2004 Club Car won't start

[reevesjo]

The starter/generator belt was slipping, so I bought a new one and installed it. the engine turned over fine, but it failed to start. I have spark, and the fuel pump is pumping gas. I cleaned the plug, squirted a little starting fluid in hole before replacing spark plug. Still, no start; not even one fire. I checked compression. Only has about 70 psi. It ran good before replacing the belt. I see in the book that 156/185 should be the compression. Will my 70 psi be the problem? I also pulled the valve cover and the clearance is .005" on both valves, so that should not be a problem. But, the 70psi bothers me. Just wondering, because it ran before replacing the belt.

I need to find a 102396501 engine manual before I open the engine. Can any of this head work be done without removing the engine?

Thanks, Joe

[lockman1]

It won't start after replacing just the S/G belt? Weird!

The only thing I can think of is that the engine is rotating opposite of what it's supposed too!
While cranking it over, watch the drive clutch, and confirm that it's turning clockwise!

As for the low compression, If it's a key-start cart, 70 psi is normal,
156 psi is for pedal start carts with WOT (wide open throttle) while testing,
or... the engine is turning counter clockwise!

If the engine is turning clockwise, and it's a pedal start cart.... then, I've got nuthin'!

[reevesjo]

It is a pedal start and is rotating CW, facing the clutch. I tried a new spark plug and squirted a little starting fluid in the intake. No start; it didn't even fire one time. I put my hand over the intake and gas came out. I have an inline spark tester and there is a strong spark. But, the compression is still only about 60 or 70 with a better compression checker. I decided to pull the head and the valves were kind of nasty. I cleaned and reseated them and started the reassembly. I am presently waiting on the cylinder head bolt torque rating before I can tighten the head down and readjust the .005" valve clearance and then finish putting things back together. It had not been using oil, so I am hoping the rings are O.K. Dread pulling the engine, but if I have to, I will. More later..........
Joe

[reevesjo]

NOW IT STARTS AND RUNS LIKE A JACK RABBIT.
I pulled the head and the valves were "crudded up" with carbon. They were not burnt or damaged, so I lapped them in with valve grinding compound. Put everything back together and now, the compression is 150psi instead of the 70psi that I recorded earlier.
AMAZING. CASE CLOSED.
Joe

[lockman1]

I'm glad it's running for you again! Thanks for the update!

[Hillbilly09]

Did you ever find that engine service manual (102396501)? I'm looking for the same service manual as well.

[reevesjo]

WOW Hillbilly09, that has been a long time ago. I got my manual from Indiana Golf Car, 1770 B East 266th Street, Arcadia, IN 46030, phone (866) 984-9339 Toll Free. www.indianagolfcar.com
I Googled the part number and a couple of Ebay responses were "not currently available". Maybe available if you contact a local Clubcar dealer. Mine was $10.00, but who knows how much today. The title is: Repair and Rebuild Manual, Engines and Drivetrain Components, Edition Code 0904C1009B. The Clubcar web page did not work this morning. www.clubcar.com They are located in Augusta, GA imagine that.