89 EZGO won't start in reverse w/voltage regulator connected??

panelbeatr · 03-18-2012, 06:51 AM

89 EZGO won't start in reverse w/voltage regulator connected?? Rebuilding basket case 3PG truckster I'd bought for engine for my 87 2PG by accident / it no fit - now finishing its rebuild. Replaced perp diff , refurbished carb and got running yesterday. Runs great in forward mode but won't start with green voltage regulator wire connected up by F/R switch. Could erratic output of charging system be knocking out the spark module?? Very weak - 12.5 volt charge output on new huge group 24 car battery. Planning to add full lighting & headlamps as cart is pre wired for 3 taillights when new but just bundled up. Looking for steering collum switch and low current draw flasher that will work with LED taillights.... Also need brake pedal switch assy - it looks pretty complicated how it keeps brake lights off when brake pedal is locked. Any out there??

panelbeatr · 03-18-2012, 12:57 PM

BTW the generator charges good going forward. Have done exhaustive checking on wireing - everything looks OK. I do have a "loose" small yellow wire with a small eylet end and a 12ga gray wire with a large eyelet...

panelbeatr · 03-21-2012, 10:33 PM

So none of you guys has any ideas??
I may swap out voltage regulator to see if it helps...

Dave Box · 03-23-2012, 09:34 AM

When you say that it doesn't start in reverse, does the engine turn over? If it does then you have some strange symptoms as the only change in reverse is the polarity of the 12 volts to the starter.
I am further confused by your stating that the wiring checks out OK but I do have a "loose" small yellow wire with a small eylet end and a 12ga gray wire with a large eyelet...
There should be no loose wires in there so where are these wires going to?

Here is the test procedure for your regulator

Fully Charge your battery and note the battery voltage

1) Check for loose, broken wiring.
2) Raise rear of cart and attach a volt meter between the regulator's red and black wires.
3) Start engine and run at mid speed, making note of the meter reading.
4) Reading should be between 14 to 16 volts.
5) If reading is above specs, check for a grounded green wire from the starter/gen.
6) If no rise in voltage, disconnect green wire from starter/generator ** and temporarily ground to frame.
7) If voltage rises within specs, replace voltage regulator.

If the voltage does not rise then the generator is defective and the first step would be to check the brushes.

** It is important to place a thin wrench under the wire to prevent the stud turning and ripping the wire off the stud inside the generator

Let us know what transpires.
Dave

panelbeatr · 03-23-2012, 11:49 AM

Quote:

Originally Posted by Dave Box

When you say that it doesn't start in reverse, does the engine turn over?yes spins smartly both directions If it does then you have some strange symptoms as the only change in reverse is the polarity of the 12 volts to the starter.
I am further confused by your stating that the wiring checks out OK but I do have a "loose" small yellow wire with a small eylet end and a 12ga gray wire with a large eyelet...This vehicle is a truckster and has many added wires for lamps and a horn that were just left bundled up when built. I do plan to add the full complement of lights & horns - these wires may be for those features - they are in the vicinity of the starter selenoid
There should be no loose wires in there so where are these wires going to?

Here is the test procedure for your regulator

Fully Charge your battery and note the battery voltage Brand new group 24 car battery that barely squeezed in with foam removed...

1) Check for loose, broken wiring.
2) Raise rear of cart and attach a volt meter between the regulator's red and black wires.
3) Start engine and run at mid speed, making note of the meter reading.
4) Reading should be between 14 to 16 volts. charges 14 volts going forward only
5) If reading is above specs, check for a grounded green wire from the starter/gen.
6) If no rise in voltage, disconnect green wire from starter/generator ** and temporarily ground to frame.
7) If voltage rises within specs, replace voltage regulator.Tried second used but very clean looking regulator last night - same thing

If the voltage does not rise then the generator is defective and the first step would be to check the brushes.

** It is important to place a thin wrench under the wire to prevent the stud turning and ripping the wire off the stud inside the generator

Let us know what transpires.
Dave

I discovered if I started it in reverse, with the green regulator wire disconnected, it would keep running in reverse with it reconnected.... Buying HEI coil & controller today as well as getting a carb intake tube installed - it is really spraying intake charge out the carb, without intake hose installed, somthing I woule expect from a 2 cycle. It has been very hard to start - took starter fluid to get started. Carb removed & jet tube carefully cleaned with welder tip cleaner and has 140# plus compression. New fuel pump and is pumping nicely. Does have fresh fuel installed but is mixed 50:1 because engine has been sitting a long time. Will update tonight unless KU basket ball game takes over ;-0 Thanks for the response ~ Mike

panelbeatr · 03-23-2012, 11:18 PM

Any one else heard of putting panty hose over carb to break up fuel during the fuel ejection / scavenging fuel induction phase??

