1993 EZGO Marathon Clone Install

MarineGrunt

Our Robins engine finally wore itself out. I decided that for now I'd just pick up a 16 hp Duromax. When I have more time I plan on making my own lift so I'll probably put in a bigger Vanguard. For now I just want to get it on the road for the wife and kids to mess around on so wanted to get an engine that would fit.

I've been trying to look up info on the swap. It seems that some say the stock clutch is fine while others say get a different clutch. We don't really need a lot of power or speed. We mainly just use it to cruise around the subdivision or drive it down to the boat ramp or beach for the kids to swim. If the clutch will make a huge difference I don't mind spending the money on one. I do have the adapter to use the stock clutch and I believe I also purchased a new spring. I ordered it awhile back so have to remember where I put it. I remember before we moved I put it somewhere where I knew I would find it...lol

I think I plan on using the stock generator. Without the comet clutch and VC pulley, how did everyone set theirs up? Were you able to use the original pulley? If not, what kind of pulley did you use and how did you mount it?

I'd like to get it as quiet as possible. I just removed the lower back compartment so will have all kinds of room for a muffler. Seems like a Flowmaster Hushpower is the way to go. I can't seem to find one that has any smaller of an opening than a 2". Is there anything smaller? I guess I can always weld on an adapter but didn't know if a bigger opening would make a difference. Anyone know if a resonator would help too?

Does anyone know the distance between the two pulleys for the drive belt? I'd like to use my original belt since it's new and pulled the engine without measuring. I can always set it back in there to get the measurement though.

If anyone has any tips or advice I really appreciate it. This will be my first engine swap on a cart so I'm sure I'll hit some snags along the way. Since I'm working a lot of hours right now I'd like for this to go as smooth and as quick as possible. Once I upgrade to the Vanguard I plan on taking my time, making a lift, new wheels and tires, etc. For now I just want to get it on the road since the nice weather is here.

Thanks in advance for any and all help.

BGW

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raydhd

I really like how my flowmaster hushpower atv muffler worked out but I don't see that one can be obtained anywhere.On on of the ATV sites they mentioned one of them contacting flowmaster about it and the short answer was the sales did not justify keeping the ATV line in production.

MarineGrunt

I wonder if a regular hushpower for a car would work? Might be worth a try anyways. If not maybe I'll try a resonator and a small muffler from a VW or something. I'd love to find one of those hushpower atv mufflers. It can get expensive experimenting with a bunch of different mufflers.

raydhd

Somebody here had some success with a walker car muffler.In think if something happened to my hushpower I would start looking for a deal on a kolpin atv muffler.

MarineGrunt

Do you have to use the throttle linkage and bracket that's mounted on the rear axle? As far as the original governor, do you even need any of it as long as you don't care about the governor? I hope it doesn't have to stay because it's going to be a tight fit if it can't go.

raydhd

I used the the stock 2 cable set up for the pedal feel and the extra return spring.I added a bell crank extension to get the throw right for a linear motion.See "clone throttle" in this section.Many others go direct from the pedal.Some have suggested that even with the governor zip tied it would kick in.I have been up to 40 mph @ 5200 rpms and so far it has not kicked in.

MarineGrunt

Thanks for the quick reply.... I think I might try and leave it then. I can raise the engine up about 3/4" more before the seat would get in the way. There's just not much room to work with but it ought to go. I plan on fabbing up a lift eventually but just wanna get it going for now. I'm contemplating buying one and being done with it. Then again, I could use that money towards a clutch. For what we use it for we don't need speed or power but it's hard not to go all out. I tend to overdo things but don't we all. I'm really trying not to here. The wife won't like it too crazy. I'll have to get another one for that! I already know she won't like how loud it'll be.

MarineGrunt

I don't think I'm going to be able to keep the governor linkage on the rear axle. There's just not going to be enough headroom. I even cut the support out for the seat and planned on moving it back a little but still not going to work. I could possibly get some 2" rectangular tubing and make a spacer to lift the seat up higher. I think for now I'll just cut it but leave a small nub so I can reattach later for when I make a lift. I sure feel like I'm doing this way out of order but, due to work, I just don't have time to do everything I want. I want the wife and kids to be able to enjoy it this summer.

Looks like I'll only have to cut off about 3/4" of the shaft and can't cut off much more. I might be able to get by without cutting any off but won't have much room to spare. I'm going to try tho so it won't take much to install a new clutch if I decide to buy a Comet after I get it going.

I'm wishing I would've just went with a 13 hp for now for an easier install and then I could've went all out this winter.

Steelerboy27

I'm currently also putting a clone in my Marathon. I did end up cutting down the govenor post on the rearend, there just wasn't enough head room.....

Skoal82

Cut it off
That's what I did in my marathon