91 GXT 800. 2 stroke to 4 stroke swap..HELP

91 GXT 800 in AZ · 11-06-2010, 10:14 PM

I have a 1991 EZ-GO GXT800. It was a 9hp 2 stroke. Motor is shot. I want to go with a 13hp Duro-Max. Who is the expert out there. Need HELP.
Also, how do i add pics. New to this....

rib33024 · 11-06-2010, 11:43 PM

Here's one way some posted

( let the forum host the picture. )

click "Go To Advanced"

then click "Manage Attachments"

click "Choose" in the pop-up window

select the file(s) from your computer

click "Upload"

close pop-up after files complete uploading.

click "Submit Reply"

"Go Advanced"

"Manage Attachments"

click --"Choose"---find the pic you want to post and click on it--click---"Upload"--wait a sec or two for the pic to upload, then Submit reply

91 GXT 800 in AZ · 11-07-2010, 11:37 AM

Thank you very much. Great help.

Dave Box · 11-07-2010, 12:17 PM

It goes without saying that you realise you will need to either change your back axle or live without reverse gear.

91 GXT 800 in AZ · 11-07-2010, 12:19 PM

Here are some pics of my project. Anyone out there with knowledge of this model would help.

Dave Box · 11-07-2010, 12:21 PM

I stand corrected, it looks like you already took care of that back end

91 GXT 800 in AZ · 11-07-2010, 12:26 PM

That's the axle that it had when i got it. Just cleaned it up a bit. I assumed that i would lose reverse. But what do i do with the governor?

Dave Box · 11-07-2010, 12:35 PM

So I guess that someone else started this project and now you have it. Clearly the rear diff has been changed in anticiation of a 4 cycle engine. I am no expert on those but it looks like the reverse gear if there.
With regard to the governor I just removed mine. My reasons were that only my wife and I drive the cart and we are both smart enough to realize that the throttle goes up as well as down. Now if my cart was being used by the kids / relatives / drunken buddies that would be a different story. Just for fun I connected up one of the cheapy rev counter / hours run meters from Ebay so I am always assured the cart is running within its limits.
Good Luck with the build I hope it goes well
Dave

91 GXT 800 in AZ · 11-07-2010, 12:39 PM

I'm confused. What do you see that makes you think I'll have reverse.? I'm new to this. I thought this was a 2 stroke rear end.... and i would need a trans to have reverse.

Dave Box · 11-07-2010, 01:34 PM

Well I could be wrong as my knowledge relates to the 2PG engine circa 1986 but I don't think that things changed that much for the 3PG. Your differential is standing up and the clutch housing is facing the drivers side. Every 2 cycle EZGO that I have seen the differential is in line with the rear axle and the clutch faces forward. I think that one of your images showed the old engine on the back of the cart bed. If you look at it you can see that the drive clutch would be parallel to the rear axle so the belt would also run across the cart. Your replacement engine would be rotated 90 degrees so the drive belt aligns front to rear. Also there is a lever and a spring shown on your differential and I assume that is your reverse gear. This is not part of a 2 cycle rear axle. Now as I say I could be wrong as my expertise is the 2PG so take my advice with a pinch of salt until a real expert turns up (I shall also monitor this thread to see if I am right or wrong).

BTW this is a fantastic project and having just completed the restoration and rebuild of mine I am very envious of your rebuild.
Good Luck
Dave

11-06-2010, 10:14 PM	#1
91 GXT 800 in AZ Not Yet Wild Join Date: Oct 2010 Location: Arizona Posts: 15	91 GXT 800. 2 stroke to 4 stroke swap..HELP I have a 1991 EZ-GO GXT800. It was a 9hp 2 stroke. Motor is shot. I want to go with a 13hp Duro-Max. Who is the expert out there. Need HELP. Also, how do i add pics. New to this....

11-06-2010, 11:43 PM	#2
rib33024 ...................... Join Date: Apr 2009 Location: FT Lauderdale FL. Posts: 16,416	Re: 91 GXT 800. 2 stroke to 4 stroke swap..HELP Here's one way some posted ( let the forum host the picture. ) click "Go To Advanced" then click "Manage Attachments" click "Choose" in the pop-up window select the file(s) from your computer click "Upload" close pop-up after files complete uploading. click "Submit Reply" "Go Advanced" "Manage Attachments" click --"Choose"---find the pic you want to post and click on it--click---"Upload"--wait a sec or two for the pic to upload, then Submit reply

11-07-2010, 11:37 AM	#3
91 GXT 800 in AZ Not Yet Wild Join Date: Oct 2010 Location: Arizona Posts: 15	Re: 91 GXT 800. 2 stroke to 4 stroke swap..HELP Thank you very much. Great help.

11-07-2010, 12:17 PM	#4
Dave Box Respect the Cart Join Date: May 2010 Location: Rocky Mount, Virginia Posts: 2,190	Re: 91 GXT 800. 2 stroke to 4 stroke swap..HELP It goes without saying that you realise you will need to either change your back axle or live without reverse gear.

11-07-2010, 12:21 PM	#6
Dave Box Respect the Cart Join Date: May 2010 Location: Rocky Mount, Virginia Posts: 2,190	Re: 91 GXT 800. 2 stroke to 4 stroke swap..HELP I stand corrected, it looks like you already took care of that back end

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11-07-2010, 12:26 PM	#7
91 GXT 800 in AZ Not Yet Wild Join Date: Oct 2010 Location: Arizona Posts: 15	Re: 91 GXT 800. 2 stroke to 4 stroke swap..HELP That's the axle that it had when i got it. Just cleaned it up a bit. I assumed that i would lose reverse. But what do i do with the governor?

11-07-2010, 12:35 PM	#8
Dave Box Respect the Cart Join Date: May 2010 Location: Rocky Mount, Virginia Posts: 2,190	Re: 91 GXT 800. 2 stroke to 4 stroke swap..HELP So I guess that someone else started this project and now you have it. Clearly the rear diff has been changed in anticiation of a 4 cycle engine. I am no expert on those but it looks like the reverse gear if there. With regard to the governor I just removed mine. My reasons were that only my wife and I drive the cart and we are both smart enough to realize that the throttle goes up as well as down. Now if my cart was being used by the kids / relatives / drunken buddies that would be a different story. Just for fun I connected up one of the cheapy rev counter / hours run meters from Ebay so I am always assured the cart is running within its limits. Good Luck with the build I hope it goes well Dave

11-07-2010, 01:34 PM	#10
Dave Box Respect the Cart Join Date: May 2010 Location: Rocky Mount, Virginia Posts: 2,190	Re: 91 GXT 800. 2 stroke to 4 stroke swap..HELP Well I could be wrong as my knowledge relates to the 2PG engine circa 1986 but I don't think that things changed that much for the 3PG. Your differential is standing up and the clutch housing is facing the drivers side. Every 2 cycle EZGO that I have seen the differential is in line with the rear axle and the clutch faces forward. I think that one of your images showed the old engine on the back of the cart bed. If you look at it you can see that the drive clutch would be parallel to the rear axle so the belt would also run across the cart. Your replacement engine would be rotated 90 degrees so the drive belt aligns front to rear. Also there is a lever and a spring shown on your differential and I assume that is your reverse gear. This is not part of a 2 cycle rear axle. Now as I say I could be wrong as my expertise is the 2PG so take my advice with a pinch of salt until a real expert turns up (I shall also monitor this thread to see if I am right or wrong). BTW this is a fantastic project and having just completed the restoration and rebuild of mine I am very envious of your rebuild. Good Luck Dave

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