94 gas DS won't rev over 2100 rpm

rangerdaver91 · 05-12-2013, 01:39 PM

Hello; I bought a 1994 club car gas DS with a FE290 Kawasaki counterclockwise rotating engine. Seller said it needed a tune up. When I got the cart I could see it had a bad spring on the driven clutch and after inspecting everything it had sheared the key on the drive clutch, I replaced them both and pulled the flywheel to make sure the key on it was ok, I then replaced all fuel lines and filters. I replaced oil and filter and air filter. After that I started the cart in maintenance mode. It would start and run but not over 2100 rpm's. I then spent hours reading post's on web sites. I then went back to work on the cart. I checked compression 155 psi cold 145 psi hot. Valve lash .010 intake and exhaust. Adjusted all cables and linkage. Installed a new carburetor. Then checked exhaust for blockage. New spark plug gaped at .032. I then disconnected ground wire from rev. limiter and unhooked governor. Still idles at 750 rpm, and 2100 rpms is max. The motor has a lot of blow-by and it smokes. I have been working on motorcycles and small engines for many years but this DS is kicking my butt! Any and all help would be greatly appreciated. Thank You in advance for any suggestions to help fix this problem.

shoelessjoe · 05-13-2013, 05:16 AM

Did you recheck your clutch work and make sure nothing is binding?

rangerdaver91 · 05-13-2013, 08:39 AM

No sir I did not. What is the best way to do this check ?

rangerdaver91 · 05-13-2013, 10:29 AM

Ok I took the belt off and started it. There was no change. Without the belt the front clutch closed up but still would only rev to around 2100 rpm. I put the belt back on and tried to back up the driveway, it moved a few feet but would not pull itself up the drive, clutch not closing hard enough to grip the belt (belt is new). Why this thing will not rev up has me stumped. Any thoughts on this matter ? Suggestions or ideas ? I need help.

shoelessjoe · 05-13-2013, 01:40 PM

Quote:

Originally Posted by rangerdaver91

No sir I did not. What is the best way to do this check ?

My thought was that perhaps the clutch wasn't shifting out fully or was binding but if you pulled the belt and it still wouldn't rev than that's not the issue.

rangerdaver91 · 05-13-2013, 02:51 PM

Even a wild guess would be good at this point. I can't figure it out.

nobuckbuild · 05-13-2013, 02:57 PM

is the cable and linkage to the carb operating fully with the seat off in maintaince mode you need to see if the carb is opening fully , also check the butterfly in the carb

Dogmike · 05-13-2013, 03:04 PM

All of the linkage is OK? The fuel lines and vaccum hoses are fine? Everything inside the black box near the battery OK? I really have no idea, wild guesses

rangerdaver91 · 05-13-2013, 03:17 PM

Yes seat is off and cart is in maintenance mode. We adjusted the linkage and cables and they are operating correctly. Engine starts to crank with less than an inch of pedal movement and opens fully at the carb. The fuel and vac lines are new as is the fuel and air filter. Every thing in black box appears to be OK. Man this thing has me stumped for real.

rangerdaver91 · 05-13-2013, 03:45 PM

Guess I need a CC guru or something

05-12-2013, 01:39 PM	#1
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43	94 gas DS won't rev over 2100 rpm Hello; I bought a 1994 club car gas DS with a FE290 Kawasaki counterclockwise rotating engine. Seller said it needed a tune up. When I got the cart I could see it had a bad spring on the driven clutch and after inspecting everything it had sheared the key on the drive clutch, I replaced them both and pulled the flywheel to make sure the key on it was ok, I then replaced all fuel lines and filters. I replaced oil and filter and air filter. After that I started the cart in maintenance mode. It would start and run but not over 2100 rpm's. I then spent hours reading post's on web sites. I then went back to work on the cart. I checked compression 155 psi cold 145 psi hot. Valve lash .010 intake and exhaust. Adjusted all cables and linkage. Installed a new carburetor. Then checked exhaust for blockage. New spark plug gaped at .032. I then disconnected ground wire from rev. limiter and unhooked governor. Still idles at 750 rpm, and 2100 rpms is max. The motor has a lot of blow-by and it smokes. I have been working on motorcycles and small engines for many years but this DS is kicking my butt! Any and all help would be greatly appreciated. Thank You in advance for any suggestions to help fix this problem.
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43

05-13-2013, 05:16 AM	#2
shoelessjoe Gone Wild Join Date: Apr 2012 Location: SE Michigan Posts: 297	Re: Need Help 94 gas DS won't rev over 2100 rpm Did you recheck your clutch work and make sure nothing is binding?

05-13-2013, 08:39 AM	#3
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43	Re: Need Help 94 gas DS won't rev over 2100 rpm No sir I did not. What is the best way to do this check ?
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43

05-13-2013, 10:29 AM	#4
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43	Re: Need Help 94 gas DS won't rev over 2100 rpm Ok I took the belt off and started it. There was no change. Without the belt the front clutch closed up but still would only rev to around 2100 rpm. I put the belt back on and tried to back up the driveway, it moved a few feet but would not pull itself up the drive, clutch not closing hard enough to grip the belt (belt is new). Why this thing will not rev up has me stumped. Any thoughts on this matter ? Suggestions or ideas ? I need help.
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43

05-13-2013, 02:51 PM	#6
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43	Re: Need Help 94 gas DS won't rev over 2100 rpm Even a wild guess would be good at this point. I can't figure it out.
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43

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05-13-2013, 02:57 PM	#7
nobuckbuild Gone Wild Join Date: Mar 2012 Location: CENTRAL PENNSYLVANIA Posts: 1,466	Re: Need Help 94 gas DS won't rev over 2100 rpm is the cable and linkage to the carb operating fully with the seat off in maintaince mode you need to see if the carb is opening fully , also check the butterfly in the carb

05-13-2013, 03:04 PM	#8
Dogmike Not Yet Wild Join Date: Aug 2012 Location: Indiana Posts: 70	Re: Need Help 94 gas DS won't rev over 2100 rpm All of the linkage is OK? The fuel lines and vaccum hoses are fine? Everything inside the black box near the battery OK? I really have no idea, wild guesses

05-13-2013, 03:17 PM	#9
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43	Re: Need Help 94 gas DS won't rev over 2100 rpm Yes seat is off and cart is in maintenance mode. We adjusted the linkage and cables and they are operating correctly. Engine starts to crank with less than an inch of pedal movement and opens fully at the carb. The fuel and vac lines are new as is the fuel and air filter. Every thing in black box appears to be OK. Man this thing has me stumped for real.
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43

05-13-2013, 03:45 PM	#10
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43	Re: Need Help 94 gas DS won't rev over 2100 rpm Guess I need a CC guru or something
rangerdaver91 Not Yet Wild Join Date: Feb 2007 Posts: 43

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