91 club cart kf 82 motor problem

tony in oz

hi guys just joined this site in the hope some of you guys will be able to help me out
I have a 91 club cart with kf 82 flathead motor when changing the oil a small piece (I think) of piston skirt came out with the old oil.

my questions are
1/can you remove the head and cylinder block to change the piston (like the old 2 stroke motors.
2/given the age of this motor and me living in Australia its hard to get help so does any body have a copy of the work manual for this motor.

thanks in anticipation
Tony

BGW

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nobuckbuild

first off that manual at the cheapest is 60 bucks , second that engine as you will find is real pita for certain parts , if it still runs run it because once the ignitor goes out under the flywheel impossible to get, or your connecting rod breaks your done for, here in the states sometimes we piece them together but that is not likely for you to be able to do over there , i would start looking at engine swap ideas while it is still running to give you time to ship stuff from over here , the cheapest way to go would be with a site sponsor vegas carts , or you could go all the way to a v twin engine , start reading in the big block section you will learn alot about what can be done with these.

nobuckbuild

to actually answer your questions

1 yes it can be done but, the weakest link in that engine is the connecting rod, the usually break and take the block with it so if your getting that deep in the engine get a rod too, and have the cylinder bored , there are oversized pistons available and of course a gasket set and then you have 300 tied up in the engine with those parts and shipping and still you have the 8 hp engine with a no longer available ignitor that can and will go out as soon as you put money into the engine

btw your engine is a kawasaki kf82 for parts

ezgo on fire

was the piece aluminum or steel. The rivets come loose and break also on the plastic cam gear. But it should start loosing power because timing will be off. Those flat head motors do not like high rpms. That is usually what breaks the rods over revving.

Springbok

If the cart still runs fine I wouldn't worry about it unless it's the oil splasher. More trouble than it's worth to get in and fix it. If it's the oil splasher you'll want to fix it because without it your engine can't oil itself. You don't have to remove the cylinder head to replace it (the oil splasher), just the clutch and the side cover behind it.

You have a pic of the piece? Sometimes the splasher will break and end up in the oil, and I could see the broken pieces making it through the oil drain hole. I would actually be more worried about it being a broken oil splasher than a piece of the piston. If you can post a picture we can probably ID it for you. I have internal engine parts from two blown up KF82 motors in my basement.

Here's a pic of a rod from the KF82 motor that was in my cart when I got it. The oil splasher is the dark triangular-shaped metal piece near my thumb, where the rod bolts together.

Springbok

Here's a blowup of the motor case and cylinder head. To replace the piston you'll have to remove the clutch and the side cover (marked "37" in the diagram) in order to unbolt the connecting rod from the crank, then remove the top cover on the cylinder head (marked "15" in the diagram) so you can push the rod and piston up and out. Luckily you don't have to remove the main bulk of the cylinder head containing the valvetrain, etc.

tony in oz

hi guys thanks for the info
I have now stripped down the motor and found heaps of mashed up metal in the sump I have concluded that the metal cover on the large plastic valve cam has detached and has been smashed up by the con rod which in turn has broken large chunks off the piston skirt
I have checked the bore and that seems ok no cracks or scratches
I managed to track down parts and have ordered a new piston and con rod and valve cam

tony

Rep

Where did you find the parts?

Springbok

Piston and connecting rod aren't hard to find, camshaft is a bit harder but not impossible to find. Are you looking for something Rep, or were you just curious?

Rep

Curious. And no, I don't have a cat.

I do have a few golf carts though!