86 Ezgo Marathon Intermittent problem

[jwhendy]

I have a 1986 Ezgo Marathon 2cycle 2pg engine. Recently rebuilt the engine with all new bearings, seals, gaskets, piston, rings, carb, fuel pump, air & fuel filters and spark plug. Runs GREAT!! Except for one small problem....

after driving it for a while, come to a complete stop, push accelerator and NOTHING! No "clicking" sound or anything, wait about 30 seconds to a minute and try again, it starts right up and runs great ... This does not happen everytime but usually after driving continuously for a good while then stopping and trying to take right back off? When looking around engine I saw something that looks like maybe a "contact" of some kind that opens and closes as accelerator peddle is pressed and wondering if maybe that "contact" is getting hot and sticking??? Really don't know for sure?? Any help would be greatly appreciated.

[racin161]

Welcome to BGW JW Yes that is a mirco switch and in fact it does activate the starter solenoid and they have been known to stick if dirty or maybe a loose wire at that switch causing you problem. With that said you maybe also want to look at the starter brushes but I would say if your hearing no clicking noise from the solenoid the switch or wiring is the problem. As you can see that switch is prone to come in contact with dirt/water/brush and what ever. Good luck and check back.

LOU

[jwhendy]

Thank you very much for the reply .... I've been reading a LOT of stuf on this forum past couple weeks helping to get this cart up and running .... I am currently working 12 hour night shifts :( so wont be able to mess with it for a few days ... But as soon as i get a chance i will try to "clean" that switch a little and check wiring to it ... Thansk again and will keep ya posted!

[felber61]

Don't mean to snag thread but if your hearing the clicking but there is a 10-15 delay before anything happens does that also point to the micro switch or the brushes?

[racin161]

If it were brushes you would hear the click of the solenoid first then the delay As I read the post there is no click of the solenoid which seems the mirco switch isn't supplying voltage to the solenoid. All help is welcome.

LOU

[jwhendy]

Ok, again, thanks for the replies .... I finally got a lil time off work today and got to mess with cart .... Checked out the microswitch, cleaned it up a little bit (didn't "look" too bad) ... Drove it until it started to mess up and noticed that when accelerator is pressed I can visually see microswitch moving and hear a faint "click" from the switch, however, it is not getting the "big click" from solenoid ..... While holding accelerator down I can tap the side of solenoid and it instantly "clicks" and engine fires right up??? Wondering if my assumption is correct that I have a solenoid going bad?? Again, this is just an intermittent problem, does not happen all the time just after driving it continuously for quite a while then stopping and trying to start right back up??

[holmsey2012]

sounds like a solenoid issue. easy fix just make sure to replace it with a continuous duty solenoid. I made that mistake once used a generic one, didn't last long.

[jwhendy]

Sorry for delay in posting back (work sucks!) LOL but just wanted to update .... Bought a new solenoid and put in cart and so far *knock on wood* it works great!! Thanks again for all the help all!