common problems with 88 EZGO

outlaw911 · 10-23-2010, 11:00 AM

I just bought an 88 ezgo cart it was in a field for a year or so motor is locked up and it came with another motor that is not assembled i am going to rebuild this over the winter from the ground up and install a lift kit and tires just wondering what common problems i should look for and if anyone has modded the 244 2cycle motors and if so what can i do bigger jug ,change ports ,larger carb ,or modding reed cage and any other advice would be great not looking for speed mostly looking for low end it will be used to push sprint car around in the pits and out on to the track

Thanks

Dave Box · 10-23-2010, 12:12 PM

There are no real problems with the little 2PG engine, it's quite a robust little trooper. Just like any rebuild cleanliness is essential. When I did mine I ordered the top and bottom end kits and that was a decision I was very pleased with. Just like any two stroke it will not tolerate air leaks so make sure that you use new gaskets (supplied with the kits). I also stuck my crankcase together with mega grey mastic. I used the grey as it is the same color as the crankcase so it looks neat when you are done. Not that it adds any performance but on reflection I wish that I had painted the crankcases when they were apart but that is a mere bagatelle. When you rebuild your engine it will be the kiss of death not to replace the crankshaft oil seals. They cost $3 each and when they fail they make your life truly tedious. With regard to the carburetor I cleaned and cleaned and then recleaned and reset my one. Then I gave up and dropped $100 on a new one. The difference was huge so my advice is don't waste your time tinkering with a 22 year old carb. (Now I await a good flaming from the boys who did). I did decide to keep my old fuel pump and it died after 3.5 hours. At $33 a new pump is IMHO a good investment. Many folks, myself included, removed the oil pump system citing concerns over its reliabiility. If you do that just remember to cap the oil line to prevent air bleeding into the crankcase. After you rebuild the engine you should run a tank at 40:1 and thenceafter at 128:1
I would not spend any money on trying to tune the 2PG, it is what it is, however I do recommend this. Fit a DAYCO HP3004 drive belt. It is only 7/8 inch shorter than your stock belt but the difference in torque and hill climbing ability will amaze you.
Goood luck with your project and keep us posted on what goes down

Dave

outlaw911 · 10-23-2010, 01:46 PM

thanks dave for the info sounds like great advice i also have a 73 harley 3 wheeler i just bought this year i have less then 400 in to both they are so much fun to mess with the harley ran great but blew motor on it so i have it at a friends house that build race two cycle motors hes going to see what he can do to get more power outta that one too this one is heading there too redoing body on ezgo and new seats and installing stereo system should have two fun toys for next year i will post pics on here as i go right now just trying to round up parts then stripping it new paint and parts i will post pics as i go hoping to have done for april 2011

thanks again
craig

outlaw911 · 10-23-2010, 02:50 PM

one other question on the spare motor everything is tore apart but the drive pulley is still on the crank shaft how do i remove that so i can get the crank out

Dave Box · 10-23-2010, 04:34 PM

Well you can either buy the tool for about $30 or you can make it for about $10. I made mine using a 3/4 fine threadhardened bolt 2 inches long and a piece of steel rod 7/16 by 3 inches long.

If the clutch has been on for many years, as was mine, it it going to be interesting. First remove the center bolt that holds the clutch on. Now I would recommend that you spray the crankshaft and clutch with liquid wrench and let it soak overnight. Now drop the steel rod into the clutch and wind in the bolt. I used the longest extension that I had and got my wife to stand on the engine block to prevent it spinning (the engine was seized). Now it is just a question of brute force and eventually it will pull out. I guess you could also use an impact wrench but I used what was available i.e. a willing wife.

BrewCityMusic · 10-24-2010, 12:50 PM

The electrical on these '88s hates sitting like that (trust me - I found out the hard way) so plan on doing a thorough job on replacing / cleaning all the terminals and connectors while you're torn apart ...

Dave as always is spot-on with sticking up for these little motors, my 88 runs 20+ mph with 2 on flat ground, and that's with 22" tires - as to a cheap and easy upgrade that you may want to consider, the stock electronic ignition is easily upgraded to a HEI system and high-output coil for under $50 front to back, and while it's not going to double your horsepower or antything, it WILL give you a noticeable increase in zip - along with the shorter belt outlined by Dave, you should have plenty of pep for getting around (and pulling in) the pits !!!

