Preventive and Routine Maintenance

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EZGO Golf Cart Preventive and Routine Maintenance - GAS

Throttle Cable Adjustment:

Adjustment: To adjust the throttle cable, check to ensure the throttle plate is fully closed and governor arm is rotated fully counter-clockwise. By the throttle cable bracket are two nuts (1/2 inch). Loosen the nut toward the rear of the car, and tighten the nut on the front of the bracket. Periodically check to ensure the throttle plate remains closed as you tighten. Tighten them tight enough to open the throttle plate fully. As a final check, press the acc pedal and listen for the acc micro switch to click. The throttle plate should not move for a few more CMs after the switch clicks. Adjusting this won't pick up a lot of speed, however, it will open the throttle plate fully so as the reach the correct top speed.

Governor Compression Spring Adjustment - For Factory Settings:

Note: Hold the accelerator cable when removing/adjusting the compression spring lock nut. Failure to hold cable will cause the accelerator cable to twist which may cause premature failure.

Pre-adjust the governor compression spring by rotating the nut until a dimension of 2 1/2" is achieved between the back of the accelerator cable bushing and the outside of the cup washer. This dimension is a pre-adjustment and may be further adjusted after a road test.

Starter/Generator Belt Tension:

A: New Belt: Tighten a NEW starter/generator belt to 90-110lbs. tension when a gauge is applied half way between the two pulleys.

B: Although not as accurate, a NEW belt may be depressed with a finger. A maximum deflection of 3/8" is acceptable

Existing Belt: Re-tighten an existing belt to 75-80 pounds using the same technique as listed above in A. A maximum deflection of 1/2" is acceptable when depressed with a finger.

Adjusting the Belt: Located behind the belt, and attached to the starter/gen. is a tension arm.

While holding down the lower adjusting nut with a 9/16" wrench, loosen the upper jam nut with another 9/16" wrench. Move the lower nut up or down until proper belt tension is reached. Hold the lower nut in place and tighten the upper nut.

Note: After adjusting some belts, the starter/gen pivot bolt can become slightly loose. Using a 3/4" socket and open end wrench, tighten the pivot bolt if needed.

Spark Plugs:

Using a 13/16" spark plug wrench, remove the spark plugs at 250-300 hours or annually and inspect. Replace the spark plugs with NGK brand BPR4ES, and gap to .028"-.030".

Note: If a plug has been burned beyond .035" it should be replaced

--Fouled spark plugs are indicated by a wet, black appearance. This could be caused by a dirty air filter element or other restrictions in the air intake system. Incorrectly adjusted valves, spark plug wires which are in poor condition or poor quality fuel could also contribute to the problem. Use NGK BPR4ES (resistor plugs) for replacement.

Tighten spark plugs to 18 ft. lbs. (24 Nm) torque.

Caution: Use care not to over tighten the plugs. Over tightening can cause damage to the aluminum cylinder head threads. Use an anti-seize compound on the threads.

*Above settings and torque specs are per E-Z-GO Service Manual 1996-2002*
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