Run away 97 DS

zellerj · 10-08-2018, 02:24 PM

I was driving my 1997 Club Car DS and the throttle stuck open. Turning off the key did nothing. I put on the brakes to stop, quickly lifted the seat and removed the spark plug wire. Running it in service mode did the same - it raced to full throttle and I could only turn it off by removing the plug wire. This cart was running great prior to this event.

About 8 years ago I disconnected the rev limiter and it was doing 20 MPH at 3000 RPM, 24 MPH at 3400 RPM. I was careful never to drive it above 3800 RPM. The cart was lifted about 8 years ago and the differential modified with a go faster gear set.

To diagnose, I removed the cover of the control box and all appears normal there. Removed the carb and the throttle butterfly valve operates as it should. Took a close look at the throttle and governor cables and they appear pretty limp. The spring on the throttle cable does not pull the governor cable back so the throttle valve is not closing, and the governor arm does not snap back the way it used to.

I think the fix could be new cables? Is there something wrong inside the differential?

Advice appreciated.

BBBHC · 10-09-2018, 07:58 AM

When the engine was running away, was the cart trying to go? Meaning did you have to keep the brakes applied to keep the cart from rolling?

Or was it as if you were in a "normal" vehicle and you had the vehicle in neutral or park?

zellerj · 10-09-2018, 08:16 AM

Two scenarios:
1) while driving the cart engine raced to full speed. Gas pedal would move up and down per normal, but the cart did not respond to the gas pedal. The brake would stop the cart, but engine still raced. Once stopped I had to remove the spark plug wire to kill the engine.

2) while in service mode, the engine would race and again the pedal did not affect the speed of the engine. Had to kill the engine by pulling off the spark plug wire.

I removed the carb and the throttle butterfly valve was working. Re-installed the carb and now there appears to be no issues. Did the throttle valve on the carb get stuck open? I am a little worried that this could happen again when my wife is driving. She might not know how to kill the engine.

BBBHC · 10-09-2018, 08:30 AM

Yeah, I understand your concern!

I don't know much about the clutch system on these carts. So hopefully someone with experience will chime in.

I am wondering if your clutch system has failed, and that might be causing the engine to runaway? Not sure if that would cause your issue or not....

If you think it looks a little "off", maybe post a picture or two of it for the gurus here to see

BBBHC · 10-09-2018, 10:07 AM

Apparently I was not quite awake yet, with the previous post.

Maybe your throttle linkage/cable is sticking?
Weird that turning the ignition off didn't shut it down....

10-08-2018, 02:24 PM	#1
zellerj Not Yet Wild Join Date: Oct 2009 Posts: 27	Run away 97 DS I was driving my 1997 Club Car DS and the throttle stuck open. Turning off the key did nothing. I put on the brakes to stop, quickly lifted the seat and removed the spark plug wire. Running it in service mode did the same - it raced to full throttle and I could only turn it off by removing the plug wire. This cart was running great prior to this event. About 8 years ago I disconnected the rev limiter and it was doing 20 MPH at 3000 RPM, 24 MPH at 3400 RPM. I was careful never to drive it above 3800 RPM. The cart was lifted about 8 years ago and the differential modified with a go faster gear set. To diagnose, I removed the cover of the control box and all appears normal there. Removed the carb and the throttle butterfly valve operates as it should. Took a close look at the throttle and governor cables and they appear pretty limp. The spring on the throttle cable does not pull the governor cable back so the throttle valve is not closing, and the governor arm does not snap back the way it used to. I think the fix could be new cables? Is there something wrong inside the differential? Advice appreciated.
zellerj Not Yet Wild Join Date: Oct 2009 Posts: 27

10-09-2018, 07:58 AM	#2
BBBHC Gone Wild Join Date: Jul 2018 Location: Central Ohio Posts: 1,720	Re: Run away 97 DS When the engine was running away, was the cart trying to go? Meaning did you have to keep the brakes applied to keep the cart from rolling? Or was it as if you were in a "normal" vehicle and you had the vehicle in neutral or park?

10-09-2018, 08:16 AM	#3
zellerj Not Yet Wild Join Date: Oct 2009 Posts: 27	Re: Run away 97 DS Two scenarios: 1) while driving the cart engine raced to full speed. Gas pedal would move up and down per normal, but the cart did not respond to the gas pedal. The brake would stop the cart, but engine still raced. Once stopped I had to remove the spark plug wire to kill the engine. 2) while in service mode, the engine would race and again the pedal did not affect the speed of the engine. Had to kill the engine by pulling off the spark plug wire. I removed the carb and the throttle butterfly valve was working. Re-installed the carb and now there appears to be no issues. Did the throttle valve on the carb get stuck open? I am a little worried that this could happen again when my wife is driving. She might not know how to kill the engine.
zellerj Not Yet Wild Join Date: Oct 2009 Posts: 27

10-09-2018, 08:30 AM	#4
BBBHC Gone Wild Join Date: Jul 2018 Location: Central Ohio Posts: 1,720	Re: Run away 97 DS Yeah, I understand your concern! I don't know much about the clutch system on these carts. So hopefully someone with experience will chime in. I am wondering if your clutch system has failed, and that might be causing the engine to runaway? Not sure if that would cause your issue or not.... If you think it looks a little "off", maybe post a picture or two of it for the gurus here to see

10-09-2018, 10:07 AM	#5
BBBHC Gone Wild Join Date: Jul 2018 Location: Central Ohio Posts: 1,720	Re: Run away 97 DS Apparently I was not quite awake yet, with the previous post. Maybe your throttle linkage/cable is sticking? Weird that turning the ignition off didn't shut it down....

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