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Old 01-10-2018, 07:27 PM   #1
flywise
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Default Golf cart engine rebuild

My golf cart is an 88 ezgo that suddenly quit a few months ago. I figured our cart days were done because I'm not paying thousands for a newer one. I searched you tube for engine rebuild vids and found a series on an engine exactly like mine and it did not look very difficult so I ordered parts. They should be here next week. I got the engine out and pulled apart. Never done anything like this so it may be a complete failure in the end but parts with shipping was less than $300 so it won't be a giant loss if it does not work out.
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Old 01-10-2018, 07:30 PM   #2
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Old 01-10-2018, 07:46 PM   #3
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Good luck Kirby. Keep us updated on your progress.
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Old 01-10-2018, 08:22 PM   #4
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Good luck Kirby. Keep us updated on your progress.
Yes sir, ill do my best to provide a lot of pictures and hope they are helpful to someone else some day
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Old 01-10-2018, 09:57 PM   #5
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I'll follow along just because.

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Old 01-10-2018, 10:02 PM   #6
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we bought one on Ebay and had it installed, Good luck
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Old 01-10-2018, 10:59 PM   #7
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Cool project.

If the rebuild doesn’t work, you may as well add a 20HP V-twin.

Lots of swap info for them.



I went to the woods because I wished to live deliberately...

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Old 01-10-2018, 11:18 PM   #8
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Cool project.

If the rebuild doesn’t work, you may as well add a 20HP V-twin.

Lots of swap info for them.



I went to the woods because I wished to live deliberately...

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I thought about a swap like that but i believe you loose reverse.
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Old 01-19-2018, 09:30 AM   #9
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Looks like the parts will arrive today.
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Old 01-19-2018, 11:20 AM   #10
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Tag and bag all the parts so you will know where they are and where they go back to. If you hone the cylinder, be sure and wash it with warm soapy water at least twice and dry completely. Wipe the cylinder walls with a white towel until there is nothing showing on the white towel. You can also wash with acetone. Light weight oil on the rings and piston, blue assembly lube on bearing parts.
When you finish and you still have parts left over don't worry.
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Old 01-19-2018, 11:38 AM   #11
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Looks like a fun project. Keep us posted.
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Old 01-19-2018, 11:40 AM   #12
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Keep us posted! Following....
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Old 01-19-2018, 05:39 PM   #13
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Quote:
Originally Posted by muzzlebrake View Post
Tag and bag all the parts so you will know where they are and where they go back to. If you hone the cylinder, be sure and wash it with warm soapy water at least twice and dry completely. Wipe the cylinder walls with a white towel until there is nothing showing on the white towel. You can also wash with acetone. Light weight oil on the rings and piston, blue assembly lube on bearing parts.
When you finish and you still have parts left over don't worry.
I bought a new cylinder head.The old one was damaged pretty bad.
These parts look good ( from India I believe).
I'm taking everything to work with me tomorrow so tomorrow afternoon I'll post more pic's. Hopefully sunday I can install it and drive it around a little.
Most likely it will be sometime next week before I get to run it
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Old 01-19-2018, 05:47 PM   #14
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Watching this


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Old 01-20-2018, 10:59 AM   #15
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Got the parts yesterday but did not have time to work on the project. I was planing to bring the engine with me to the FD this morning but for the first time in more than 10 years I forgot to set my alarm. Luckily my internal clock woke me up just 15 min late but I was in a hurry so didn't have time to load it.
Anyway here are the parts, from India. They seem as well built as the original parts so I have some confidence going forward.

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Old 01-20-2018, 01:06 PM   #16
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Hope them pistons are already fitted to the cylinder and the rings already gapped. If not, google and youtube is your friend. Don't just throw them together without checking. Typically the ring gap is .018 to .025. If you place a ring inside the bore you can measure the gap with a feeler gauge. Be sure to put the ring back in the piston with the same side up as it came with, assuming it was on correctly to begin with. Some rings have a chamfered edge or a tiny pip mark that must be installed toward the top of the piston.

Last edited by muzzlebrake; 01-20-2018 at 01:15 PM..
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Old 01-20-2018, 01:08 PM   #17
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Quote:
Originally Posted by muzzlebrake View Post
Hope them pistons are already fitted to the cylinder and the rings already gapped. If not, google and youtube is your friend. Don't just throw them together without checking.

Ill.check into it
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Old 01-21-2018, 06:35 PM   #18
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Made a little progress
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Old 01-21-2018, 06:39 PM   #19
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Got home from church and jumped into this deal. Little snag getting that piston in but not terrible.



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Old 01-21-2018, 06:48 PM   #20
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https://youtu.be/GYIlBnMqtk4

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Old 01-21-2018, 07:06 PM   #21
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Sorry I didn't take a ton more pictures but in all honesty there were not very many steps to this deal. I've never rebuilt an engine or in this case the top end of an engine. That said I've always been one to at least try new things especially when there really is no negative to be had. It was burned up so probanly nothing I could do to make it worse. If the lower end is good I'd encourage anyone to rebuild a top end. It's a very simple process. Tomorrow I'll mix some fuel and actually drive it around a little. I ran it only as long as the vid. Because I don't want to burn it up with straight gas.
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Old 01-21-2018, 07:11 PM   #22
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Funny. I've got a cart like that and I've never added oil to gas...
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Old 01-21-2018, 07:26 PM   #23
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Funny. I've got a cart like that and I've never added oil to gas...
Start adding some ( 50/1 )
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Old 01-21-2018, 07:36 PM   #24
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This was cool reading how you did the rebuild of the top end. I have not done a rebuild of small motors. Very cool.
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Old 01-21-2018, 07:48 PM   #25
flywise
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This was cool reading how you did the rebuild of the top end. I have not done a rebuild of small motors. Very cool.
It was much easier than I anticipated.
Thank goodness
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Old Yesterday, 12:45 PM   #26
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curious as to why your adding oil if its not a 2 stroke?
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Old Yesterday, 12:54 PM   #27
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curious as to why your adding oil if its not a 2 stroke?
me too.
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Old Yesterday, 03:15 PM   #28
flywise
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Quote:
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curious as to why your adding oil if its not a 2 stroke?
It is a 2 stroke
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