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Unread 07-23-2011, 09:09 AM   #1
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Default Ezgo Marathon Resistor to Controller conversion kit

I'm sitting here waiting for the Marathon to be delivered......

I have been developing a bolt on conversion kit to bring 1980s Ezgo Marathon into the 21st Century

I will have kits available in mild to wild packages. The kit will include throttle extension, bell crank, mounting bucket, and all the electronic components including; controller, solenoid kit, & potentiometer kit.

I'll post pics of the guinea pig here... later today
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Unread 07-23-2011, 10:30 AM   #2
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Default Re: Ezgo Marathon Resistor to Controller conversion kit

Can't wait to get my hands on one of these kits. It will be great to get everything in one package to do the conversion, instead of trying to piece it all together.
Thanx Scottyb
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Unread 07-23-2011, 05:43 PM   #3
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Default Re: Ezgo Marathon Resistor to Controller conversion kit

Okay the guinea pig is here. Pictures as promised
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Unread 07-23-2011, 11:37 PM   #4
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Default Re: Ezgo Marathon Resistor to Controller conversion kit

OKay the cart is a 1990 Marathon... Little rough but she ran and was cheap. Ideal for the project........
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Unread 07-23-2011, 11:42 PM   #5
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Default Re: Ezgo Marathon Resistor to Controller conversion kit

To get started I pulled the 4 center batteries just to get some working room Then I removed a few wires and bolts and lifted the Speed Wiper Assembly and Resistor coil box right out of the cart......... leaving lots of room for the new stuff
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Unread 07-23-2011, 11:58 PM   #6
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Default Re: Ezgo Marathon Resistor to Controller conversion kit

I completed the bracket construction and mounted the electronic components.....

Bolted everything down .... installed the new throttle linkage kit. and tested the Potentiometer output as mounted..... I was happy with the readout

All that left is to make new 4g cables and rewire the secondary circuit. I will install a HD switch cam and we have a 21st century Solid State speed control cart with a 400amp Alltrax on board !



Thanks for following along...
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Unread 07-24-2011, 09:00 AM   #7
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Default Re: Ezgo Marathon Resistor to Controller conversion kit

That seems easy enough, will you be showing the next part? the secodary wiring? I need all the info I can get.
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Unread 07-24-2011, 09:05 AM   #8
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Default Re: Ezgo Marathon Resistor to Controller conversion kit

Hopefully, I will get some wiring pics later today.
The kit will include detailed mechanical instruction & diagrams for primary and secondary wiring.
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Unread 07-24-2011, 12:00 PM   #9
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Default Re: Ezgo Marathon Resistor to Controller conversion kit

Scotty, great job on the install, looks really clean. Just a couple Questions for you....

Did you have to purchase a longer accelerator rod (that new one looks really shiny lmao) or is there a secondary bell crank involved?
Any particular reason you went with a steel box instead of an aluminum one? just thinking of heat disapation on heavier duty controllers here.....
Did you make that bell crank or was that something you purchased for the kit?


I'm really jealous... I need to go to Harbor Freight and get a Brake...... I still have to do that the old fashioned way of welding plates together........
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Unread 07-24-2011, 12:38 PM   #10
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Default Re: Ezgo Marathon Resistor to Controller conversion kit

This is the prototype. Sheet metal was shop scrap I thought of aluminum but, I am trying to keep the costs low... the new controllers are producing less heat. Alltrax has discontinued the big body 4845 shown because the heat problem has been diminished by cooler running components. And the new generation controllers have fans and no heat sink... I am making the bellcrank and the throttle extension.
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