outlaw911 · 10-24-2010, 01:17 PM

thanks I know about the electric had some issues with my harley and it was stored inside but some of the contacts had gotten rusted i cleaned them up and it worked great already started cleaning that stuff could you help me with how to switch the ignition to hei part numbers and maybe a wiring digram or pics would be great i know the harley uses the points to fire the hei really looking foward to tearing into this thing spent yesterday cleaning and spraying everything with PB nut blaster and making list of parts i need

outlaw911 · 10-24-2010, 01:22 PM

here is the first pics i took of the cart

BrewCityMusic · 10-25-2010, 09:31 AM

Here's the basic wiring diagram for the HEI conversion, the part number on the module isn't relevant, as any HEI module for a late 70's Chevy 350ci will do (I went with an Accel brand but the stock ones are just fine too)

As to a high-output coil, the one I bought off Ebay can be found here:

http://cgi.ebay.com/ebaymotors/HD-UN...Q5fAccessories

Now, as to a couple of tips that should help you out with the conversion, number one is to mount the HEI where it's going to have a VERY good ground, as well as some sort of heatsinking as they run really, REALLY hot. I cleaned off a spot on the frame to mount mine:

Lastly, with this coil you'll need to replace your plug wire, I just bought a set of 4cyl ford wires off Ebay for $7 and used one of those (and stashed the rest as spares) but you also could easily pick up a universal from Advance Auto, NAPA, etc. Also, in a pinch you can use a standard automotive coil if you have one laying around.

Once the HEI conversion is done, you should be able to fire up and go, BUT there's about a 50/50 chance you'll start fine and run with no power, like 2mph - if that's the case, reverse the red and blue wires from the pulsar on the HEI - for some reason that seems to be a common issue with the conversions, I can't really explain it but figured I'd throw it in to save you a bit of panic if it happens to you!

Keep us posted on the progress!

outlaw911 · 10-28-2010, 08:29 PM

thanks that will be my weekend progect tore fenders off this past weekend and took to car wash to clean it up and paint frame and motor area and started making custom seats also installed new sound insuation

10-23-2010, 11:00 AM	#1
outlaw911 Not Yet Wild Join Date: Oct 2010 Posts: 41	common problems with 88 EZGO I just bought an 88 ezgo cart it was in a field for a year or so motor is locked up and it came with another motor that is not assembled i am going to rebuild this over the winter from the ground up and install a lift kit and tires just wondering what common problems i should look for and if anyone has modded the 244 2cycle motors and if so what can i do bigger jug ,change ports ,larger carb ,or modding reed cage and any other advice would be great not looking for speed mostly looking for low end it will be used to push sprint car around in the pits and out on to the track Thanks
outlaw911 Not Yet Wild Join Date: Oct 2010 Posts: 41

10-23-2010, 12:12 PM	#2
Dave Box Respect the Cart Join Date: May 2010 Location: Rocky Mount, Virginia Posts: 2,190	Re: common problems with 88 EZGO There are no real problems with the little 2PG engine, it's quite a robust little trooper. Just like any rebuild cleanliness is essential. When I did mine I ordered the top and bottom end kits and that was a decision I was very pleased with. Just like any two stroke it will not tolerate air leaks so make sure that you use new gaskets (supplied with the kits). I also stuck my crankcase together with mega grey mastic. I used the grey as it is the same color as the crankcase so it looks neat when you are done. Not that it adds any performance but on reflection I wish that I had painted the crankcases when they were apart but that is a mere bagatelle. When you rebuild your engine it will be the kiss of death not to replace the crankshaft oil seals. They cost $3 each and when they fail they make your life truly tedious. With regard to the carburetor I cleaned and cleaned and then recleaned and reset my one. Then I gave up and dropped $100 on a new one. The difference was huge so my advice is don't waste your time tinkering with a 22 year old carb. (Now I await a good flaming from the boys who did). I did decide to keep my old fuel pump and it died after 3.5 hours. At $33 a new pump is IMHO a good investment. Many folks, myself included, removed the oil pump system citing concerns over its reliabiility. If you do that just remember to cap the oil line to prevent air bleeding into the crankcase. After you rebuild the engine you should run a tank at 40:1 and thenceafter at 128:1 I would not spend any money on trying to tune the 2PG, it is what it is, however I do recommend this. Fit a DAYCO HP3004 drive belt. It is only 7/8 inch shorter than your stock belt but the difference in torque and hill climbing ability will amaze you. Goood luck with your project and keep us posted on what goes down Dave

10-23-2010, 01:46 PM	#3
outlaw911 Not Yet Wild Join Date: Oct 2010 Posts: 41	Re: common problems with 88 EZGO thanks dave for the info sounds like great advice i also have a 73 harley 3 wheeler i just bought this year i have less then 400 in to both they are so much fun to mess with the harley ran great but blew motor on it so i have it at a friends house that build race two cycle motors hes going to see what he can do to get more power outta that one too this one is heading there too redoing body on ezgo and new seats and installing stereo system should have two fun toys for next year i will post pics on here as i go right now just trying to round up parts then stripping it new paint and parts i will post pics as i go hoping to have done for april 2011 thanks again craig
outlaw911 Not Yet Wild Join Date: Oct 2010 Posts: 41

