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Old 07-22-2021, 12:21 PM   #1
insandity290
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Default 1986 EZGO 2PG Top End Problems

Hello! I am not new to BGW but this is my first help post, so please forgive me if this is the wrong place.

Anyways - I have a 1986 EZGO (new to me) that sounded like it was revving to the moon but hardly moves, even having the rear end off the ground. The belt ran up on the clutches fairly well, although the drive clutch is a little wore out, and the belt paused about halfway before climbing on up. The cart just sounded like it was struggling pulling me (200 lbs) around my relatively flat yard. Compression was 90 psi, so I decided to tear it down to rebuild it.

I got to looking at the piston and it is a 0.25 over so someone has had this apart in the past. After looking harder at it, the piston doesn't have an intake window. Could this be one of the major issues going on here? If this engine is supposed to have an intake window on the piston, surely it isn't getting enough air/fuel to run correctly? The piston rings also have a tremendous gap, like 1/4 to 1/2 inch, where I believe they should be 0.010 to 0.016. The cylinder looks fine, no scarring or damage, so I ordered a new 0.25 over piston/rings/gaskets. Just wanted to get some input on the intake window on the piston and see what you guys think about that issue, but wanted to provide a little background as well. Thanks in advance!
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Old 07-22-2021, 12:33 PM   #2
Dabble Inn
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Default Re: 1986 EZGO 2PG Top End Problems

Wow, sounds like a way wrong rebuild. Yes it needs the window and be sure to install it towards the intake side, since it's such a wrong piston it makes me wonder what .025" over is actually over what? Perhaps it's .025" over whatever it's suppose to go in and your bore could still be stock size??

I'd get the mic out and start measuring to be sure, good luck
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Old 07-22-2021, 12:44 PM   #3
insandity290
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Default Re: 1986 EZGO 2PG Top End Problems

Quote:
Originally Posted by Dabble Inn View Post
Wow, sounds like a way wrong rebuild. Yes it needs the window and be sure to install it towards the intake side, since it's such a wrong piston it makes me wonder what .025" over is actually over what? Perhaps it's .025" over whatever it's suppose to go in and your bore could still be stock size??

I'd get the mic out and start measuring to be sure, good luck
Thanks for the quick reply, my thoughts exactly. I measure the bore of my cylinder and it is 2.844, roughly 0.009" over stock. To me, it seems like someone took the cylinder to a local shop, NAPA, something, and said to find a piston that fits. I read that someone was using a Polaris piston and machining the window into the piston for their rebuild, so I am thinking that whoever chose to put this piston in got the Polaris piston due to its size/wrist pin location, etc and didn't machine the window.
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Old 07-22-2021, 01:48 PM   #4
Dabble Inn
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Default Re: 1986 EZGO 2PG Top End Problems

Ohh buoy, lovely..... Ok, Think I'd get a .25" over Ezgo piston/rings and have a machine shop mate it to the cylinder
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Old 07-22-2021, 02:16 PM   #5
insandity290
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Default Re: 1986 EZGO 2PG Top End Problems

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Originally Posted by Dabble Inn View Post
Ohh buoy, lovely..... Ok, Think I'd get a .25" over Ezgo piston/rings and have a machine shop mate it to the cylinder
That's exactly what I am going to do. Thanks for your help!
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