2022 Cushman Hauler 1200X EFI Check Engine Light

[Silo318]

It has been running fine but started running poorly and then wouldn't start. It will turn over and fire intermittently but will not start. Fuel pump working and has fuel flow with lines removed. Oil is full and clean. Check engine light is steady on with no flashing. Light goes off when cranking. I've cleaned all ground points from battery to the starter. Does anyone have a suggested place to start troubleshooting?

[CharleyL]

Have you checked the spark plugs? You likely have some kind of ignition problem and the most likely place to start is to remove and examine the spark plugs for wear proper gap, etc. They will likely need cleaning too. Also check the ignition wiring for burn holes and to be sure that they are connected properly.

Your Cushman Hauler is not really a Cushman. EZ Go makes models of their little trucks with the Cushman name as part of the model, but the real Cushman company has been out of business and gone for over 30 years. Go to an EZ Go dealer for help/parts.

Charley

[kgsc]

Actually Cushman and Ezgo are both under Textron. Lots of the parts are common.

[Silo318]

Well, this is embarrassing. Did some troubleshooting of the ignition system but didn't find any problems. Tried starting it again and it runs just fine. Found an owner's manual online and it says the check engine light will illuminate steady on to demonstrate functionality of the system and go off when the engine is running. Otherwise, it will flash to indicate a code when the gas pedal is pressed.

[CharleyL]

Thanks for letting us know, and I'm glad that you have a good running kart again.

Charley

[Silo318]

I spoke too soon. I drove it about a mile and on the way back home, it started losing power and quit running in my driveway. It shows definite signs of a fuel problem. Either the fuel pump or injector. The fuel pump is running, and the fuel pressure is 7 psi. I've tried but was unable to find a reference telling me what the fuel pressure should be. I hate to start throwing parts at it, a new fuel pump is just under $500. The cart still doesn't show any codes from a flashing check engine light. Any suggestions how to find the correct fuel pressure.

[CharleyL]

The fuel pump in my 1987 Cushman was a positive displacement Cushman original, now un-obtanium, and they never worked very well anyway even when new. I removed it, made a cover plate and gasket to plug the hole in the crankcase, and bought an electric fuel pump from O'Riley Auto Parts. It's for automotive use, but it works. As long as the fuel pressure isn't high enough to open the float needle valve in the carburetor, it doesn't matter, as long as when the needle valve is open, there is enough pressure to fill the float bowl in the carburetor. I never measured it's fuel pressure, just installed it connected direct to the carburetor of the 2 cylinder 22 hp OMC engine in mine, removing the bypass filter and return line to the tank and my motor never ran as good as it has after doing this. Electric fuel pumps are self regulating, and will pump whenever the line pressure drops. They are cheap too, at about $50. Two wires to hook up - red to a connection that has power when the key switch is on, and black to a convenient bolt on the frame. I mounted it to the frame just ahead, and at the same approximate level as the output fuel connection of the fuel tank. The new filter that was supplied with the pump had an air leak, so I bought an automotive fuel filter and added it between the fuel tank and fuel pump. The price for a new original fuel pump should convince you to try going this way.

Injectors do go bad, but it's usually one and not both at once. I am familiar with construction equipment Diesels, but nothing this small. There should be a way to remove and clean them, but I have no experience here.

You should update your profile. Not an exact address with street name and number, but at least the town or city, state. If someone is near, they may be able to provide hands-on help. I have helped several that were close to me. It would be nice if you posted a few photos of your ride too, and your best one can be added to your Avatar (like mine on the left). We all like to see what each other is driving.

Charley

[Silo318]

Thanks Charley, I took your advice and updated my profile. I'm checking Textron parts and service manuals to see if they will help. I've also watched some videos on Kawasaki motorcycles and now believe I have fuel flow but no pressure even though I hear the pump running. Videos show that the pump should cycle on for a few seconds with the key on and the shut off. Mine keeps running and does not cycle.

[CharleyL]

Is it an electric fuel pump? If it is, it should only run to maintain fuel pressure, and should shut off frequently. This is how my replacement pump operates. It will run for a few seconds every time I turn the ignition key on, then shut off until the engine begins using fuel. It will then run in short cycles to maintain fuel pressure.

The original mechanical pump on my OMC engine operated via a lever riding on a cam on the timer shaft inside the crankcase, much like the ones on old car engines. Removing it left a hole in the side of the crankcase that needed a plate and gasket to cover it to keep dirt out of the crankcase and oil in.

If your fuel pump has wires going into it, it's an electric fuel pump. It should only make noise until it reaches fuel pressure, then it should shut off until the carburetor float opens the valve to let more fuel into the float chamber. If there is anything wrong with the float or this valve, the fuel will continue to flow and the excess will come out of the vent on top of the carburetor, and the fuel pump will continue to run, trying to build up pressure in the line to the carburetor.

You should be able to post photos now. Look down below your post window to find "Attach Files" and click on "Manage Attachments". You should be able to add the photo file names and their location on your computer. You can add several. When complete, click on "Submit Reply" and your photos will be attached to your post as they are uploaded.

Charley

[Silo318]

Update: I bought a new fuel pressure test kit and checked pressure and found 42 psi while running and it stayed there as RPMs were raised and lowered. I watched several videos Polaris ATV electronic fuel injection tests, and they indicated the pump maintain pressure after the motor is shut off. Mine dropped to 0 psi when the motor was shut off. Pulled the fuel pump out and found the filter bag missing. Drained the tank and found the filter bag appeared to have been cut off and left in the tank. Don't know why anyone would think that's a good idea. I bought the cart used. Plan now is to buy a pump rebuild kit and clean the fuel injector. Will post results.