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Old 10-16-2014, 07:58 PM   #1
Rmiller863
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Default Club car idles(starter/gen), dies when I press gas

I bought a 2005 club car carry all 6. The cart idles when you turn the key, it's a key start. But as soon as I press the gas pedal it cuts off? I bypassed the rpm limiter by cutting the brown wire on the bottom off the motor thinking that would do it. No luck? Could it be a micro switch. My fuses are all good and it can't be the coil... I've had bad coils before, it would never cut the cart off, it just wouldn't go.

Any suggestions? Thanks in advance
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Old 10-17-2014, 06:27 AM   #2
lockman1
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Default Re: Club car idles(starter/gen), dies when I press gas

Welcome to BGW Rmiller!

First off... your one of the very few here that has a stock "key start" cart, (95% of us have "pedal start" carts)
So, it might be a good idea to mention that every time you post with a question about your cart!

I don't know much about them, except that they have a relay in the Electrical Component Box.
and by reading in one of my manuals about them, I bet the relay is the culprit!

Here's the test procedures for the relay:



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Attached Images
File Type: jpg KS-relaytest1.jpg (413.9 KB, 0 views)
File Type: jpg KS-relaytest2.jpg (427.8 KB, 0 views)
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Old 10-17-2014, 08:44 PM   #3
Rmiller863
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Default Re: Club car idles(starter/gen), dies when I press gas

Thanks, I'll try it and let you know
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Old 10-24-2014, 09:28 PM   #4
Seafarer12
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Default Re: Club car idles(starter/gen), dies when I press gas

I bet your carb is gunked up. I had the same problem with my xrt. The thing would idle fine then you had to coax it up to speed. There are a lot of small passages that can get plugged. My xrt us to work at a concrete plant so it was really nasty. I tor the carb apart 4 or 5 times and finally just bought a new one. Each time it would get a little better but not great. Now it is just mildly doggy, but that is club card fault for putting such a small engine in a utv. Also, hook the brown wire back up.
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Old 10-27-2014, 12:58 PM   #5
Rmiller863
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Default Re: Club car idles(starter/gen), dies when I press gas

Well everything you mentioned tested ok. The problem was the micro switch under the relay. When I press the gas it releases the switch and kills the cart. I put electrical tape around the switch to keep it pressed and it runs. Any clue on this? Thanks


I also have a 2001 club car that that's a piston rod knocking. It's a pedal start. Not wanting to sink a lot of money in a new motor. Any ideas on replacement motors? I've been told you can't rebuild club cars, they are pressed from the factory and a machine shop has to do it? Any advice is appreciated. Thanks
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Old 10-27-2014, 09:50 PM   #6
clgodwin79
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Default Re: Club car idles(starter/gen), dies when I press gas

Wierd. My Transporter had the exact same indications as yours. Would crank and run, but immediately die when you touch the gas pedal. If you hold the key to start, you can press the gas and it runs normally until you let off of the key back to ON vice start. Anyway, I tested my relay and it's bad and I'm waiting for my new one to get here. Another thing about mine is that, if you operate the throttle locally at the carburetor instead of from the gas pedal there are no issues at all and it doesn't die. I'll post back when I get and install the new relay to say for sure rather or not it fixed my issue. I just wanted to make sure it was my issue before I ordered the relay because it's the only $42 relay I've ever seen. Most are much cheaper.
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Old 10-28-2014, 06:33 AM   #7
lockman1
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Default Re: Club car idles(starter/gen), dies when I press gas

It's good to see you guys get together!
now we have to get Superdutyw in on this discussion!

The only reason I knew ANYTHING about key start carts is because
I bought a supplement service manual for my FE350
and it has wiring diagrams and other stuff for key start carts.

Rmiller...

I didn't see the microswitch in the wiring diagram until you mentioned it!

Check the wiring of it...

Orange wire: to the top or COM post
Brown wire: to the top/side or NO post
Red wire: to the bottom/side or NC post

Maybe the brown and red wires got switched somehow!

As for your 2001... Somebody is giving you a line of BULL!
Club Car/Kawasaki engines ARE rebuildable (with minimal damage), and all of the rebuild parts are readily available!
The only thing that is "pressed" on is the drive clutch, and for that, you need a drive clutch puller!
And speaking of the drive clutch... worn buttons in the drive clutch will sound like a rod knock!
Remove the drive belt and run the engine to see if the knock is still consistent!

Hope some of this helps!

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Old 11-02-2014, 08:45 PM   #8
Rmiller863
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Default Re: Club car idles(starter/gen), dies when I press gas

Thanks for the help. Do you happen to have the wiring diagram for the relay in the continuos run cart? I unplugged a few of the wires when testing and am not sure I have them in the right place? Thanks
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Old 11-03-2014, 06:49 AM   #9
lockman1
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Default Re: Club car idles(starter/gen), dies when I press gas

They're labeled in the pics of the test procedures above!
click on pic to enlarge:

KS-relaytest1.jpg
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Old 11-03-2014, 01:57 PM   #10
Rmiller863
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Default Re: Club car idles(starter/gen), dies when I press gas

Awesome! Thanks again for the help
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