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Old 05-15-2014, 02:43 PM   #1
LBC970
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Default 99 Turf II, Crank, No Start

Oops, ClubCar Turf 2!

Same symptoms, different cart...

Cart: RG9939-806915
Engine: FE350D-BS11 (2002 Emissions sticker on the top...)

Cart died while being driven, driver said he heard a "chuff" sound, then lost all power. The starter cranks just fine...
-Battery is at 13+ volts, tests at 600 CCA and passes.
-Both micro switches in the box test ok,
-Solenoid tests ok, and since I broke it while testing it, I replaced it with a new one.
-All grounding straps are hooked up and fine.
-Tested compression, 30 PSI
  • Squirt of oil, no effect on compression. Thinking valves
  • Rebuild head, include new valve stem seals, and a deep clean.
  • Reassemble head and engine
  • Check compression, 75 PSI

This is where I am, when looking into the compression requirements for this engine, I find that the FE350 key start is supposed to be 75 PSI, but I find the compression for a FE350 pedal start should be 156 PSI. So I start thinking about piston rings. I do a cylinder leak test, and am only getting about a 17% leak reading. That's pretty darn good, within specs by about 20%!

I'm wondering if the guy we picked this cart up from dropped a key start motor into a pedal start cart. That's the only justification I can come up with as to why I am getting a solid 75 PSI and no major cylinder leak.

The engine in this cart has an emissions sticker saying it passes all pollution standards set by the state of California for the model year 2002, but the cart if only a '99.

Also, when taking the head off and apart, there was about an 1/8th inch of carbon build up on everything, that's all gone now. I was picking it off in large flakes...

Any help would be appreciated, I am stumped!

Thanks

EDIT: I should also say, I am getting fuel to the carb, and to be sure, I swapped out the carb for a known working one.

Last edited by lockman1; 05-15-2014 at 06:17 PM.. Reason: Info!
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Old 05-18-2014, 04:49 PM   #2
LBC970
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Default Re: 99 Turf II, Crank, No Start

Nobody? I'm still working on this one. I'm starting from the beginning on Wednesday and hoping I missed something...
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Old 05-19-2014, 06:36 AM   #3
lockman1
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Default Re: 99 Turf II, Crank, No Start

The FE350 should have a sticker on it showing if it has an ACR or not, (Automatic Compression Relief valve)
Here's my petal start FE350, ~ without ACR:

021 (3).JPG

You never said if you checked for spark at the spark plug!
If no spark, the coil, or rev limiter might have went bad!

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Old 05-19-2014, 10:23 PM   #4
LBC970
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Default Re: 99 Turf II, Crank, No Start

Quote:
Originally Posted by lockman1 View Post
You never said if you checked for spark at the spark plug!
If no spark, the coil, or rev limiter might have went bad!

Sorry, I did leave that out. I did check for spark, beautiful blue spark...

I will check for the "NON ACR" sticker in the morning.

Thanks lockman!
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Old 05-20-2014, 07:30 AM   #5
LBC970
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Default Re: 99 Turf II, Crank, No Start

I too have the "NON ACR" sticker. Meaning my compression should be at 158 psi, and I am only at 75. That would cause it to not run I suppose. Time for a full set of gaskets, maybe rings. Just doesn't make sense to me since it passed the cylinder leak test.

Thanks lockman
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Old 05-20-2014, 07:50 AM   #6
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Default Re: 99 Turf II, Crank, No Start

I'm not sure how you did your compression test,
but Kawi engines are finicky! All intake parts (airbox, filter, and tube) must be connected, and crank start with a wide open throttle.

I'm guessing you did it that way, but you never know!

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Old 05-22-2014, 05:47 PM   #7
LBC970
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Default Re: 99 Turf II, Crank, No Start

Quote:
Originally Posted by lockman1 View Post
I'm not sure how you did your compression test,
but Kawi engines are finicky! All intake parts (airbox, filter, and tube) must be connected, and crank start with a wide open throttle.

I'm guessing you did it that way, but you never know!

Yep, I sure did. It's been a crazy week here, haven't had a chance to mess with it yet. Hopefully next week will be slower. I will post if I find anything.

Thanks lockman, I appreciate the help.

Cody
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Old 06-11-2014, 09:23 AM   #8
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Default Re: 99 Turf II, Crank, No Start

After nearly a month of checking this and that, still a no go.

I did find a valve rocker with some major pitting on the contact pad, so I replaced it, and after installing everything, noticed I was getting zero movement in the valves. This would explain my compression being at 45psi. However when I took the head back off and turned the engine over, it looks as though the mechanism for pushing the valve push rods starts off fine at first, then slowly gets off track and eventually stops moving all together while continuing to crank.

Time to crack the case I think!
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Old 06-12-2014, 11:51 AM   #9
LBC970
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Default Re: 99 Turf II, Crank, No Start

After pulling the motor and opening the case, I found the gear cog that times the valve openings with the crank, had sheared the bolts off, and was just spinning in place. That would explain why I would occasionally get a hiccup from the motor at the beginning of a crank, but was unable to build compression. The valves were staying closed.

In case someone else runs into this!
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