Repair and Service Guides
The aim of these Repair and Service Guides is to give you guideline instructions and schematics for the range of preventative and corrective maintenance you need to perform on your EZ GO Golf Cart. EZGO carts are simple vehicles with basic replacement parts. The maintenance suggested is easy to carry out and can be done with anyone who is experienced in repairing and maintaining vehicles. Therefore we hope these EZGO Repair and Service guidelines gives you the confidence and assistance to repair your carts hopefully saving you time and money.
RECOMMENDED PREVENTATIVE MAINTENANCE ROUTINES
Daily Routine
| SI.No | Component | Service Description |
| 1 | Body | Clean |
| 2 | Reverse Warning Device | Check operation and replace lights/alarm as necessary |
| 3 | Tires | Check for damage, treath depth(wear) and tire pressure |
| 4 | Fuel Gauge | Check operation and clean as required |
| 5 | Engine Oil | Check and refill as required |
| 6 | Starter Motor Belt | Check for wear and cracks. Ensure correct tension |
Monthly Routine (20 hourly)
| SI.No | Component | Service Description |
| 1 | Battery | Clean battery terminals with baking soda solution of water. Check charge condition and connections are tight. |
| 2 | Wiring | Check for loose / broken connections and degradation of insulation |
| 3 | Accelerator | Check for fluid movement |
| 4 | Service Brake | Check brakes operate correctly and adjust as required |
| 5 | Parking Brake | Check brakes operate correctly and adjust as required |
| 6 | Choke Cable | Check for fluid movement and adjustment |
| 7 | Carburetor Linkage | Check and adjust as necessary |
| 8 | Direction Selector | Check and adjust as necessary |
| 9 | Engine | Listen for changes in noise, vibration, hunting and oil leaks |
| 10 | Cooling Fan | Check for build up of dirt and debris, clean as required |
| 11 | Steering Assembly | Look for too much play or if too stiff |
| 12 | Rear Axle | Inspect for oil leakage. Replace with SAE 30 as needed |
Quarterly Routine (60 hourly)
| SI.No | Component | Service Description |
| 1 | Front Axle | Look for damage, loose or missing fittings |
| 2 | Front Shock Absorbers | Check for oil leaks and loose fittings |
| 3 | Front Springs | Inspect for loose fittings and cracks at footings |
| 4 | Front Wheel Alignment | Inspect tires for wear and align wheels as needed |
| 5 | Parking Brake | Check for damaged linkage rod, wear to latch arm or catch braket and apply light lubrication oil |
| 6 | Rear Shock Absorbers | Check for oil leaks and loose fittings |
| 7 | Engine Electrical System | Inspect coil and spark plugs for loose or deteriorated wires and connections |
| 8 | Fuel System | Inspect fuel tank, cap, lines, filter, pump and carburetor for leaks. Replace any worn or damaged components |
| 9 | Throttle/Governor Linkage | Carry out operation checks and examine governed speed |
Semi-Annual Routine (125 hourly)
| SI.No | Component | Service Description |
| 1 | Rear Axle | Look for damage, unusal noise and loose or missing fittings |
| 2 | Direction Selector | Inspect for wear and fluid movement, lubricate as required. Examine shift cable spring length |
| 3 | King Pins | Inspect for too much play or overtightness of retaining nuts. Lubricate pins with wheel bearing grease |
| 4 | Steering Assembly | Inspect bellows for holes and pinion seal condition for grease leakage. Replace as needed |
| 5 | Air Cleaner | Replace air cleaner |
| 6 | Oil Filter | Either Clean filter in a solvent or replace with new. Always replace 'O'rings. |
| 7 | Engine Oil | Replaced with a SAE 10W-30 or 10W-40 grade oil. |
Annual Routine (250 hourly)
| SI.No | Component | Service Description |
| 1 | Front Wheel Bearings | Adjust in accordance with wheels service guidelines below. Pack with wheel bearing grease. |
| 2 | Rear Axle | Add lubricant (SAE 30) as required |
| 3 | Brakes | Clean and adjust in accordance with breaks service guidelines below. Inspect brake shoe linings |
| 4 | Fuel Filter | Replace |
| 5 | Spark Plugs | Replace and gap plugs to 0.028-0.03 in. (0.71-0.76mm) |
| 6 | Muffler/Exhaust | Check gaskets for leaks and ensure all fastenings are tight |
| 7 | Valves | Check valves as per engine service guidelines below |
500 Hourly Routine
| SI.No | Component | Service Description |
| 1 | Timing Belt | Check tension for signs of wear and damage. Replace if found |
| 2 | Carburetor | Clean in accordance with engine service guideliens below |
| 3 | Cylinder Head and Pistons | Remove carbon buildup. Check valve seats for carbon build up. |
EZGO REPAIR AND SERVICE GUIDELINES
Body and Chassis
Wheels and Tires
Front Suspension and Steering
Speed Control Cables
Engine, Fuel System and Power Train
Brake System
Rear Axle and Suspension
Continuously Variable Transmission (CVT)