1983 ezgo gas

Yinzer · 06-16-2016, 02:06 PM

Greetings

I am new to this forum and looking to locate a wiring diagram, repair manual and any information installing a accelerator switch for a 1983 Gas EZGO with 2-Cycle Fuji-Robin Engine.

My son ( 11 ) managed to find a free golf cart that he would like to redo as a summer project together.

There are several issues with the cart and we are in the information gathering phase. I have spent the last week searching the web and have not be very successful locating the materials needed above to begin the epic project.

Any information would be extremely helpful and we look forward to the forum support/feedback.

Rich

cart around · 06-16-2016, 02:21 PM

This manual will work for you.

Yours is an 83. It was the only year with a muffler behind the engine. Many people say they were an undesirable year because of issues. I don't know that to be fact. My brother recently bought one, and it has the same issues that other years have. I think it's a good little cart.

Post some pictures of your engine, and wiring, so we can see if anything bad jumps out at us.

Luckily, I'm bilingual. I speak both English, and Yinzer.

Yinzer · 06-16-2016, 02:27 PM

Our budget is $400.00 and purchasing a repair manual would eat up 1/4 of our funds.

Yinzer · 06-16-2016, 02:31 PM

Thanks for attachment !!!!!!!!!

I will post additional photos of engine wiring tonight.

cart around · 06-16-2016, 02:39 PM

I couldn't make the picture bigger for a better look, but I don't see a carburetor on there.

About 20 bucks on ebay.

Maybe that big red round thing is covering it up.

Has it run yet?

Yinzer · 06-16-2016, 03:53 PM

Accelerator / Microswitch ?

The person who previously owned the cart "bypassed a bad switch to start the engine " and I'm not certain what he did because of the wiring mess.

The engine will only start if the key is turned like a car ignition to the on position until it starts. It will also not start unless it is in either drive or reverse. Extremely dangerous especially with potential young driver.

(It really struggles to start and is a topic for another thread. I will post video once we get to that phase but think it might be the starter or bad belt.)

If the engine stops running, the key needs to be turned off and turned on until the engine starts again. To keep it running, one foot needs to be on the gas and the other foot on the break ( power breaking ) to keep the engine from stalling.

To go from drive to reverse, the key needs to be turned to the off position, lever put in reverse and key turned to start engine. Again, if the engine stops running the key needs turned off and turned to on position to restart it.

Depressing the gas peddle with key in the on position to start engine doesn't work. I am not sure if this is supposed to be a feature on this early of a golf cart or not. If so, I assume the accelerator switch was what the previous owner bypassed but I am not certain.

Am I on the right diagnoses path? Any ideas / suggestions welcome.

Yinzer · 06-16-2016, 03:58 PM

Cart Around, Thank you for the attachment and feedback !

cart around · 06-16-2016, 06:14 PM

Ok, this is very important.
The engine changes directions to run in reverse. Make sure that it has completely stopped turning before trying to start in the opposite direction.

The cart does not idle. It should stop running every time you take your foot off the gas.

The key switch is connected in series with the pedal switch. They both need to make contact to run.
If your pedal switch has been bypassed, there are three options.
1) Buy a new switch for roughly 20 bucks.
2) Drill rivets out of switch, clean contacts, rivet back together.
3) Swap it with backup switch that is mounted on the Reverse switch. It should have a wire coming from the hot side of the key switch. Its only purpose is to turn on the backup buzzer while in reverse. They are the same. Mount it at the pedal location.

Starting only in forward, or reverse is normal. That switch has 4 big electrical contacts that have to be made to determine which direction the starter will turn. They do not make contact while in between positions.

I will post a picture of how the throttle cable should be connected to the carburetor.

When this thing is running right, it will be more fun than the Turnpike ride at Kennywood.

cart around · 06-16-2016, 06:26 PM

When you take your foot off the gas, the cable should pull your carburetor closed.

Stepping on the gas should do two things. It makes contact with the microswitch on the pedal to activate the solenoid.

It also makes the throttle cable longer. It should slide through the slot in the throttle lever on the carburetor. The carb has a spring that opens the lever by itself.

You will see in the pictures that my cable has a small spring from an ink pen slid over the end.

That spring makes sure that the switch makes contact before the carb opens. It prevents backfiring, and gives a smooth throttle response for slow operation.

