1992 GXT-804 Spruce Up Project (Pics)

[TJsMan]

Hey all, noob here so please forgive me if this post is inappropriate. I picked up a 1992 E-Z-Go Gxt-804 and it's my first cart. I've wanted one for over 15 years! Picked this up as a "does not run" example at a school district sale for $200. I got it home and noticed two fuses were missing. I replaced them and the cart fired up after some coaxing. I'd like to document with pictures my process for cleaning this cart up and getting it to run mechanically sound. Any suggestions along the way would be very appreciated. I'm hoping to make this a collaborative project with my 5 boys (ages 1-12) and help them learn some mechanics and small engine repair principles.

I'll post initial pics from when we bought it below once my 7 day link restriction comes off, it is VERY dirty in the engine bay, but is in very good shape and will clean up nicely. There is also absolutely no problematic rust, just surface rust here and there and not much of it.

I plan to post pics as we make visual progress.

Here's what I've done so far.
- New Generator Belt
- New Drive Belt
- New (Slightly used) tires (the old ones looked like drag racing slicks!)
- New Spark Plugs
- Valve Adjustment (Thanks EZGOMike for a great tutorial on this forum!)

After doing the items above the cart fires right up even when cold. Power seems to be better as well.

Here's what I'll be doing mechanically (any suggestions on what I'm missing are appreciated)
- New Engine Oil
- New Differential Oil (The Manual just says 30W do I need anything special?)
- New Fuel Filter
- New Air filter
- Compression test cylinders
- A negative battery terminal kill switch
- New Choke Cable
- Troubleshoot all lights, (none are working)
- Clean oil filter
- Procure a new gas cap (I have one but it's missing the float gauge)
- Timing Belt replace (eventually)
- Alignment (It looks like it just needs a tie rod adjustment)
- Sort out rattling and vibration (someone on the forum suggested rubber tape where the bed meets the frame)
- Clean and reasonably detail the engine bay (Just get all of the gunk gone!)
- New Coil and Wires (eventually)

Here are the cosmetic/livability items I want to do
- Detail cart exterior and apply plastic restore to cowl and other trim pieces
- Create two "side saddle" seats with lap belts that attach on top of the bed to allow for a couple more passengers
- re-upholster the front seat (items already purchased for this I do my own upholstery work)
- Knock out any rust and overcoat with rust killing paint
- Find or fabricate a canopy
- Install front lap belt
- Install a loud novelty triple horn (already have one)
- Add more front lighting (if the existing headlights aren't adequate at night)

Please chime in if I'm missing something!

[cart around]

You can post pictures right now. Click on the go advanced button. Click on the paperclip. Upload 5 pictures at a time with no restrictions.

[TJsMan]

Originally Posted by cart around

You can post pictures right now. Click on the go advanced button. Click on the paperclip. Upload 5 pictures at a time with no restrictions.

Nice! Thanks for that!

[trig123]

Originally Posted by TJsMan

Nice! Thanks for that!

Good find.

I know you and your family will enjoy this. Just remember when ordering some of the parts you mentioned to buy only OEM ignition parts if you can find them. If it runs and the coil is stock by all means use it. Never buy aftermarket ignitors. Again if it runs yours is good.
This is a Pre Mci engine
The rear end on most of these carts take 30w non detergent. I just buy the walmart cheap stuff
I use 10w30 oil in the engine. 1.5 quarts
Check that compression and let us know what it is. Make sure throttle is wide open when testing. Take one spark plug out at a time when doing this. I usually reach over and remove one of the small wires off coil but thats just me.
A good pressure washing is in order. I cover all electrical stuff with plastic bags.
Check that compression first where you know how the engine is. Good luck.

[TJsMan]

Good suggestion Trig, I will indeed check compression first as it's a pretty good indicator if the engine is on its last legs or not. Will report back.

[TJsMan]

Well all I got around to three more items on my list today.

Compression test:
120 psi dry
125 psi wet
Identical results on both pistons.

Given this is a 30 year old engine and was in service with a school district I’m content with those numbers. It shows some wear but still has some life left. Also afterward I did some further valve adjustment and the engine starts up and purrs, it also has more power so those numbers may be a tad better if I re-tested.

Lighting Issue: I got this issue mostly figured out. I now have headlights and taillights so I can scoot around at night. Though the little orange lights on the sides of the headlights do not come on. Not sure if bulbs are out or if they are some sort of blinker that I no longer have controls for.

Does anyone else have this style of cart and could enlighten me on if the orange lights go on with the headlights?


Kill switch: My ignition is worn out and can be turned with a screw driver so I also thought it prudent to add a secondary kill switch. I also like the thought of cutting power when I’m not using the cart.


Also I took a pic with the bed flipped up. Feeling lucky at the lack of rust, but there’s plenty of gunk to go around.



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[Cartmaster]

those orange lights, i think you will find are just reflectors LOL.

[TJsMan]

Originally Posted by Cartmaster

those orange lights, i think you will find are just reflectors LOL.

Unfortunately not, there are bulbs behind those orange lenses.


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[trig123]

Mine light up but most use them as reflectors as cartmaster said if they don't work.
If you had turn signals then you can get new ones.

Mine were still good so I connected them to my headlight switch. Looks pretty good at night.

That compression is a little low but if it runs then you are fine. I like to see 170 psi on mine. Look good at the two middle valves under cover. See if there are more threads showing where you adjust than two outer ones. Common on these engines for those intakes to pull in head.

Show us a picture of under the valve cover and I can tell right away if sooner or later you will have to replace those valves

[TJsMan]

Thanks Trig will do. I'm betting it may be a tad better in reality, it pulls up steep hills very well (and I'm NOT small) with the latest valve adjustment and I was just using a Harbor Freight gauge set which is likely not perfectly accurate.

So are you saying the two middle valves are intakes? I wasn't sure about that. Also what do you mean by "pull in head?"