Replacing the electric motor on an EZ-GO golf cart can be done with some common automotive mechanic tools and without an inordinate amount of time and effort for people with some mechanical aptitude. If you are not used to doing mechanical maintenance on a vehicle, get a local experienced EZ-GO shop mechanic to do the job to avoid the frustration and additional cost of not getting the new motor installed properly. Golf courses are a good place to find such mechanics.
Obtain Replacement Motor and Necessary Tools
Find the serial number of the golf cart. Since 1976, the serial number is located in or under the passenger side's dash, facing toward the steering wheel. Call EZ-GO or use their website to verify the cart's model year with its serial number.
Decide weather to buy a new electric motor from the dealer or from an aftermarket dealer. Make sure to specify the model and the serial number when ordering a replacement motor.
Gather all of the specific tools needed for the job. The working area is relatively tight, so the exact tools listed should be used.
Place the Run-Tow/ Maintenance switch in the Tow/Maintenance position if the EZ-GO golf cart is a precision drive system (PDS) model.
Use an insulated wrench to disconnect the negative (-) battery cable from the battery to avoid shock and battery explosion hazards. Remove all wires attached to the motor.
Take a piece of chalk or paint pen and mark the motor housing and the axle housing so it will be easier to properly align the new motor to the axle.
Remove the snap ring and the speed sensor from the motor end cover if your EZ-GO is a PDS model.
Remove the bolts that attach the motor to the axle housing. Gently pull the motor away from the axle. Tap on the motor with a rubber or plastic faced hammer if it seems stuck.
Install a bumper spline between the motor input pinion shaft and the axle's splines. Coat the male portion of the spline with a small amount of molybdenum grease.
Match the motor spline with the input shaft of the axle and align the orientation marks on the motor.
Install the mounting hardware and use a torque wrench to tighten the nuts to 66 inch-pounds of torque. Connect the speed sensor to the motor's end cover on EZ-GO PDS models.
Connect wire marker F1 to motor terminal F1, wire marker F2 to motor terminal F2, wire marker A1 to motor terminal A1, and wire marker A2 to motor terminal A2 (this applies to EZ-GO PDS models).
Connect wire marker S1 to motor terminal S1, wire marker S2 to motor terminal S2, wire marker A1 to motor terminal A1 and wire marker A2 to motor terminal A2 (this applies to non-PDS EZ-GO models).
If the serial number contains "UL", only enter the actual digits into the online serial number lookup.
EZ-GO Contact Information: P.O. Box 388 Augusta, Georgia 30903-0388 1-877-394-6727