1989 ezgo gxt 800 3pg engine help

[KFD220]

I recently purchased a 1989 ezgo gxt800 gas cart. I have now found that my motor is seized. I believe it has to do with the lower end not the piston. How do I remove the clutch? Also does anyone know the bearing numbers so I can cross reference with an auto parts store? Any other input of things to check or do while I have it pulled apart? I don't have much to spend though because I got burned on this cart already. Thanks in advance for any help and info.

[1989Marathon]

You'll need a puller to get the primary clutch off. I used a short piece of brass bar, and a trailer hitch ball with a 3/4" fine thread. The ball was $6 versus the $25 for the puller. You can also buy a bolt from the hardware store. You basically cut a piece of brass rod and put it into the clutch mounting hole. Then screw the ball/bolt into the clutch. Tighten the ball/bolt and it will push on the brass rod, which pushes against the crank. This will loosen the clutch from the crank. Use the largest diameter brass rod you can so it doesn't drive it's way into the crank bolt hole.
If I recall correctly, the crank bearings are #6208. Get the ones with the open cage. Once you remove the old bearings, you'll see a number on the outer race. You'll need three of them.

[KFD220]

Thank you that's what I needed. Is there anything else that's tricky about these motors?

[1989Marathon]

No, they are pretty simple. Just make note of the shims on the crank(if there are any) when you take it apart. When assembling, use 2-stroke oil on everything, and lube the crank before installing new crank seals.
Why do you think the lower end is seized, and not the piston?

[KFD220]

Because the head is off and the piston and cylinder wall looks pretty good. My dad works on machinery but not these motors and that's his guess also after looking at the piston and cylinder. So basically we are just guessing for now.

[1989Marathon]

Originally Posted by KFD220

Because the head is off and the piston and cylinder wall looks pretty good. My dad works on machinery but not these motors and that's his guess also after looking at the piston and cylinder. So basically we are just guessing for now.

If the head is off, disconnect the exhaust and intake and see if you can lift the jug off. You don't want to split the case if you don't have to.
Plus, if it's the top end, you don't have to pull the motor.

[KFD220]

Ok I already have pulled the engine out to be able to work around it a little easier, but go ahead and take off the jug?

[1989Marathon]

If the jug comes off easy, you know the problem is in the bottom end. The jug needs to come off anyway to work the lower end. Does the crank move at all? There isn't much inside the lower end that will cause it to seize except bearings. Maybe something under the flywheel?
Unless it's been sitting and getting wet for a while, the lower end is bullet-proof.

[KFD220]

Well I just pulled the jug with minimal resistance and still unable to turn the engine by hand. Now I'm almost positive it is the lower end. What do you mean something under the fly wheel? I was hoping to have it going by Sunday for opening day of dove season but it doesn't look like that's gonna happen cuz all the parts houses are closed Saturday.

[1989Marathon]

Maybe something got lodged under the flywheel, but not likely. Is the piston still in good shape with no pieces missing? You will need 3 bearings, 2 seals and gaskets to put it back together. I've never seen one completely locked up because of the bearings. They will usually break loose and feel like they have sand in them because of the rust.