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Old 07-10-2020, 04:45 PM   #1
Motorman 007
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Default 2002 CC DS rev limiter or governor?

Hi guys. Back again. Different cart. When driving the cart the engine appears to over rev hitting the rev limiter and the cart surges badly. At first it seemed like the belt was slipping allowing the engine to over rev. New belt same issue. I’ve been trying to tweak the governor and throttle linkage adjustments to get it to run right but it seems like the motor just wants to “run away”. Is this an adjustments issue or rev limiter issue? Engine will over rev right upon start up when I drive it. I can get it to run fine in maintenance mode without the rev limiter kicking in.
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Old 07-10-2020, 05:50 PM   #2
Fairtax4me
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Default Re: 2002 CC DS rev limiter or governor?

How fast does it go top speed? Usually you have to get up around 20mph to get near the rev limiter assuming everything else is working properly and the governor modified. If you're hitting the limiter and the engine Sounds like it's running fast at anywhere from 10-14mph, you most likely have a clutch problem.

Quite often if it hits the rev limiter when first taking off, its because the primary clutch is not closing smoothly. That can be because the clutch is worn out and needs rebuild or replacement. Or it can be due to the secondary clutch sticking and not letting the belt pull down into the clutch. Usually a rebuild takes care of that, but it may need a new helix/ ramp since if it gets to the point of sticking that is usually significantly worn and grooved.
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Old 07-10-2020, 06:15 PM   #3
Motorman 007
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Default Re: 2002 CC DS rev limiter or governor?

Thanks for the quick reply. As soon as I posted my thread, I started to think clutch. It revs right up before really gaining any speed. In maintenance mode the Primary clutch appears to be working fine. But if I drive it the rev limiter kicks in quickly.
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Old 07-11-2020, 12:34 PM   #4
Motorman 007
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Default Re: 2002 CC DS rev limiter or governor?

So I’ve pretty much determined it’s the drive clutch not closing all the way allowing the engine to over rev hitting the rev limiter. In my attempt to remove the clutch with my puller the bolt is now snapped off in the clutch. I didn’t think that my air gun would do it but it did. What are my options now?
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Old 07-11-2020, 02:41 PM   #5
Fairtax4me
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Default Re: 2002 CC DS rev limiter or governor?

The puller snapped off in the clutch?

Try a sharp tap on the bolt end with a hammer and a large punch or drift and see if some impact will jar it loose. If that doesn't work use a wood block to brace against the outer sheave of the clutch and try giving it a few whacks.
If it still doesn't budge then you may need to disassemble the clutch and heat the center shaft near the engine to try to get it to expand and pop off.
The last ditch option is to cut if off.
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Old 07-11-2020, 03:31 PM   #6
Motorman 007
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Default Re: 2002 CC DS rev limiter or governor?

Quote:
Originally Posted by Fairtax4me View Post
The puller snapped off in the clutch?

Try a sharp tap on the bolt end with a hammer and a large punch or drift and see if some impact will jar it loose. If that doesn't work use a wood block to brace against the outer sheave of the clutch and try giving it a few whacks.
If it still doesn't budge then you may need to disassemble the clutch and heat the center shaft near the engine to try to get it to expand and pop off.
The last ditch option is to cut if off.
Thanks. That’s exactly what I did. Beat the snot out of from the backside with a 2x4 and a 5 pound hammer. Finally broke free. Thankfully the crankshaft is not damaged and the clutch retaining bolt screws in fine. Need a new clutch because I damaged it so badly.
Thanks for replying Fairtax
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