1988 EZGO GXT-800 Repair Manual

The 1988 EZGO GXT-800 is a gasoline-powered utility vehicle featuring a 244cc 2-stroke engine, forward/reverse transmission, mechanical brakes, solid rear axle, leaf spring suspension, and 18-inch knobby tires. This repair manual covers maintenance procedures, troubleshooting, parts replacement, and service specifications for the GXT-800 model year. Below are key sections for safety, technical specifications, maintenance procedures, troubleshooting, and parts information.

1. Technical Specifications 2. Safety Precautions 3. Routine Maintenance 4. Engine Service 5. Transmission & Drivetrain 6. Brake System 7. Electrical System 8. Suspension & Steering 9. Troubleshooting Guide 10. Parts & Diagrams 11. Warranty Information

Technical Specifications

Key components: 244cc 2-stroke gasoline engine, forward/reverse transmission, mechanical brake system, solid rear axle.

Specification	Description
Engine Type	244cc 2-stroke air-cooled gasoline
Fuel Capacity	5.5 gallons
Transmission	Forward/Reverse gear drive
Brake System	Mechanical drum brakes
Suspension	Leaf spring front and rear
Tires	18x8.5-8 knobby turf
Payload Capacity	800 lbs
Top Speed	12 mph
Oil Type	2-stroke oil mix 50:1
Spark Plug	Champion RJ19LM

Safety Precautions

Always follow safety procedures when servicing the GXT-800.

Disconnect spark plug wire before performing any engine work.
Use jack stands when lifting vehicle; never work under unsupported vehicle.
Wear safety glasses when working with batteries or fuel system.
Work in well-ventilated area when handling gasoline or oil.

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

Routine Maintenance

Regular maintenance ensures optimal performance and longevity.

Check engine oil level: Verify proper 2-stroke oil mixture in fuel tank.
Air filter service: Clean foam filter every 50 hours; replace if damaged.
Spark plug: Clean and gap to 0.030" every 100 hours; replace annually.
Tire pressure: Maintain 15 PSI in all tires.
Brake adjustment: Check pedal free play; adjust cables as needed.

CAUTION! Use only recommended 2-stroke oil; improper mixture can cause engine damage.

Engine Service

Compression Test: Should read 90-110 PSI at cranking speed.
Carburetor Adjustment: Main jet 1.5 turns out from seated position.
Ignition Timing: Fixed timing; no adjustment required.
Fuel System: Clean fuel filter every 200 hours; replace fuel lines if cracked.
Cooling System: Keep cooling fins clean; ensure proper airflow.
Engine Mounts: Check for cracks or loose bolts every 100 hours.

Transmission & Drivetrain

Forward/reverse transmission with chain final drive.

Service Procedures: Check transmission oil level (SAE 30); inspect drive chain tension (1/2" deflection); lubricate chain with chain lube; inspect sprockets for wear.

Transmission removal: Disconnect battery, remove seat, disconnect shift linkage, remove mounting bolts. Chain adjustment: Loosen axle nuts, adjust chain tension, retighten axle nuts to 65 ft-lbs.

Brake System

Mechanical drum brakes with cable actuation.

Brake adjustment: Turn adjuster nuts at brake rods until proper pedal free play achieved.
Brake shoe replacement: Remove wheel, disconnect brake cable, remove retainer springs.
Cable lubrication: Apply light oil to cable ends and pivot points.

Tip: Test brakes on level surface after adjustment; ensure vehicle stops smoothly.

Electrical System

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

Battery maintenance: Check water level monthly; clean terminals; secure hold-down.
Starter/generator: Test output (13.5-14.5 volts at 1800 RPM).
Wiring inspection: Check for frayed wires, loose connections, corrosion.
Lighting: Test headlights, taillights, brake lights; replace bulbs as needed.
Fuses: Check 15-amp fuse in fuse holder near battery.

WARNING! Disconnect battery negative cable before performing electrical work to prevent shorts.

Suspension & Steering

Leaf spring suspension with recirculating ball steering.

Front suspension: Inspect leaf springs for cracks; check bushings for wear. Steering: Check for play in steering box; adjust if necessary. Wheel bearings: Repack annually with high-temperature grease. Tie rods: Check for loose ends; replace if worn.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check fuel mixture, spark plug, compression test.
Poor performance	Clogged air filter, carburetor adjustment	Clean air filter; adjust carburetor mixture.
Brakes dragging	Cable adjustment, stuck mechanism	Adjust brake cables; lubricate pivot points.
Electrical failure	Battery, fuse, connections	Test battery voltage; check fuse; inspect wiring.
Transmission noise	Low oil, worn gears	Check oil level; inspect for metal particles.

Reset: Disconnect battery for 30 seconds to reset electrical system.

Parts & Diagrams

Genuine EZGO parts available through authorized dealers. Common replacement parts: air filter (EZGO 603256), spark plug (Champion RJ19LM), brake shoes (EZGO 603359), drive chain (EZGO 603471).

CAUTION! Use only EZGO-approved parts to maintain warranty and ensure proper fit.

Warranty Information

Original warranty: 1 year limited warranty from date of purchase. EZGO is a Textron Company. For technical support, contact EZGO Customer Service at 1-800-241-5855 or visit www.ezgo.com. Keep original purchase receipt for warranty claims.