G16 Valve Adjustment and other Reasons I can't get over 4K RPM

[BrewCityMusic]

The title sorta sums it up, I just installed the Plowmans "Hot Setup" and had Don redo my Primary Clutch for good measure so I figured I should install a Tach (which I did, an Equus 8086) ... And I am now realizing that no matter WHAT I do (even downhill to the floor with 2 riders) I can't get it over 4000RPM. I have the throttle cable straight to the carb and adjusted at both ends so Yes, the butterfly is opening completely, the choke has been checked and it's opening and closing as it should, etc so I would assume it's valve adjustment time ... The cart takes off fairly well and gets right up there to 4000 then just flatlines and won't go any higher, engine tone sounds the same, etc. Valves or anyone have someplace else to look first ?!?

Also, about an hour into the first full day of riding (yesterday) the cart became noticeably louder and had a sort of a "tinging" sound - I didn't think anything of it (much) but this AM it got a little bit LOUDER and the tinging got slightly more pronounced ... Pulled it to check for ratlles (none) and bad gasket (not the case) - hoping I don't have a bad baffle or ?

Any other ideas why I can't break 4k?

[bigstik40]

I know you said you have the throttle connected directly to the carb. but from your symptoms, it sounds like somehow, your governor might still be in the "mix" and still regulating throttle opening. I'm not 100% sure here, but I think when you connect throttle directly to carb. you need to also disconnect the cable from the governor. You may want to double check your installation again. Good luck - RAY

PS- As far as the "tinging" sound - not sure - maybe exhaust leak or pre-ignition (spark knock).

[BrewCityMusic]

The way I did it was to unhook the cable from the pedal to the governor and run it straight to the carb, then the cable from the governor to carb was zip-tied out of the way (it's still hooked up at the governor end but the other end is just sitiing there hooked to nothing) - I can't really see how it could still be affecting anything but I'll puill it today and triple-check all the operation of the butterfly, choke, etc (and give the valves a tweak once I locate my feeler gauges, they're MIA up in the shop somewhere)


I'm leaning towards something internal w the muffler, we ran it a bit last night and it gets louder as the cart warms up, then after about 2-3min of running it starts to make that noise and changes tone a bit ... Might be the new muffler breaking in or ?? - I'm going to give Don at Plowmans a call this AM and see if he's familiar with what it's doing, he's been great so far with everything so hopefully he'll have an idea.

Thanks and if anyone else has better governor info, etc that could relate to the issue, I'd appreciate the insight !

[bigstik40]

From your description it appears that the governor can't be doing anything, so scratch that idea. Just grabbing at straws here!! I would make sure you have your tach set correctly and it is not fibbing. Good luck - RAY

[BrewCityMusic]

That's sorta what I figured too but hey - I've been wrong enough times to not discount anyone elses opinions ...

The tach *seems* to be reading correctly, if I set it to single cylinder then it seems to read double the RPM's (unless of course I'm cranking this thing at 8000RPM which I feel to be unlikely, LOL) so I'm assuming it's a double-fire ignition system, when I set it to "2cyl" it seems to be working just fine - my EZGO's are the same way with induction tachometers though so I'm relatively certain THAT part of the equasion holds water too!

[Mike Mac]

I have a G8, but just connecting the throttle cable directly to the carb. didn't allow full throttle. I had to shorten the gas pedal more than an inch to allow the extra travel of the pedal to open the carb. fully.

[BrewCityMusic]

when I did the mod, Mike, I had to crank the cables almost to the ends AND I had to pull the pedal and rotate it back on the splines to give myself the extra travel too ... It *seems* to be allowing a full range of motion with the butterfly but to check it I obviously have to slide the carb itself back an inch or so to be able to see the operation of the butterfly - I'm wondering if that little bit of "stretch" might not be causing it to work in the "inspection" position but not actually on the cart installed ... Definitely some food for thought and I'll take a better look at that today, Thanks! (I think I have about 2 more splines left that I can move the pedal if I need more travel, but I'm also going to have to figure out the brake pedal release trigger then because it already disengages about an inch into the pedal travel which is sorta a PITA especially when backing up from a "locked" stop) ....

[Mike Mac]

Can't help with the brake pedal either. But moving the pedal back on the spline one notch left the Gas pedal in an uncomfortable position. That's why I cut it off, then put it back in the stock position. i have a picture of it on here somewhere, doesn't look out of place or anything, so you may want to look into it later when you have solved your more important problems.

After rereading, I would think you'd have to observe the throttle plate movement with everything in position. but just watch the throttle arm on the carb. Not the butterfly. With the filter housing removed of course.

[bigstik40]

Originally Posted by BrewCityMusic

That's sorta what I figured too but hey - I've been wrong enough times to not discount anyone elses opinions ...

The tach *seems* to be reading correctly, if I set it to single cylinder then it seems to read double the RPM's (unless of course I'm cranking this thing at 8000RPM which I feel to be unlikely, LOL) so I'm assuming it's a double-fire ignition system, when I set it to "2cyl" it seems to be working just fine - my EZGO's are the same way with induction tachometers though so I'm relatively certain THAT part of the equasion holds water too!

2 cyl is correct !! I went through this with my tach a while back and discovered then that our G16's have 1 spark per revolution (sparks on compression and exhaust strokes). I'm out of gas here, so good luck. - RAY Hmmm. wonder if your problem could be (low) fuel flow related??!!