If you are holding your foot on the brake, it sounds like you don't have that throttle response.

EDIT: Do not start a new thread. Keep everything here to avoid confusion.

Yinzer · 06-17-2016, 09:29 AM

Wiring

06-16-2016, 02:06 PM	#1
Yinzer Not Yet Wild Join Date: Jun 2016 Posts: 25	1983 ezgo gas Greetings I am new to this forum and looking to locate a wiring diagram, repair manual and any information installing a accelerator switch for a 1983 Gas EZGO with 2-Cycle Fuji-Robin Engine. My son ( 11 ) managed to find a free golf cart that he would like to redo as a summer project together. There are several issues with the cart and we are in the information gathering phase. I have spent the last week searching the web and have not be very successful locating the materials needed above to begin the epic project. Any information would be extremely helpful and we look forward to the forum support/feedback. Rich
Yinzer Not Yet Wild Join Date: Jun 2016 Posts: 25

06-16-2016, 02:31 PM	#4
Yinzer Not Yet Wild Join Date: Jun 2016 Posts: 25	Re: 1983 ezgo gas Thanks for attachment !!!!!!!!! I will post additional photos of engine wiring tonight.
Yinzer Not Yet Wild Join Date: Jun 2016 Posts: 25

06-16-2016, 02:39 PM	#5
cart around Test before replacing Join Date: Aug 2013 Location: Ohio side of the Pennsylvania border. Posts: 3,496	Re: 1983 ezgo gas I couldn't make the picture bigger for a better look, but I don't see a carburetor on there. About 20 bucks on ebay. Maybe that big red round thing is covering it up. Has it run yet?

06-16-2016, 03:53 PM	#6
Yinzer Not Yet Wild Join Date: Jun 2016 Posts: 25	Re: 1983 ezgo gas Accelerator / Microswitch ? The person who previously owned the cart "bypassed a bad switch to start the engine " and I'm not certain what he did because of the wiring mess. The engine will only start if the key is turned like a car ignition to the on position until it starts. It will also not start unless it is in either drive or reverse. Extremely dangerous especially with potential young driver. (It really struggles to start and is a topic for another thread. I will post video once we get to that phase but think it might be the starter or bad belt.) If the engine stops running, the key needs to be turned off and turned on until the engine starts again. To keep it running, one foot needs to be on the gas and the other foot on the break ( power breaking ) to keep the engine from stalling. To go from drive to reverse, the key needs to be turned to the off position, lever put in reverse and key turned to start engine. Again, if the engine stops running the key needs turned off and turned to on position to restart it. Depressing the gas peddle with key in the on position to start engine doesn't work. I am not sure if this is supposed to be a feature on this early of a golf cart or not. If so, I assume the accelerator switch was what the previous owner bypassed but I am not certain. Am I on the right diagnoses path? Any ideas / suggestions welcome.
Yinzer Not Yet Wild Join Date: Jun 2016 Posts: 25

06-16-2016, 03:58 PM	#7
Yinzer Not Yet Wild Join Date: Jun 2016 Posts: 25	Re: 1983 ezgo gas Cart Around, Thank you for the attachment and feedback !
Yinzer Not Yet Wild Join Date: Jun 2016 Posts: 25

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06-16-2016, 06:14 PM	#8
cart around Test before replacing Join Date: Aug 2013 Location: Ohio side of the Pennsylvania border. Posts: 3,496	Re: 1983 ezgo gas Ok, this is very important. The engine changes directions to run in reverse. Make sure that it has completely stopped turning before trying to start in the opposite direction. The cart does not idle. It should stop running every time you take your foot off the gas. The key switch is connected in series with the pedal switch. They both need to make contact to run. If your pedal switch has been bypassed, there are three options. 1) Buy a new switch for roughly 20 bucks. 2) Drill rivets out of switch, clean contacts, rivet back together. 3) Swap it with backup switch that is mounted on the Reverse switch. It should have a wire coming from the hot side of the key switch. Its only purpose is to turn on the backup buzzer while in reverse. They are the same. Mount it at the pedal location. Starting only in forward, or reverse is normal. That switch has 4 big electrical contacts that have to be made to determine which direction the starter will turn. They do not make contact while in between positions. I will post a picture of how the throttle cable should be connected to the carburetor. When this thing is running right, it will be more fun than the Turnpike ride at Kennywood.

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