2006 Club Car UTV Ingersol Rand XRT 810 - no crank

Mikerizer

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I have a 2006 Club Car, Ingersol Rand XRT 810, with a Kawasaki FE350D-CS11 motor.

It sat up for a couple of years. A few months ago, I cleaned out the gas tank, and replaced every component to the motor, including fuel pump, fuel lines, fuel pump, level sensor, etc.

It runs great! But...getting it started is a pain. The battery is good and the solenoid is new. It sounds like the starter is engaging, but not turning the motor over. If I turn the crankshaft manually with by gripping the torque converter housing, I can get it off the compression stroke, and the starter turns the motor over and it cranks and runs.

Does this motor have a mechanism that is supposed to temporarily relieve compression for starting up? I know many smaller engines do. It's either that, or may be the starter itself.

Thanks BAT!
 

grcauto

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Does it do this hot or cold or hot only?
 

Mikerizer

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Does this look like your engine? In the general specs it says it has an automatic compression release.

The model number matches up. It's difficult to make a visual comparison. On the cart, it has a larger fuel tank positioned elsewhere on the frame. Also, the throttle control is actuated by a gas pedal, and the air filter and breather are positioned differently. I'll dig around deeper for information regarding the automatic compression release.
 

Mikerizer

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Dear mike, I am seeing only a direct drive generator slash starter, no gear reduction, nothing also suggest it has a mechanism such as you wrote.

Thanks for the info...there's got to be something going on here that I'm missing. Once it starts turning, it will spin until it catches up. As the temps cool, I'm having to choke it, so the starter is turning the engine even more. I may also need to check the CCA specs for the battery.
 

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The highlighted parts identify as a plate and a valve. Looks like a reed valve. I wonder if this is the automatic compression release, or merely a breather apparatus, kind of like a PCV valve?
FE350D valve and plate.PNG
 

Mikerizer

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The camshaft part number is 49118-2112, but I can't find a good picture of it. I did find a 49118-2121, that DOES have the automatic compression release mechanism.
 

billr

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I doubt that high-lighted stuff has anything to do with compression-release. Probably for crankcase venting, as you suggested.

I'm just guessing, but I think this will certainly have compression-release since it has a direct-drive starter/generator. The operating requirements for a starter are considerably different than for a generator, so I expect some compromising has been done and the starter is not as robust as it would usually be. Also, it sounds like the same basic engine can have either manual or electric start; and manual start engines almost always have compression-release these days.
 

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Well, I've tried the following:
  1. Shut off the fuel supply and ran it out of gas, to make sure the carb wasn't hydrolocking the cylinder. (Also, confirmed that the oil level is correct, and it's not thinned out by gas)...still wouldn't turn the motor over.
  2. Removed the spark plug and tried to crank...same results; won't turn the motor over.
  3. Hooked up jumper cables; it sounded like the starter/generator was trying harder, but still wouldn't turn over.
So, I don't think compression is the problem...I think the starter/generator needs to be replaced/rebuilt. I'll check all the electrical connections before I remove it, though.
 

Mikerizer

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minute 2.35. of this video. If you jump power to green, does it crank?

here is a link to this video, you tube at its best.

Thanks for the video! Actually, my cart is trying to crank, it just doesn't seem to have enough "umph" to turn the motor over. I can hear the solenoid kicking in, and the motor barely budges. Also, I have the microswitches set to where the starter engages with the gear in neutral, so the gas pedal position sensor is irrelevant.
 

billr

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I gotta ask... with the spark plug out, does it turn freely by hand?
 
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