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Old 08-01-2021, 02:18 PM   #1
silverviper
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Default Golf cart suddenly backfiring through carb while driving

1993 DS Club Car

I fixed this golf cart up last summer and it has been working phenomenal every weekend up to this point. While driving today, it suddenly started backfiring, Losing power, jerky. It would take off and then repeat the backfiring. Had to tow it back to the cabin after it died. Got it back and it started immediately, but after 20 seconds started backfiring again through the carb with the air filter hose pulled off. I replaced the spark plug as something basic, same issue.

Replacement History: I replaced the carb last summer with an Amazon one, the original was damaged. Top arm for the throttle was bent. I made tweaks since then to the A/F and had it dialed in to run not too rich or lean. I also replaced the fuel pump. I have a zip tie on the back spring to increase its speed a few mph.

I took off the carb just now to clean it, nothing stood out that there was an issue. I put the carb back on and now *appears* to be working fine after driving a mile, no backfiring. I dumped some sea foam in the tank as well.

Would a dirty carb cause this issue suddenly while driving? I’m a little worried something more serious is causing this since it happened suddenly. It’s on the 4th to 5th tank of 91 this summer. Had stabil in the tank over the winter.
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Old 08-01-2021, 03:49 PM   #2
silverviper
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Default Re: Golf cart suddenly backfiring through carb while driving

Update: worked good for 2 miles and started backfiring, jerking, loss of power. Same issues. Wouldn’t start so had to be towed back. Got it back and tested for spark. Saw a small white spark dancing around. Put the spark plug back in and started immediately. Is this possibly a coil issue? Also noticed next to the rev limiter an eyelet with brown wire tucked folded neatly next to it and not connected to anything.
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Old 08-01-2021, 10:11 PM   #3
hook57
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Default Re: Golf cart suddenly backfiring through carb while driving

Intake valve not closing maybe? Valves may need cleaning if not seating properly....
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Old 08-02-2021, 07:29 AM   #4
crash12888
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Default Re: Golf cart suddenly backfiring through carb while driving

I'm almost thinking the rev limiter is getting warm and shutting down.
On the very front of the motor right above the oil drain plug is a little black box, remove the brown ground wire from the block with a 10mm and tape it up, give it a test run.
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Old 08-02-2021, 11:07 AM   #5
charlie99
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Default Re: Golf cart suddenly backfiring through carb while driving

A backfire always suggests a timing problem to me. Either spark timing (sheared flywheel key and now moving flywheel), or valve timing (loose or broken rivets on the plastic cam gear)
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Old 08-02-2021, 11:42 AM   #6
crash12888
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Default Re: Golf cart suddenly backfiring through carb while driving

In some other instances that might be the case but 9 times out of ten regarding golf carts it is unburned fuel in the cylinder and/or muffler due to ignition cutting out while the engine is still turning.
Don't go too deep before you check the basics...
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Old 08-02-2021, 06:41 PM   #7
Fairtax4me
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Default Re: Golf cart suddenly backfiring through carb while driving

The Brown wire is the ground wire for the rev limiter. Disconnect by someone in the past. That disables the rev limiter, so that's out of the equation.

Sounds like coil failing, or the vent tube for the carb is blocked. The carb bowl has to be able to vent or it will vapor lock and cause problems when the carb gets hot.
If the tube is still there it's the one hanging down from the top of the carb. If there's not one there check and clean the nipple that sticks off the front of the carb up at the top near the throttle stop screw.
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Old 08-03-2021, 06:18 AM   #8
crash12888
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Default Re: Golf cart suddenly backfiring through carb while driving

Quote:
Originally Posted by Fairtax4me View Post
The Brown wire is the ground wire for the rev limiter. Disconnect by someone in the past. That disables the rev limiter, so that's out of the equation.

Sounds like coil failing, or the vent tube for the carb is blocked. The carb bowl has to be able to vent or it will vapor lock and cause problems when the carb gets hot.
If the tube is still there it's the one hanging down from the top of the carb. If there's not one there check and clean the nipple that sticks off the front of the carb up at the top near the throttle stop screw.
Oops, didn't fully read the second post........
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Old 08-07-2021, 06:49 PM   #9
silverviper
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Default Re: Golf cart suddenly backfiring through carb while driving

Got to work on this thing today and attempt to replace the coil. Took off the muffler and started removing the flywheel cover. Removed/loosened all the bolts on the shroud except the far back center one. What a PITA. I have it backed out to where it is touching a crossmember frame. It won’t go out anymore. Do I really need to remove the engine mount bolts and slide the engine forward!? Unreal if this is the case.
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Old 08-07-2021, 10:09 PM   #10
Fairtax4me
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Default Re: Golf cart suddenly backfiring through carb while driving

Unfortunately, yes. Motor has to be moved forward to get that last bolt out.
No, it's no fun replacing the coils on these, which is why I always recommend a genuine Kawasaki coil. Whether from a Club Car dealer or from Kawasaki parts source. They last 15 years vs the china cheapos that last 2-3 months.
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