1986 EZ-GO Golf Cart Service Manual

The 1986 EZ-GO Golf Cart Service Manual provides comprehensive maintenance, repair, and troubleshooting information for the 1986 EZ-GO golf cart models. This manual covers engine systems, electrical systems, braking systems, steering, suspension, body components, and routine maintenance procedures. Below are key sections for specifications, maintenance schedules, troubleshooting, and repair procedures.

1. Features and Specifications 2. Maintenance Schedule 3. Engine Systems 4. Electrical Systems 5. Braking System 6. Steering and Suspension 7. Body and Frame 8. Troubleshooting Guide 9. Safety Precautions 10. Parts and Accessories 11. Warranty Information

Features and Specifications

Key components: Gasoline engine, electrical system, braking system, steering mechanism, suspension system, body frame.

Feature	Description
Engine Type	2-cycle gasoline engine
Horsepower	9 HP @ 3600 RPM
Fuel Capacity	5.5 gallons
Transmission	Forward/Reverse gear system
Battery	12-volt automotive type
Tires	18 x 8.50-8 turf tires
Brakes	Mechanical drum brakes
Steering	Rack and pinion
Suspension	Leaf spring suspension
Weight Capacity	800 pounds

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Daily: Check tire pressure, battery charge level, fuel level.
Weekly: Inspect brakes, steering components, clean air filter.
Monthly: Change engine oil, check spark plugs, inspect drive belt.
Quarterly: Lubricate steering and suspension components, check battery terminals.
Annually: Comprehensive inspection of all systems, replace fuel filter.

WARNING! Always disconnect battery before performing electrical maintenance. Use proper safety equipment.

Engine Systems

2-cycle gasoline engine maintenance and repair procedures.

Oil Change: Drain old oil, replace with SAE 30 motor oil.
Spark Plug: Replace every 100 hours of operation with Champion RJ19LM.
Air Filter: Clean foam element monthly, replace if damaged.
Fuel System: Check fuel lines for cracks, replace fuel filter annually.
Compression Test: Should read 90-120 PSI for proper engine function.

CAUTION! Engine components become hot during operation. Allow to cool before servicing.

Electrical Systems

Battery: 12-volt automotive type, maintain proper water level.
Charging System: Generator charges battery during operation.
Starter/Generator: Combined unit for starting and charging.
Ignition System: Points and condenser ignition system.
Lights: Headlights and taillights standard equipment.
Fuses: 15-amp fuse protects electrical system.
Wiring: Color-coded wiring harness for easy identification.

Braking System

Mechanical drum brake maintenance and adjustment procedures.

Front Brakes: Adjust brake cable tension for proper pedal feel. Rear Brakes: Check brake shoes for wear, replace if lining is less than 1/8 inch.

Brake Adjustment: Park on level surface, set parking brake, adjust until wheels lock. Brake Inspection: Check cables for fraying, lubricate pivot points, test brake function regularly.

Steering and Suspension

Rack and pinion steering with leaf spring suspension.

Turn off engine and set parking brake before inspection.
Check steering wheel play (should be less than 1 inch).
Inspect tie rod ends for wear and proper lubrication.
Check leaf springs for cracks or sagging.
Verify proper wheel alignment and tire pressure.

Tip: Regular lubrication extends component life and improves handling.

Body and Frame

Steel frame with fiberglass or metal body panels.

Frame Inspection: Check for rust or structural damage.
Body Panels: Inspect for cracks, secure all fasteners.
Seats: Check mounting brackets, replace worn upholstery.
Windshield: Clean with mild detergent, inspect for cracks.
Storage: Keep in dry location when not in use.
Paint: Touch up scratches to prevent rust.
Fasteners: Tighten all body bolts and screws regularly.
Accessories: Install only EZ-GO approved accessories.

WARNING! Do not modify frame or body structure as this may compromise safety.

Troubleshooting Guide

Common issues and solutions for 1986 EZ-GO golf carts.

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel level, spark plug, compression test.
Poor performance	Clogged filter, bad plug	Clean air filter, replace spark plug.
Electrical issues	Battery, connections	Test battery voltage, clean terminals.
Brakes not working	Adjustment, worn shoes	Adjust brake cables, replace brake shoes.
Steering problems	Worn components	Inspect tie rods, lubricate steering.

Safety Precautions

Always follow safety procedures when servicing golf cart.

CAUTION! Use jack stands when working under cart. Disconnect battery before electrical work. No smoking near fuel system.

Parts and Accessories

Genuine EZ-GO parts ensure proper fit and performance.

EZ-GO manufactures original equipment parts for all models. Aftermarket parts available but may affect warranty. Common replacement parts: spark plugs, air filters, brake shoes, batteries, tires. For parts ordering, contact authorized EZ-GO dealer with model and serial number.

Warranty Information

Original warranty coverage and service support information.

1986 EZ-GO golf carts were covered by limited warranty from manufacturer. Current service available through authorized dealers. For technical support, contact EZ-GO customer service at 1-800-EZGO-123 or visit www.ezgo.com. Keep maintenance records for warranty claims.