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Old 11-12-2011, 04:18 PM   #1
mattpatt
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Join Date: Oct 2011
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Default The journey begins... 85 EZ Go

First things first.... Here's the pic of what my cart looks like...



Purchased for $200 from a friend of a friend who said it ran fine then all of a sudden got to where it didn't have any power. Did the customary changing of the fuel lines, cleaning of the gas tank, new gas, new fuel filter and cleaning of the carb. This helped a little but cart was till way down on power then it got to where it wouldnt run at all. Did compression test and had 30psi. So time for rebuild.

With help from my Dad I managed to get the motor out of the cart and the clutch off.





While I had the motor out I took the opportunity to work on the muffler. I took it to my work and had it bead blasted and it came out looking like this.



So this is where I stand at the moment. I just tested the crank shaft and there is a tiny bit of movement up and down left and right so I think I'm probably going to need the full kit instead of just the top end. Next will be the task of getting the flywheel off.

Matt
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Old 11-12-2011, 07:06 PM   #2
1lane66
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Location: MEMPHIS TN.
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Default Re: The journey begins... 85 EZ Go

Matt looks a lot like mine,,87, wasn't in much better shape either. paid $300 for mine and since then have put close to $1000 more in it and still unable to get it to run at top speed. But it's been educational. One day I'll figure out what I'm doing wrong in not being able to get mine to run properly. Good Luck with your project and lots of knowledge here at buggies. Donald
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Old 11-12-2011, 09:29 PM   #3
mattpatt
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Default Re: The journey begins... 85 EZ Go

This thing has seen it's better days for sure. This is going to be a slow rebuild process since I don't just have $1000 to plop down on the table and get everything that I will need at one time.
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Old 11-13-2011, 12:06 PM   #4
1lane66
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Default Re: The journey begins... 85 EZ Go

Understand that, I took on a few side jobs out of my shop to get a few things I needed up front and the rest has been as I go. There are a few pics of mine in my profile sections. It's been a head ache at times but like I said it's been educational. Just don't let it get to you on the days it just doesn't seem to go right. Have fun
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Old 11-18-2011, 09:37 PM   #5
mattpatt
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Default Re: The journey begins... 85 EZ Go

Got the flywheel pulled today. Soaked it in PB Blaster for a day or so and it popped right off with the flywheel puller. My goal for tomorrow is to get the motor completely tore down and we'll see how bad the damage is.
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Old 12-30-2011, 03:44 PM   #6
mattpatt
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Default Re: The journey begins... 85 EZ Go

Started the rebuild process today. Got the motor split and the bearings out of one side. I'm having trouble removing the pulser as I'm afraid I'm going to strip the screws (see unable to remove pulser thread). Here are some pics of what I found so far. Please excuse me if I do not use technical terms for some things. This is the first time I've worked on something like this. First off I removed the shroud over spark plug and removed the bolts from around where the spark plug attaches. I noticed one of bolt holes has some damage. Will this cause problems? Bolt hole in lower right hand corner



Also here are some pics of the piston and rings... no wonder it wouldn't run





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Old 12-30-2011, 03:58 PM   #7
Plumbergs
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Default Re: The journey begins... 85 EZ Go

Looks like a fun project, and wow that piston has definitely seen better days! From the looks of that bolt hole, it seems to have enough meat left that with a washer it would snug down fine.
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Old 12-30-2011, 04:15 PM   #8
mattpatt
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Default Re: The journey begins... 85 EZ Go

Thanks for the info. Yeah, I'm having a little issue removing the pulsar plate but other than that everything has been going good. Need to get the bearings pressed onto the new crankshaft. I didn't take a pic of it but the bearing on the pulsar side of the crank was starting to come apart! This motor has seen better days for sure. But I keep telling myself that once I get done I'll have basically a brand new motor. I hope... :-)
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Old 12-30-2011, 04:17 PM   #9
mattpatt
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Default Re: The journey begins... 85 EZ Go

I also forgot to mention that two of the bolts that hold the head down were loose and I could not find any traces of a head gasket.
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Old 12-31-2011, 04:14 PM   #10
mattpatt
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Default Re: The journey begins... 85 EZ Go

Okay got the pulser marked with a punch and got it off. Ended up rounding out one of the screws so I'm going to have to find a replacement. Now I think I'm going to either take both halves of the motor to the car wash for a thorough cleaning or put them in the blast booth at work and have them bead blasted. Haven't decided yet. Here are some more pictures from the tear down. One bearing was shot and both crankcase gaskets were blown too.









Matt
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