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Unread 05-23-2011, 01:48 PM   #41
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Default Re: "Early 90's EZGO - Needs a Rebuild"

Alright!

Engine is totally off and on the workbench right now, oil tank and lines and pump are in the garbage, but I think I will hang on to the linkages - those ball joints look like they could come in handly.

Firstly, thanks for the encouragement Madoc - taking the engine out made me recehck the carb (bowl full, float non stuck, jet clean), clean the reed valves (yikes! Philthy!), and wash all the dirt off the frame of the cart. My only shortcut was to cut wires versus unhooking them, but that's an easy fix.

Word to the wise - taking the engine bolts out without an impact gun would be crazy. If you want the engine off, make sure you have an impact gun.

I'm guessing the open end of the crank left exposed by removing the pump isn't really an issue? Anyone cap theirs, or just leave it as is?

Last bit, doing the exhaust test, I thought the rings looked fine. Now that I have the engine out, and can look throught the intake, we have 1 missing ring, and one worn flat to the side of the piston. Guessing a new top end was the right way to go, as this sort of "strippage" likely put the jug out of spec.
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Unread 05-23-2011, 07:38 PM   #42
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Default Re: "Early 90's EZGO - Needs a Rebuild"

way to go. no issue on the pump. good call on the linkages. the ends can be used elsewhere. now you can see what's going on! spiff it up, and maybe paint some partts, you will be proud.
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Unread 05-23-2011, 09:11 PM   #43
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Default Re: "Early 90's EZGO - Needs a Rebuild"

Love the pics Madoc - how long that black paint last on the muffler, or did you use BBQ paint? Nice to see your cart's guts - look like mine except clean and nice.

Alreadt steel wooled the canopy, and painted the canopy supports black. Got some brown metal flake for the body too (thank you Menards).

Just curious, am I the only guy on this site who wants to use his golf cart for golfing?
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Unread 05-24-2011, 10:22 AM   #44
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Default Re: "Early 90's EZGO - Needs a Rebuild"

Quote:
Originally Posted by ScooterMcTavish View Post
Love the pics Madoc - how long that black paint last on the muffler, or did you use BBQ paint? Nice to see your cart's guts - look like mine except clean and nice.

Alreadt steel wooled the canopy, and painted the canopy supports black. Got some brown metal flake for the body too (thank you Menards).

Just curious, am I the only guy on this site who wants to use his golf cart for golfing?

Strangely enough, no your not Although we do seem to be a rare breed these days.
Good luck with your rebuild, these are good little motors when in good health !

Chris.
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Unread 05-25-2011, 06:24 PM   #45
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Default Re: "Early 90's EZGO - Needs a Rebuild"

So the clutch came off surprisingly easy - it was hard to find a 3/4" fine thread bolt, and I used a reversed 3/8" bolt with 1/2" head as the pusher rod, and it came off pretty easy (though I didn't have the right socket, so had to hammer on a Vise Grip). Gotta say, I'd hate to take out the retaining bolt for the clutch without an impact gun.

However, I go to use the steering wheel puller to take off the flywheel, and yay! The kit doesn't come with the M6 bolts I apparently need to put into the wheel. And the longest bolts my local hardware store had were 2", in other words, 1" too short. Now if I could take the brass oil pump fitting off, it would work with the shorter bolts.

Anyone ever take it off? Easy or hard? Or, should I just wait until I can get the correct bolts? Hacksaw time?

Grumble, grumble.
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Unread 05-25-2011, 07:27 PM   #46
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Default Re: "Early 90's EZGO - Needs a Rebuild"

I don't take mine to the course (I just beat the hell outta theirs when I'm golfing) but I DO shag a 7-iron around the yard and chase it with mine :)
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Unread 05-25-2011, 08:37 PM   #47
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Default Re: "Early 90's EZGO - Needs a Rebuild"

Quote:
Originally Posted by ScooterMcTavish View Post
So the clutch came off surprisingly easy - it was hard to find a 3/4" fine thread bolt, and I used a reversed 3/8" bolt with 1/2" head as the pusher rod, and it came off pretty easy (though I didn't have the right socket, so had to hammer on a Vise Grip). Gotta say, I'd hate to take out the retaining bolt for the clutch without an impact gun.

However, I go to use the steering wheel puller to take off the flywheel, and yay! The kit doesn't come with the M6 bolts I apparently need to put into the wheel. And the longest bolts my local hardware store had were 2", in other words, 1" too short. Now if I could take the brass oil pump fitting off, it would work with the shorter bolts.

Anyone ever take it off? Easy or hard? Or, should I just wait until I can get the correct bolts? Hacksaw time?

Grumble, grumble.
your on the right track, but i am afraid you will have to be inventive for the longer bolts. don't get desperate and bang on it, it will come off.
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Unread 05-25-2011, 10:23 PM   #48
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Default Re: "Early 90's EZGO - Needs a Rebuild"

Thanks Madoc,

I'm anal enough to do it right, so I'll see if I can get longer bolts tomorrow. Problem I had wasn't the pulling; it was that I couldn't even start the thread on the steering wheel puller because the bolts were too short.

Last thing I want to do after doing all this work is screw something up by being impatient. We're almost at two weeks here, and all I have done is the engine out, clutch off, and the canopy clean with the supports pained black.

Still figure I have at least two weeks of work left, which should be in time for the golf course opening.
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Unread 05-26-2011, 12:04 PM   #49
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Default Re: "Early 90's EZGO - Needs a Rebuild"

Couldnt help but see Madoc's post in a 3pg seal thread where the poster went to a machine shop to have his flywheel removed:

Quote:
ski, that's just not fair. we want to see hair fly and a lot of sceaming.
Well, I PB'd the flywheel yesterday, and got the longer bolts today - think I'll start trying to get it off at lunch today. If any hair flies or screaming begins, I will share my adventures with you.
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Unread 05-26-2011, 01:18 PM   #50
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Default Re: "Early 90's EZGO - Needs a Rebuild"

Well, the bolts were still not long enough, so I used my Dremel to cut off the two pieces at the end of the shaft that would have grabbed the oil injector pump.

OK, so now I got the steering wheel puller on, lots of PB shot all over, and I cannot turn the ratchet any more. Did some hammering on the metal part, and still, no budge.

Can an impact gun be used here, or is that a path to pain and suffering?
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