83 2pg starts when jumped but not otherwise

MoBell412

Im very green when it comes to these carts and their workings, and im having some starting issues with my 1983 marathon. Im getting 12v at the battery before cranking, and the motor will crank and crank ( quickly at first, then more delayed after the first few turns) but wont fire up. If I hook up jumper cables it'll crank right up and run with force but when I take the cables off it slowly dies. My first thought is starter/generator. I checked all the cables and connections and they're old but still very much intact and tightened. Most of the wiring other than these thick red cables looks like they were rigged up by the previous owner. Any one have a wiring diagram for this? Im finding a lot of wires that were cut, most of them being ground wires. Any input is appreciated. I have an automotive multi meter but honestly don't know where to begin other than checking the battery for 12 v . Im not sure how to locate anything else because like I said, Im extremely new to all this. Thanks in advance,
-Matt

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BGW

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Dave Box

OK Matt, there is nothing too complicated here so let's fix this thing.

It sounds to me like the battery isn't charging and as long as you have a strong booster battery it will run. That is actually a good sign as getting the 2PG to run can be miserable. So first off I can see from image three that you have a large braid from the battery negative to the chassis. Remove the end from the chassis and clean the frame to bare metal, also clean the wire lug to ensure that you have a great ground. From that point there should be three wires,

1. The braid to the battery
2. A cable to the forward reverse switch
3. A ground to the engine block.

Once you are happy they are all there and clean then fully charge your battery. Now jack up the rear end or remove the drive belt so it doesn't run away from you. Connect your meter to the battery and look for about 12.5 volts. Start the engine and get up up to a nice fast idle, say 2000 rpm (don't over do it) Now does the meter read 14.5 (ish) volts?

If not you have, as I suspect a charging issue which is probably the regulator or the generator. It is easy to test which it is but we can save that for the next post.

In the meantime here is a manual for the 86 which is essentially the same.

Dave

Attached Files

85-EZGO(2).pdf (6.71 MB, 0 views)

jlloyd

Not to high jack the thread but I bought an 86 ezgo yesterday and the guy I got it from said he could crank it to show me it runs, we'll he hooked a monster battery charger with like a 200 amp jump start setting to the battery (because he said the battery was weak) and sure enough it turned over really fast for about 10 seconds then fired up.... So we snatched the cables off real quick and loaded it on the trailer after I got home I decided to see if the battery in it would crank it.... I pushed the gas and it turned over and over but would not start. So I had a brand new battery that I bought last weekend for the other cart I'm rebuilding so I put the new battery in the cart,... But same thing
It would just turn over and over but not crank, I Tried everything even starting fluid and nothing. I done a compression check and it was pushing 100 psi.
Also I looked down at the crank shaft seal on the clutch side and the rubber part if the seal was out on the shaft and tore from it metal part so thinking that was the problem I turned the motor over while spraying starting fluid all over the seal and shaft also behind the flywheel..... And still nothing,
I think the battery jumper was turning it over so fast it just couldn't help but fire up
While the new battery maybe won't turn it over fast enough with bad crank seals and low compression... Maybe he has the same problem???



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jlloyd

I say if you know you are using a good battery, check crank seals and top end compression


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