10-23-2010, 02:50 PM	#4
outlaw911 Not Yet Wild Join Date: Oct 2010 Posts: 41	Re: common problems with 88 EZGO one other question on the spare motor everything is tore apart but the drive pulley is still on the crank shaft how do i remove that so i can get the crank out
outlaw911 Not Yet Wild Join Date: Oct 2010 Posts: 41

10-23-2010, 04:34 PM	#5
Dave Box Respect the Cart Join Date: May 2010 Location: Rocky Mount, Virginia Posts: 2,190	Re: common problems with 88 EZGO Well you can either buy the tool for about $30 or you can make it for about $10. I made mine using a 3/4 fine threadhardened bolt 2 inches long and a piece of steel rod 7/16 by 3 inches long. If the clutch has been on for many years, as was mine, it it going to be interesting. First remove the center bolt that holds the clutch on. Now I would recommend that you spray the crankshaft and clutch with liquid wrench and let it soak overnight. Now drop the steel rod into the clutch and wind in the bolt. I used the longest extension that I had and got my wife to stand on the engine block to prevent it spinning (the engine was seized). Now it is just a question of brute force and eventually it will pull out. I guess you could also use an impact wrench but I used what was available i.e. a willing wife. Last edited by Dave Box; 10-23-2010 at 04:35 PM.. Reason: sp

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10-24-2010, 12:50 PM	#6
BrewCityMusic Hammer Down !!!! Join Date: Jun 2010 Location: Lake Geneva, WI Posts: 2,681	Re: common problems with 88 EZGO The electrical on these '88s hates sitting like that (trust me - I found out the hard way) so plan on doing a thorough job on replacing / cleaning all the terminals and connectors while you're torn apart ... Dave as always is spot-on with sticking up for these little motors, my 88 runs 20+ mph with 2 on flat ground, and that's with 22" tires - as to a cheap and easy upgrade that you may want to consider, the stock electronic ignition is easily upgraded to a HEI system and high-output coil for under $50 front to back, and while it's not going to double your horsepower or antything, it WILL give you a noticeable increase in zip - along with the shorter belt outlined by Dave, you should have plenty of pep for getting around (and pulling in) the pits !!!

10-24-2010, 01:17 PM	#7
outlaw911 Not Yet Wild Join Date: Oct 2010 Posts: 41	Re: common problems with 88 EZGO thanks I know about the electric had some issues with my harley and it was stored inside but some of the contacts had gotten rusted i cleaned them up and it worked great already started cleaning that stuff could you help me with how to switch the ignition to hei part numbers and maybe a wiring digram or pics would be great i know the harley uses the points to fire the hei really looking foward to tearing into this thing spent yesterday cleaning and spraying everything with PB nut blaster and making list of parts i need
outlaw911 Not Yet Wild Join Date: Oct 2010 Posts: 41

10-25-2010, 09:31 AM	#9
BrewCityMusic Hammer Down !!!! Join Date: Jun 2010 Location: Lake Geneva, WI Posts: 2,681	Re: common problems with 88 EZGO Here's the basic wiring diagram for the HEI conversion, the part number on the module isn't relevant, as any HEI module for a late 70's Chevy 350ci will do (I went with an Accel brand but the stock ones are just fine too) As to a high-output coil, the one I bought off Ebay can be found here: http://cgi.ebay.com/ebaymotors/HD-UN...Q5fAccessories Now, as to a couple of tips that should help you out with the conversion, number one is to mount the HEI where it's going to have a VERY good ground, as well as some sort of heatsinking as they run really, REALLY hot. I cleaned off a spot on the frame to mount mine: Lastly, with this coil you'll need to replace your plug wire, I just bought a set of 4cyl ford wires off Ebay for $7 and used one of those (and stashed the rest as spares) but you also could easily pick up a universal from Advance Auto, NAPA, etc. Also, in a pinch you can use a standard automotive coil if you have one laying around. Once the HEI conversion is done, you should be able to fire up and go, BUT there's about a 50/50 chance you'll start fine and run with no power, like 2mph - if that's the case, reverse the red and blue wires from the pulsar on the HEI - for some reason that seems to be a common issue with the conversions, I can't really explain it but figured I'd throw it in to save you a bit of panic if it happens to you! Keep us posted on the progress!

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