1990 EZGO Marathon 2 smoke with HF 420 swap

Gula · 10-08-2019, 09:00 PM

So i picked up this 30 year old golf cart as a project and toy for the fam, ahem "me" removal of 2 smoke was immediately done, then came ckeanup

Gula · 10-08-2019, 09:05 PM

Cleanup of 30 years worth of dirt, oil, fuel took a few days. I work on this intermittently (40yr old college student) between homework, fam and normal adulting stuff. Test fitting of engine without old mounts removed created a tight fit.

BIKERMIKEYBLACK · 10-09-2019, 12:19 AM

2 smoke lol and it looks like it gas closet racks on the back lol
Man wat a rare find !!

Gula · 10-09-2019, 02:24 AM

Unsure of the golf lingo, so im not sure what you meant. Thats ok though. Well cleaned up the bay enough to rattle can black it! Also nearly finished grinding down the engine cradle from all the cuts/leftover mount pieces. And "machined" via drill and file the flange for the axle housing. And and I designed this blue doodad in fusion360 converted it to a stl file and printed it on a 3d printer. Its the thingie under the LED that im upgrading this to.

slonomo · 10-09-2019, 07:11 AM

Very cool. Whats the plan with the drive line? Chain? CVT?

Gula · 10-09-2019, 11:16 AM

Driveline will be a TAV40 setup on the motor side. After smashing up the old driven unit i was able to extract the splined tube that fits over the axle input. Took that and macjoned it down to 1.250 ish plan is to bore out a 10-12 tooth sproket and weld it onto that shaft.

chrisr32 · 10-09-2019, 12:23 PM

I found a 16t with 40 chain, with more looking may be able to get a smaller sprocket. This has the 1 1/4 ID on the sprocket.

https://www.mscdirect.com/browse/tnp...SABEgJnSfD_BwE

slonomo · 10-09-2019, 09:13 PM

Quote:

Originally Posted by Gula

Driveline will be a TAV40 setup on the motor side. After smashing up the old driven unit i was able to extract the splined tube that fits over the axle input. Took that and macjoned it down to 1.250 ish plan is to bore out a 10-12 tooth sproket and weld it onto that shaft.

Very cool. Nice clean work.

Gula · 10-11-2019, 02:54 AM

That hole on the sprocket does not look 1.250, but must be machineable th that. Thank you Sire. Ahem my apologies but Macjoned is a fatfingered version of Machined without proofreading. So not much progress, but i received a reply from redbeardsgarage email person. I inquired about an alternator kit he installed on the HF 670 engine. I asked if the standoff for the pulley would also fit the 420 engine, as he has wrenched on both engines 420/670 in his YT channel. He said no, but the company making the kit will soon be making an alternator kit for the 420cc too! "Cool"
I also milled two of the 4 slots needed to slide engine forward a bit and the mount back onto the rear crossmember on the motor cradle (rear was barely on) On the front cross member i have to raise it by 1" to clear the rubber isolators; as well as the needed offset of the motor plate for chain alignment on the axle input. Long sentence, anyways. While bored i practiced turning down the exterior diameter of an out of round 1/4" thick 6" plate. Long story there, don't ask! This is for turning down the inner diameter of that now round plate to match the old driven shaft sleve.
That's all for practice before i ruin a real sprocket as some get expensive.

Gula · 10-11-2019, 03:10 AM

Oh and i efffffed up by smashing sparkplug pullermabobber pretty guud. Epoxy to the rescue. GTG now. Well time to order that 12t procket for 40 chain. Practice with round piece is next week probably because ill be swamped with homework this weekend. That and fam, laundry........

10-09-2019, 12:19 AM	#3
BIKERMIKEYBLACK Gone Wild Join Date: Jun 2011 Location: Kingston Springs Tn. Posts: 874	Re: 1990 EZGO Marathon 2 smoke with HF 420 swap 2 smoke lol and it looks like it gas closet racks on the back lol Man wat a rare find !!

10-09-2019, 07:11 AM	#5
slonomo Searching for The Way Join Date: Oct 2009 Location: Medina, Ohio (NEOHIO) Posts: 11,436	Re: 1990 EZGO Marathon 2 smoke with HF 420 swap Very cool. Whats the plan with the drive line? Chain? CVT?

10-09-2019, 12:23 PM	#7
chrisr32 Gone Wild Join Date: Jan 2019 Posts: 190	Re: 1990 EZGO Marathon 2 smoke with HF 420 swap I found a 16t with 40 chain, with more looking may be able to get a smaller sprocket. This has the 1 1/4 ID on the sprocket. https://www.mscdirect.com/browse/tnp...SABEgJnSfD_BwE
chrisr32 Gone Wild Join Date: Jan 2019 Posts: 190

10-11-2019, 03:10 AM	#10
Gula Not Yet Wild Join Date: Oct 2019 Location: Commiefornia Posts: 15	Re: 1990 EZGO Marathon 2 smoke with HF 420 swap Oh and i efffffed up by smashing sparkplug pullermabobber pretty guud. Epoxy to the rescue. GTG now. Well time to order that 12t procket for 40 chain. Practice with round piece is next week probably because ill be swamped with homework this weekend. That and fam, laundry........

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