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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Unread 02-17-2016, 10:40 PM   #1
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Default Decision made. Going ahead with restoration

It's possible I may regret doing this, but I've decided to fix up a very rough EX GO Cushman Electric Truck. I posted a couple of questions in a previous thread about the drive system. Apparently, it's a Series Drive; a workhorse, but not built for speed. That is exactly what I needed so here goes. I'll post a few pictures of my progress.
Apparently, this thing started out as a fleet vehicle in some kind of chemical warehouse here in Texas. Looks like something from the salty roads of the snowy northeast.
The box is good for scrap metal. The battery trays were pretty much gone and most of the steel on this thing was falling apart. Surprisingly, the two rails that make up the base of the frame are in surprisingly good shape.
Looking it over, I noticed that the front springs were mismatched - one was a two-leaf and one was a three-leaf. And the right side sprig was snapped in half, just behind the front axle.
I noticed that the steering center link was rubbing on the lower steering arm. A closer look revealed that the front axle was bent, right under the right side spring plate.
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Unread 02-17-2016, 10:53 PM   #2
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Default Re: Decision made. Going ahead with restoration

The machine wouldn't run unless I shorted the terminals on the solenoid. And I couldn't understand why I showed some voltage on the load side of the solenoid until I realized that what I thought was the diode was actually a 250 ohm resister across the big terminals. It turns out the diode was missing from the small terminals altogether. I'm not sure for how long it was gone because the nuts were corroded and appear to have been on for a very long time. I bought a new solenoid and diode and now the motor works properly with speed control and in both directions.
The wiring was disconnected for the extra resistor for the half speed reverse circuit and the microswitch isn't even there on the F + R switch. Once I get the car on its wheels, I'll decide whether to replace it or to just be careful not to drive too fast in reverse. I'm thinking about hooking the wires up to a hidden toggle switch that I can use to cut the cart speed down like a valet switch if I have a younger driver. Decisions for a future date.
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Unread 02-17-2016, 10:55 PM   #3
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Default Re: Decision made. Going ahead with restoration

New battery trays being welded into place. Then some square tubing to make up the beginnings of a seat base and the truck box.
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Unread 02-17-2016, 11:00 PM   #4
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Default Re: Decision made. Going ahead with restoration

Used a rust conversion primer and a satin black paint.
I managed to straighten the front axle on a press and assemble the new front end this afternoon. New springs, shocks and tie rod ends. Still something didn't look quite right. I knew this thing took a serious hit on the right front, but why is the left spindle drooping like that?
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Unread 02-17-2016, 11:07 PM   #5
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Default Re: Decision made. Going ahead with restoration

Maybe because the spindle is shaped like a friggin' banana.
I could hear a bad bearing when I spun the wheel. Now I know why it went bad! There's no way I'm going to straighten this thing out.

Do any of you know where I can find a decent used spindle? I'm sure the dealer is going to charge a fortune for a new one and I have a sneaky feeling it'll be a special order part. I really want to get this thing on the wheels so I can go play. I may have to run it bent until I can find a replacement but I'm sure it'll trash my new tires quickly on concrete with all of that positive camber.

Any suggestions?
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Unread 02-18-2016, 11:56 AM   #6
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Default Re: Decision made. Going ahead with restoration

Found a new spindle at the dealer for $112. Not too bad.

Does anyone have a simple way to service the rear differential lube without pulling the cover plate? I seem to have a fill plug but no drain plug.
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Unread 02-19-2016, 02:32 AM   #7
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Default Re: Decision made. Going ahead with restoration

No luck with the new spindle at the EZ GO dealer. Apparently, most of the parts are interchangeable on these machines but not this. They did find a listing in an aftermarket catalog and ordered one in. It'll take a week or so and I need this thing rolling sooner than that so I put the bent one in the vise, heated it and straightened it out. I won't trust it for long term use but it'll work for now.
New wheels are on. Back brakes are in good shape. Someone installed the wrong cable on the left side so the equalizer bar was pretty cockeyed. I shimmed the cable back with a thick washer and now the equalizer is even. It appears that the left rear axle shaft is new but not the right side. I think I read one of ScottieB's comments that these should always be done in pairs so I expect that I'll end up changing it out.
My parts guy did some digging around and found some new pedal pads. The old ones were pretty ratty looking so I was glad he had them.
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Unread 02-19-2016, 02:37 AM   #8
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Default Re: Decision made. Going ahead with restoration

Pictures keep loading upside down.
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Unread 02-19-2016, 02:39 AM   #9
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Default Re: Decision made. Going ahead with restoration

Batteries and speed controller installed.
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Unread 02-19-2016, 05:55 AM   #10
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Default Re: Decision made. Going ahead with restoration

Good job getting it back together.
i think golf cars of houston has a boneyard to get used parts.
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