1991 EZGO won't turn over, running out of options.

[BigDaddy325]

Hi everyone,

My parents bought a dud 1991 EzGo cart that used to barely run but now won't turn over, and I've done all the basic trouble shooting.

When I hit the gas, the starter starts to spin but the engine won't turn over. I've also noticed a bit of gas pooling in the airbox and some backfiring through the connection to the carb, but haven't worked on a lot of carburated engines and figured it was from the repeated attempts at starting.

Things I've already done:

Cleaned spark plugs and checked for spark
Made sure the plugs were getting fuel
Brand new Carb
Tested battery(ies) standing and under load

I just ordered a new starter thinking that maybe it's dying and can't get the engine firing up to speed, because I'm not sure what else could be the culprit at this point.

It's worth mentioning when they bought it last year, it drove pretty sluggishly on flat ground, and could not run up hill at all.

Please help!

[newtjl]

Can you turn the engine over fairly easily by hand?

[BigDaddy325]

Originally Posted by newtjl

Can you turn the engine over fairly easily by hand?

Doesn't seem to have any trouble, not a suspicious amount of resistance?

[cramey]

I'm a bit confused and it my just be the terminology.

You said the engine turns by hand, but won't turn over with the starter - or will it turn over with the starter and simply not start.

If the starter is not turning the engine over - you might want to check all battery connections, wire to the starter engine. If it still doesn't turn over, then check voltage on both top posts of your solenoid. One is hot always (connects to battery) the other is should be hot only when you depress gas.

if you don't get any voltage, you can jumper from one hot to the other to see if you can force it to engage the starter. this will tell you if the starter is bad or the solenoid/key wiring

hope that helps

[cart around]

Do a compression check. The valves probably need to be adjusted.

[BigDaddy325]

Originally Posted by cramey

I'm a bit confused and it my just be the terminology.

You said the engine turns by hand, but won't turn over with the starter - or will it turn over with the starter and simply not start.

If the starter is not turning the engine over - you might want to check all battery connections, wire to the starter engine. If it still doesn't turn over, then check voltage on both top posts of your solenoid. One is hot always (connects to battery) the other is should be hot only when you depress gas.

if you don't get any voltage, you can jumper from one hot to the other to see if you can force it to engage the starter. this will tell you if the starter is bad or the solenoid/key wiring

hope that helps

That's my bad, the starter does turn the engine but it won't start. Just kind of putters. I was thinking the starter could be dying and therefore not strong enough to get the engine up to speed to run.

[newtjl]

Originally Posted by cart around

Do a compression check. The valves probably need to be adjusted.

Good call. If it has fuel and sparkle, it only needs the compression. These engines need valve adjustments fairly regularly to run really well.

[cramey]

based upon the before sluggish performance - the compression / valve adjustment sounds like the right way to go.

[BigDaddy325]

Originally Posted by cart around

Do a compression check. The valves probably need to be adjusted.

I've got a compression tester somewhere, will give it a try. Is that a tough fix?

[cramey]

pretty simple .

Check Youtube for EZGO valve adjustment. There are at least 5 videos which show the process step-by-step.

It took me longer to find my old feeler gauge set - than it took to do the job.

BTW - Manual recommends .004 for gap - many of the videos recommend .006. I'm not sure that there is a huge difference with that small amount, but I would recommend testing compression before & after. Your "after" readings should be be above 120 - - preferably above 150..

If after adjustment you are below 120 - then you probably got bigger issues (rings, pistons, etc...)