1988 EZGO 2 Stroke Single 295cc Repair Manuals

The 1988 EZGO 2 Stroke Single 295cc is a gasoline-powered golf cart engine known for its reliability and simple design. This repair manual covers comprehensive maintenance, troubleshooting, and repair procedures for the 295cc Robin EC25-2PG engine, including carburetion, ignition system, fuel system, cooling system, electrical system, and transmission. Below are key sections for safety, specifications, maintenance procedures, troubleshooting, and parts identification.

Engine Specifications

Key technical details for the 295cc 2-stroke engine.

Safety Precautions

Essential safety procedures before performing any repairs.

1. Disconnect battery cables before working on electrical system.
2. Allow engine to cool completely before servicing.
3. Work in well-ventilated area when handling fuel.
4. Use jack stands when lifting cart; never work under unsupported vehicle.
5. Wear safety glasses and gloves during repairs.

WARNING! Gasoline is highly flammable; no smoking or open flames near work area. Engine components become extremely hot during operation.

Routine Maintenance

Regular maintenance schedule and procedures.

1. Check engine oil level: Use SAE 30 motor oil, check dipstick monthly.
2. Fuel mixture: 128:1 oil to gasoline ratio with oil injection system.
3. Spark plug: Replace every 100 hours of operation (Champion UJ-16).
4. Air filter: Clean foam element every 50 hours, replace if damaged.
5. Battery: Check water level monthly, clean terminals, maintain charge.

CAUTION! Over-tightening spark plug can damage cylinder head threads. Use proper torque specifications.

Fuel System

• Carburetor: Float-type with adjustable idle mixture screw
• Fuel Pump: Pulse-type operated by crankcase pressure
• Fuel Filter: In-line filter between tank and pump
• Oil Injection: Automatic oil mixing system
• Fuel Lines: Check for cracks and leaks regularly

Ignition System

CDI ignition system components and testing procedures.

Components: Spark plug, ignition coil, CDI unit, pulsar coil, starter/generator.

Testing: Check spark plug gap (0.030"), test coil resistance (primary 0.5-1.0 ohms, secondary 5-10k ohms), verify CDI output, inspect wiring connections. Timing: Fixed timing, no adjustment required.

Cooling System

Air-cooled system maintenance and troubleshooting.

1. Inspect cooling fins for debris and clean regularly.
2. Check fan belt tension and condition.
3. Ensure cooling shrouds are properly installed.
4. Verify thermostat operation (opens at 140°F/60°C).

Tip: Overheating can cause piston seizure; maintain clean cooling system.

Electrical System

12-volt electrical system components and testing.

1. Battery: 12V, check specific gravity (1.265 fully charged).
2. Starter/Generator: Test output (14V at 3750 RPM).
3. Voltage Regulator: Maintains proper charging voltage.
4. Solenoid: Engages starter circuit.
5. Wiring: Inspect for corrosion and damaged insulation.

WARNING! Disconnect battery before testing electrical components to prevent short circuits.

Transmission & Drive

Transaxle and drive system maintenance.

1. Check transmission fluid: Use 30W motor oil, change annually.
2. Inspect drive belt: Replace if cracked or worn.
3. Check clutch operation: Primary and secondary clutches.
4. Lubricate rear axle bearings annually.
5. Inspect brake system: Adjust cable tension, check pads.

WARNING! Transmission fluid may be hot after operation; allow to cool before draining.

Troubleshooting Guide

Parts Identification

Major components and part numbers for the 295cc engine.

Torque Specifications

Critical fastener torque values for proper assembly.

• Cylinder Head Bolts: 18-20 ft-lbs
• Spark Plug: 18-22 ft-lbs
• Connecting Rod Bolts: 14-16 ft-lbs
• Flywheel Nut: 50-55 ft-lbs
• Clutch Bolts: 25-30 ft-lbs
• Wheel Lug Nuts: 55-65 ft-lbs

Service Support: Contact EZGO technical support at 1-800-241-5855 for additional assistance.