Here I go again! EZGO 4x4 project

garydee · 04-25-2011, 12:22 PM

Here I go again, another new project! I found an EZGO ST4x4 that really needed some TLC and followed me home. It has a strong sounding 18HP Honda V. Though needing a new CVT clutch (the stock ones are known to be weak), it looks like it has some good potential.

I’m thinking 26’s or 28’s, possibly a 1 to 2 inch lift (depending on half-shaft angles). This should be fun!

scotth89 · 04-25-2011, 02:04 PM

Nice...I want one.

sak00 · 04-26-2011, 11:00 AM

I can't even leave you alone for a week without you losing your mind. You SUCK!!

Can't wait to see it up and running. 26" or 28" tires? I think someone has tire envy. Hee, hee, hee.

garydee · 05-02-2011, 10:53 PM

Well, we got a used clutch for the beast (thanks Big Mule) and was able to get it on the road for its "first shake" down drive. First impressions, it’s a powerful son-of-gun! Seems faster that my Cushman. Steered good, brakes real good. Little noise from possibly the secondary clutch – still checking that out. Turned well in 2 wheel drive. Locked in, a different story. Just as I thought, front CV’s have issues, mainly the drivers side. Ill have to try cross referencing replacements for those. I read somewhere they are like a Polaris CV half shafts. This will take some digging.

One thing I noticed on this one is that it sets higher in the front end than most I have seen (which is not many). I would like it down in the front to get the CV angles better. I’ll play around with that when I install some new strut bushings. Oh what fun!

sak00 · 05-03-2011, 06:27 AM

Mmmmmm........Sound like a pleasant surprise so far. Hopefully the CV axles won't be a big deal.

garydee · 05-03-2011, 08:39 PM

I have decided that it’s best to first focus on lowering the front end to straighten the CV shaft angles. Looking at this ST4X4, it sits up higher than all the other pictures I have seen.

At first my thoughts were that someone had possibly moved the struts higher in the holders as sort of a make-shift lift. After closer inspection, I could see they were seated properly. After knocking the dirt off the strut labels I found something interesting.

The guy I bought this cart off as said it was some type of EzGo prototype. I discounted this because I know that these were mass produced between 2005 though (I believe) 2008.

The label on the shock said “Monroe” with a date of 2003. Even the part of the label that should show the part number had “TBD” (to be determined); “for development and testing only”. Just my luck, another odd-ball.

Later model ST4x4’s have the strut coil spring just above the strut holder – these are a good 3 inches higher, giving it the unwanted extra lift or extra stiffness for some reason. The last picture below is what the later model struts look like.

Now I will have to debate the next step; either find a shorter strut or fabricate a bracket to move the top higher in the upper mount. Where’s my “easy” button?

Marathon Man · 05-03-2011, 09:04 PM

This was the cart ezgo dropped all knowledge of lol

garydee · 05-24-2011, 10:58 PM

Quote:

Originally Posted by Marathon Man

This was the cart ezgo dropped all knowledge of lol

I believe that! Parts will suck you dry if you can find them!

Still getting a good feel for this project. We have been driving it a couple times a week to build confidence that we have a decent cart to start with, and I believe we do.

Fixed the worn out bushings in the front struts - We decided to leave it higher in the front and just lift the rear about 2 or 3 inches. This should even it out the stance and make clearance for the larger tires. Considering that this cart is about 7 inch's wider than a regular EZ-GO, I'm confident the handling will still be acceptable. After more research, I believe that the CV angles are still within working range. After all, they built it this way!

For now, I'm working with the carburetor tackling a bit of an idle issue.

Looking forward, I came up with an idea for the worn out Locker actuators. These carts come with electric solenoids on the outside of the diff's - ya.. good idea Ez-Go! Considering the replacements costs are over $100 each, I'm going to convert these to pneumatic cylinders. MAN I loves these projects!

garydee · 05-28-2011, 10:01 PM

More work done this week. Did an oil/filter change, changed differential fluids (the front looked like new) and greased the drive shafts. I also adjusted the engine valves. The transmission / transfer case takes “tractor fluid” called Mobilfluid 424 or Castrol Universal Tractor Fluid – never heard of this stuff before now. I only need a couple of quarts, but so far I have only found this in 5 gallon buckets. Any ideas?

