Club Car Carry All- Fuel issues

phoenixmill4

New User
I have an older Carry All built under the Husqvarna brand with a Kawasaki gas/carbureted engine. Under 300 hours and it is giving me fits with fuel flow. It bogs down under load and stalls.

Troubleshooting:

Fuel filter- new
Fuel lines- free and clear
Fuel pump (pulsing)- good flow to carb
Carb- new (ouch), replaced under 100 hrs ago
Gas tank- removed line from installed fuel tank and ran it into a spare tank (that was pristine)

Idles fine, on flat even surface, uneven terrain and load causes it to choke out of starve for fuel and stall and sometimes backfires when turned off

Thoughts?
 
Just general information not specific to any brand...

Have you changed the plug? Do it just to say you did, fought the same problem on a Kawasaki lawn mower. $200 worth of parts and much frustration later ended when I replaced a perfectly good looking plug!

Exhaust backfire is usually a sign of weak or intermittent ignition.

Intake sneezing is usually lean mixture or retarded ignition timing.

When adjusting mixture be sure the air cleaner is in place, any baffling or cleaner box is in place and completely assembled. Learned that one the hard way too!

New carbs are often adjusted too lean. If it is a slide carb, try raising the needle. If fixed jet, compare the original carb jet size.
 
Some of those engines are prone to ignition coil failure. Especially if it happens after the engine has been run for 30 minutes or so. Did your problem begin after running for some time?
Dave
 
Can't help you with yours, as I am in a similar boat. Won't run, troubleshoot the problem, identify the problem, fix the problem, runs fine for a bit then back to won't run. Troubleshoot the problem, find another problem, fix that problem, runs fine for a bit, then back to won't run.

Mine has had a complete new ignition system, complete new fuel system, and I just keep chasing the problem around in a circle. I want to fix it so I can sell it without losing my shirt.

Where did you get your carburetor? I can't find anything but cheap aftermarket carburetors, which everyone says are junk. The one I bought has a sticking float that I can't figure out. Works fine with the bowl off but sticks with the bowl on, but it's plastic so you can't bend it and even if you could bend it there's no indication of where it might be hanging up.

This post was edited by BarnyardEngineering on 05/12/2022 at 11:56 am.
 

Identified the engine as a Kawasaki, then chased a guy in KY at a small engine repair shop to get me a factory replacement ($350) with no refunds. Same exact carb, have the factory manual for engine and all the parts illustrations
 
There is (a float drop limiting tab that should prevent the float from hitting the bowl. Look closely at the float
suspension pin and tabs. Jim
 
Im more familiar with Yamaha carts but they all have the common pulse line thats is connected to the crankcase. Sometimes they get clogged with gunk and need to be blown out. You can take the hose off at the pump and puff on it pushing the stuff back into the crankcase.
 
BarnyardEngineering, I've seen that type float stick. It's always been the needle sticking in the seat, not
the float rubbing or the hinge sticky. Always happens after sitting for a few days. I blame it on evaporating
ethanol, but who knows. Take the bowl off and pull down on the float and the needle pops loose. It will run
until it happens again. Always happens at random, sometimes it does it sitting for a week, sometimes it can
sit 3 months and start just fine.

It hasn't done it for a while now, so I'm leaving it alone, but next time I plan to try to give the needle
some extra clearance in the seat bore...Somehow.
 
Check the air intake in the choke assembly for mud dobbers . Unable to blow out. you will need to clean out with a 7/16 drill.
 
Kawasaki engines are usually very mechanically reliable. I'd suspect either fuel supply or ignition problems. For Club Cars and John Deere Gators, the shop manuals can walk you through a thorough trouble-shooting procedure.
 

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