1987 EZ Go Gas Golf Cart Service Manual

The 1987 EZ Go Gas Golf Cart is a reliable utility vehicle featuring a 2-stroke gasoline engine, forward/reverse transmission, mechanical brake system, and durable steel frame. This service manual covers maintenance procedures, troubleshooting, repair instructions, and technical specifications for proper servicing and operation. Below are key sections for safety, technical specifications, maintenance procedures, troubleshooting, and repair guidelines.

1. Technical Specifications 2. Safety Precautions 3. Routine Maintenance 4. Engine Service 5. Transmission & Drivetrain 6. Brake System 7. Electrical System 8. Steering & Suspension 9. Troubleshooting Guide 10. Parts & Diagrams

Technical Specifications

Key components: 2-stroke gasoline engine, forward/reverse transmission, mechanical brake system, steel frame construction.

Specification	Description
Engine Type	2-stroke gasoline engine
Displacement	244cc
Fuel System	Carburetor with fuel pump
Transmission	Forward/Reverse gear system
Brake System	Mechanical drum brakes
Frame	Steel construction
Weight Capacity	800 lbs maximum
Fuel Capacity	5 gallons
Oil Type	2-stroke oil mixture
Tire Size	18 x 8.50-8

Safety Precautions

Always follow safety procedures when servicing the golf cart.

Park on level surface and engage parking brake before servicing.
Disconnect battery cables when working on electrical system.
Allow engine to cool before performing maintenance.
Use proper lifting equipment when raising the cart.
Wear appropriate personal protective equipment.

WARNING! Gasoline is flammable; no smoking near fuel system. Engine parts become hot during operation.

Routine Maintenance

Regular maintenance ensures optimal performance and longevity.

Daily: Check tire pressure, fuel level, and brake operation.
Weekly: Inspect battery terminals, clean air filter.
Monthly: Check spark plug, change oil mixture.
Quarterly: Inspect brake pads, adjust throttle linkage.
Annually: Comprehensive inspection of all systems.

CAUTION! Use only recommended fluids and parts. Follow proper disposal procedures for used oil and filters.

Engine Service

Spark Plug: Gap 0.030 inches, replace every 100 hours.
Air Filter: Clean with compressed air, replace if damaged.
Fuel Filter: Replace every 200 hours or annually.
Carburetor: Adjust idle speed to 1200 RPM.
Compression: Minimum 90 PSI for proper operation.
Oil Mixture: 50:1 gas to oil ratio.
Cooling System: Air-cooled, keep fins clean.

Transmission & Drivetrain

Forward/reverse transmission with chain drive system.

Maintenance: Check transmission fluid level monthly. Inspect drive chain tension and lubricate regularly. Replace worn sprockets and chains as needed.

Transmission fluid: Type A automatic transmission fluid. Chain tension: 1/2 inch deflection at midpoint. Sprocket alignment: Ensure proper alignment to prevent premature wear.

Brake System

Mechanical drum brakes with parking brake feature.

Park cart on level surface before brake adjustment.
Adjust brake cable tension for proper pedal feel.
Inspect brake shoes for wear every 6 months.
Replace brake cables if frayed or damaged.

Tip: Test brakes at low speed after adjustment to ensure proper operation.

Electrical System

12-volt electrical system with battery, starter/generator, and ignition system.

Battery: Check water level monthly, clean terminals.
Starter/Generator: Test output voltage (13.5-14.5V).
Ignition System: Check points gap (0.020 inches).
Lights: Test headlights and taillights regularly.
Wiring: Inspect for damage or corrosion.

WARNING! Disconnect battery before electrical work. Avoid short circuits.

Steering & Suspension

Rack and pinion steering with leaf spring suspension.

Steering: Check for play in steering wheel. Adjust tie rod ends if necessary. Suspension: Inspect leaf springs for cracks. Lubricate suspension points every 3 months. Wheel bearings: Repack annually with high-temperature grease.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel level, spark plug, compression test.
Poor performance	Air filter, carburetor	Clean air filter, adjust carburetor mixture.
Brakes not holding	Worn shoes, adjustment	Adjust brake cables, replace worn shoes.
Electrical failure	Battery, connections	Test battery voltage, clean connections.
Transmission noise	Chain tension, sprockets	Adjust chain tension, inspect sprockets.

Reset: Disconnect battery for 5 minutes to reset electrical system.

Service: Contact authorized EZ Go service center for major repairs.

Parts & Diagrams

Genuine EZ Go parts recommended for replacement. Refer to official parts manual for detailed diagrams and part numbers.

Common Replacement Parts: Spark plugs, air filters, brake shoes, drive chains, battery, tires.

Ordering: Use model number and serial number when ordering parts. Serial number located on frame near passenger side.