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Old 06-30-2011, 10:54 PM   #1
amcjeep
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Default 87 2PG EZGO sputtering

I just bought a 87 ezgo with the 2 cycle 2PG engine. The engine sputters and never smooths out, even when choking it. Has many new parts from the PO. New coil, all tune up parts, compression is 120. I also checked and cleaned the carb.

Is it possible the pulsar coil or ignitor? Any way to test these parts?

Thanks in advance!
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Old 07-01-2011, 07:07 AM   #2
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Default Re: 87 2PG EZGO sputtering

you can test the pulsar by putting a DMM set to ohms on the red and blue wires coming from the engine, you should have between 90-150ohms as a reading (and just to be fully safe, switch the DMM to the lowest AC setting and turn it over, you should get right around a volt if the pulsar is good) ...

As to the ignitor, generally those are good (create spark) or bad (zero, zip, zilch, nada) - and unfortunately, the only reliable test is to replace them.
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Old 07-01-2011, 07:45 AM   #3
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Default Re: 87 2PG EZGO sputtering

The pulsar test good. I even removed the exhaust to no avail. Is there any timing or anything else I should be checking? It feels like a misfire- never smooths out.
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Old 07-01-2011, 07:46 AM   #4
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Default Re: 87 2PG EZGO sputtering

It feels like a misfire- never smooths out- even with the wheels off the ground.
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Old 07-01-2011, 08:24 AM   #5
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Default Re: 87 2PG EZGO sputtering

The little 2PG is remarkable tolerant about timing and as this is a pain to check I would start with the fuel system. Is there a fuel filter in the line? There should be and if it has been there for a while I would replace it. Get one with a nice big clear chamber so you can see the fuel flow. Are you sure that you are not running nasty old fuel? If not then drain it and mix a fresh batch of 128:1 (assuming that the oil pump is removed)

The engine a very intolerant about air leaks so you should check that all the bolts around the carburetor are tight and that the gaskets are in place. If you have any doubts spray some WD40 on the joint and see if the engine changes pitch.

It is also my experience that once a 2 cycle plug craps out it never really works again even after cleaning. Invest a couple of $$ in a new plug.

Finally when you say you cleaned the carburetor, did you take it down to the last nut and bolt and blow out every orifice, nozzle and jet? A lot of guys think that emptying an aerosol of cleaner into the air intake will work and I promise you that it doesn't.

Dave
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Old 07-01-2011, 10:04 AM   #6
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Default Re: 87 2PG EZGO sputtering

good point, Dave - make sure you completely pull and thoroughly clean ALL of the jets in the carb, as even a partial blockage of one port can wreak havoc with your running. Here's a diagram of your carb with the jets circled to aid in removal and cleaning:

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Old 07-02-2011, 01:38 PM   #7
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Default Re: 87 2PG EZGO sputtering

Still sputtering, completely cleaned the carb. Sputters all the time... never smooths out. As far as I can tell there are no intake leaks. Pops back through the carb at times letting off and on the throttle.
Reed valves or something with the internal engine not showing on the compression test?
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Old 07-02-2011, 01:42 PM   #8
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Default Re: 87 2PG EZGO sputtering

The engine may be rattling too hard to tell with the sputtering.
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Old 07-02-2011, 03:10 PM   #9
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Default Re: 87 2PG EZGO sputtering

try this just for fun - I doubt your seals are shot or it wouldn't run but they may be in some stage of "going" ... Jack up the cart so as to avoid any nasty accidents, then start it up and hold it at as steady a low speed as you can. Have a friend spray some WD40 or carb cleaner at the rear of the engine where the crankshaft exits (right up against the block) then do the same spraying at the front of the engine by the intake fan. If either causes an increase in RPM's, you're sucking air at the seals and will need to replace them (which will not affect a compression test, so until you do this test you can't rule them out)
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Old 07-03-2011, 09:29 PM   #10
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Default Re: 87 2PG EZGO sputtering

^^Yup, good test. You can also slip the drive belt off too (instead of the jack stands) if so inclined.

Another thought if the test above doesn't work - it's also good to check the fuel vacuum line that attaches to the cranckcase. This is usually hooked up somewhere near the fuel line, and can be worn and cracked. Even with new seals, I had to replace mine to get my suck on.
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