to be loose when the engine isn't running!
The 1/2" V-belt (closest to the engine) is the starter/generator belt, and is the one you should be checking!
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Old 10-18-2014, 12:21 PM   #7
mdc
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Exclamation Re: 06 gas club car turns over (sometimes)

Lockman...thanks for double checking on which belt to check. I assumed I was to check the drive (1inch) belt. I went to check it and came back scratching my head because it was at just the right tension. (moves freely like you said)

Going to check the s/g belt (1/2 inch) this afternoon. That has to be it!

Markus
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Old 10-18-2014, 06:24 PM   #8
lockman1
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Default Re: 06 gas club car turns over (sometimes)

....

It's kinda funny... my cart started doing the same thing... literally... just this weekend!
I'm thinking it's because I only ride it but a total of 8 hours every 2 weeks, (lots of stops and starts)
And maybe, (in my situation) it's not enough to give the battery a REALLY good charge!
My cart is coming home with me tomorrow,
and the first thing I'm going to do is put a battery charger on it just for s**ts & giggles...

I suggest you may want to try that on yours also! (even if the battery is fairly new!)

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Old 10-19-2014, 06:08 PM   #9
mdc
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Default Re: 06 gas club car turns over (sometimes)

Lockman...You are the man!! You got me on the right track. It definitely was the s/g belt although I needed to tighten it instead of loosen it. The s/g belt was just loose enough to slip "sometimes", then others times in just the right condition it would grab enough to turn over the motor. When the belt would not move I wrongly assumed the starter wasn't turning but on further inspection it was.

Stop and started 30 times today just to test it out, not one failed start

Looking back it seemed so obvious. I'm a little embarrassed.

Good luck on yours but you probably would have caught this problem already.

Thanks again Lockman,
Markus
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Old 10-20-2014, 06:26 AM   #10
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Default Re: 06 gas club car turns over (sometimes)

Nothing to be embarrassed about Markus, We all have our days! I'm glad it worked out for you!

Happy carting!
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