panelbeatr · 03-25-2012, 03:25 PM

More troubles- I installed new HEI setup - no change in poor running - installed brand new carb (3/4" throat vs 1" stock) ran some better. Disconnected new fuel pump's line to carb (all new lines) and it pumped nicely when engine cranked. I then installed home made intake plumbing taken from a Saab turbo car - ran worse.(see photo) I tinkered with it some more and got it to run somewhat acceptibly so I fitted the rear wheels, dropped it to the ground for its maiden voyage and NOTHING..... Then jacked up the rear diff to remove any engine load and still just kept puffing out little fart sized puffs of smoke. BTW I did diluite the gas back down to 100:1 - the motor look really wet inside and had been ran for at lease an hour on the stronger mix. I pulled the exhaust to see if the piston skirt had collapsed like my PG2 had last year, making it not run for anything. I plan to BBQ my muffler while KU plays today - will that issue prevent if from starting?? New battery,spark plug,coil, HEI,fuel pump throttle & choke cables, replaced diff with used assy..... maybe I should just BBQ the whole thing - just kidding.... photos below of extra wires I mentioned previously that I now know are for lights & horns. Photo of my home brew intake to stock air cleaner. (yes I tried w/o filter installed) My current compression ratio is 155 after running it previously... Any way to test pulser assy??

panelbeatr · 03-26-2012, 07:27 PM

Tearing down engine to replace crank seals and check timing. The HEI coil will throw a 3/4" spark - be careful around it!! It turns out someone had rebuilt the PG3 with a single port PG2 piston.... :-( BTW found a small hand tool to remove crank seals w/crank installed will post soon if it works.

panelbeatr · 03-26-2012, 09:27 PM

Intake tube had gas standing in it - new carb installed ????

Doc's BoneCracker · 03-27-2012, 05:58 AM

Quote:

Originally Posted by panelbeatr

Any one else heard of putting panty hose over carb to break up fuel during the fuel ejection / scavenging fuel induction phase??

Never Heard of this one?

03-18-2012, 12:57 PM	#2
panelbeatr Getting Wild Join Date: Sep 2010 Location: NE KS Posts: 111	Re: 89 EZGO won't start in reverse w/voltage regulator connected?? BTW the generator charges good going forward. Have done exhaustive checking on wireing - everything looks OK. I do have a "loose" small yellow wire with a small eylet end and a 12ga gray wire with a large eyelet...

03-23-2012, 09:34 AM	#4
Dave Box Respect the Cart Join Date: May 2010 Location: Rocky Mount, Virginia Posts: 2,190	Re: 89 EZGO won't start in reverse w/voltage regulator connected?? When you say that it doesn't start in reverse, does the engine turn over? If it does then you have some strange symptoms as the only change in reverse is the polarity of the 12 volts to the starter. I am further confused by your stating that the wiring checks out OK but I do have a "loose" small yellow wire with a small eylet end and a 12ga gray wire with a large eyelet... There should be no loose wires in there so where are these wires going to? Here is the test procedure for your regulator Fully Charge your battery and note the battery voltage 1) Check for loose, broken wiring. 2) Raise rear of cart and attach a volt meter between the regulator's red and black wires. 3) Start engine and run at mid speed, making note of the meter reading. 4) Reading should be between 14 to 16 volts. 5) If reading is above specs, check for a grounded green wire from the starter/gen. 6) If no rise in voltage, disconnect green wire from starter/generator and temporarily ground to frame. 7) If voltage rises within specs, replace voltage regulator. If the voltage does not rise then the generator is defective and the first step would be to check the brushes. It is important to place a thin wrench under the wire to prevent the stud turning and ripping the wire off the stud inside the generator Let us know what transpires. Dave

03-26-2012, 07:27 PM	#8
panelbeatr Getting Wild Join Date: Sep 2010 Location: NE KS Posts: 111	Re: 89 EZGO won't start in reverse w/voltage regulator connected?? Tearing down engine to replace crank seals and check timing. The HEI coil will throw a 3/4" spark - be careful around it!! It turns out someone had rebuilt the PG3 with a single port PG2 piston.... :-( BTW found a small hand tool to remove crank seals w/crank installed will post soon if it works.

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03-21-2012, 10:33 PM	#3
panelbeatr Getting Wild Join Date: Sep 2010 Location: NE KS Posts: 111	So none of you guys has any ideas?? I may swap out voltage regulator to see if it helps...

03-23-2012, 11:18 PM	#6
panelbeatr Getting Wild Join Date: Sep 2010 Location: NE KS Posts: 111	Any one else heard of putting panty hose over carb to break up fuel during the fuel ejection / scavenging fuel induction phase??

03-26-2012, 09:27 PM	#9
panelbeatr Getting Wild Join Date: Sep 2010 Location: NE KS Posts: 111	Intake tube had gas standing in it - new carb installed ????