After screwing with the old carb, I fixed the idle issue the easy way – I got a new carburetor. Now it purrs! I also ditched the electric fuel pump setup the previous owner put on it and replaced the broken; stock engine fuel pump. Now it’s the way it should be.

Got a new clutch that will be a bit more reliable and I feel comfortable that it won’t come apart like the stock "2 ramp" ones did (see the picture). It’s also has a much smoother engagement.

This drive clutch is .25 inches smaller that the stock one, making me wonder about the engine RPM. In this cart setup, the governor that limits the RPM is on the transmission / transfer case (not on the engine) – so it will spin the engine up until the governor feels the proper input RPM (this is going through the CVT).

Another thing that is confusing, some Honda manual’s say the maximum RPM is 3,600 – then I saw another spec for 3,800. Being that this engine has some hours under its belt, I’d rather be conservative with this setup. On my shake-down run it screamed up to 28MPH- that’s 3 MPH over the stated 25MPH in the brochure. I’ll have to move my “tiny tach” to a place that’s easily readable while driving.

Well it is driving better and better! Next up is the front half shaft replacements or rebuilds.

sak00 · 05-29-2011, 04:32 AM

Too Kool!! Your making better progress than I am on my project. Sounds like the bugs are getting worked out and you got ya a good cart.

04-25-2011, 02:04 PM	#2
scotth89 Not Yet Wild Join Date: Nov 2010 Location: Conroe, TX Posts: 46	Re: Here I go again! EZGO 4x4 project Nice...I want one.

04-26-2011, 11:00 AM	#3
sak00 What was I thinking? Join Date: Jul 2009 Location: Brooksville, Florida Posts: 577	Re: Here I go again! EZGO 4x4 project I can't even leave you alone for a week without you losing your mind. You SUCK!! Can't wait to see it up and running. 26" or 28" tires? I think someone has tire envy. Hee, hee, hee.

05-02-2011, 10:53 PM	#4
garydee Getting Wild Join Date: Oct 2009 Posts: 133	Re: Here I go again! EZGO 4x4 project Well, we got a used clutch for the beast (thanks Big Mule) and was able to get it on the road for its "first shake" down drive. First impressions, it’s a powerful son-of-gun! Seems faster that my Cushman. Steered good, brakes real good. Little noise from possibly the secondary clutch – still checking that out. Turned well in 2 wheel drive. Locked in, a different story. Just as I thought, front CV’s have issues, mainly the drivers side. Ill have to try cross referencing replacements for those. I read somewhere they are like a Polaris CV half shafts. This will take some digging. One thing I noticed on this one is that it sets higher in the front end than most I have seen (which is not many). I would like it down in the front to get the CV angles better. I’ll play around with that when I install some new strut bushings. Oh what fun!
garydee Getting Wild Join Date: Oct 2009 Posts: 133

05-03-2011, 06:27 AM	#5
sak00 What was I thinking? Join Date: Jul 2009 Location: Brooksville, Florida Posts: 577	Re: Here I go again! EZGO 4x4 project Mmmmmm........Sound like a pleasant surprise so far. Hopefully the CV axles won't be a big deal.

05-03-2011, 09:04 PM	#7
Marathon Man Gone Wild Join Date: Aug 2010 Location: brooksville fl Posts: 412	Re: Here I go again! EZGO 4x4 project This was the cart ezgo dropped all knowledge of lol

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05-29-2011, 04:32 AM	#10
sak00 What was I thinking? Join Date: Jul 2009 Location: Brooksville, Florida Posts: 577	Re: Here I go again! EZGO 4x4 project Too Kool!! Your making better progress than I am on my project. Sounds like the bugs are getting worked out and you got ya a good cart.

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