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Unread 10-25-2012, 04:38 PM   #1
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Default 89 Ezgo 2pg with pinion gear out

I aquired a 89 2pg with the pinion gear out of it and I am wondering how much of a job it is to fix it. I think I know where to get used parts to fix it and I was told it was running when the rear end went out. It's a pretty rough lookin old m/c, but the body is good and no rust. Is it worth fooling with?
I put my 12volt charger on the starter generator and nothing happened, but I could here the solenoid clicking, but that was it. It was sitting out in the open for about 4 years and I am wondering how much weather the electrical parts would take out in the open like that.
Any ideas would be appreciated.
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Unread 10-26-2012, 07:30 AM   #2
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Default Re: 89 Ezgo 2pg with pinion geat out

I would think that if the pinion gear is bad, then the ring gear is bad as well. I have never set up a new ring and pinion but I have heard that on truck axles it requires very careful adjustment/shimming of the pinion bearing in order to be aligned perfectly and to last a long time. Replacing the whole rear axle would likely be the easiest thing to do.

When you say that it was sitting out in the open, do you mean that the roof and seat were off so it was raining directly onto the engine/starter for 4 years?

There are 3 cables on my 1990 marathon starter generator, so when you attach the jumper cables, you would need to hook up to the right combination of 2 terminals in order for the starter to spin. Or perhaps the starter brushes are stuck or the commutator is a little corroded (this can be cleaned with steel wool).
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Unread 10-26-2012, 02:10 PM   #3
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Default Re: 89 Ezgo 2pg with pinion geat out

I hooked the charger to the battery leads, 100 amp starting boost and all I got was a click from the starter switch. It apparently sat out a good part of the time without any cover on the motor compartment. I did notice the coil wire pulled out from the coil that goes to the plug. How does that connect into the coil?
I plan on replacing the complete rear banjo. My main concern is it worth it?, I don't have anything in it, as a guy gave it to me for parts for mine, but nothing regarding the motor fits. They are both 89 models, but mine is a 3pg and motors and clutch and drive components look and mount differently. Getting back to the starter, I didn't have a battery in it, I just connected to the cart's leads and of course the starter was dead.
I'll have a lot of cleaning of the parts and checking out the electrical system, just wondering if I want to take it on.
Got to get my other one going first.
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Unread 10-26-2012, 03:29 PM   #4
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Default Re: 89 Ezgo 2pg with pinion gear out

Yes- you did it right- if you were hooked up to the battery cable then it should have spun the engine if you heard the solenoid click. Maybe the contacts on the big forward/reverse selector switch are really corroded.

If I were you, I'd try to piddle with it a little over the winter and try to see if a good cleaning of switches, terminals and starter brushes/commutator will get the engine to spin and then check to see if the engine has much compression and go from there before you source and buy a rear axle.
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Unread 10-26-2012, 04:03 PM   #5
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Default Re: 89 Ezgo 2pg with pinion gear out

Thanks for the advise!, that's exactly what I'll do. Was there enough crank in that charger to spin that starter? says it's 100amp start boost, I didn't know if that was enough without the battery assist. What about that coil wire, can you just clean it up on the end and stick it back down into the coil?
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Unread 10-26-2012, 05:45 PM   #6
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Default Re: 89 Ezgo 2pg with pinion gear out

I think that a 100 amp start setting should have spun it- you could try it again with the spark plug out.

The hole in the coil where the wire goes has a coarsely threaded terminal in the center (it looks like a wood screw sticking up). Just push the wire into the hole and twist the wire 2-3 turns as yo are pressing it into that hole in the coil.
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Unread 10-26-2012, 05:56 PM   #7
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Default Re: 89 Ezgo 2pg with pinion gear out

Man, You've have been a world of help to me, I want you to know how much I appreciate all your time patiences and expertise, Many thanks Erik!!
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Unread 10-27-2012, 05:52 PM   #8
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Default Re: 89 Ezgo 2pg with pinion gear out

Cut off about 3/4 of an inch before reinstalling in the coil.

LOU
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Unread 10-27-2012, 07:36 PM   #9
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Default Re: 89 Ezgo 2pg with pinion gear out

This may be a dumb question but you did try and spin the motor by hand to make sure it's not seized, yes?

Ring and pinion isn't that hard to setup but you would need the proper shims like Kyerik said. Plus, you'd have to have all the specs for setting up. Here's a video of how to do it if you're curious...
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Unread 10-28-2012, 09:16 AM   #10
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Default Re: 89 Ezgo 2pg with pinion gear out

The motor will turn and is not seized, I pulled the plug and shot oil in it and it will turn. The guy who gave it to me swears it was running when the rear end went out.

Man, is that your shop?, it looks like you could eat off that work bench!!
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