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



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Unread 07-11-2019, 01:36 PM   #1
Not Yet Wild
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Location: Dallas/Ft Worth Texas
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Default 1989 EZGO Marathon Father/Son Rebuild Project .

Two newbies to the golf cart world. We decided to do a project together so we could hang out in the garage away from the women folk. In reality, it gave me a way to spend more guy time with my 15 yr old son. We have zero experience in the golf cart world or any other restoration projects. I was an aircraft mechanic for 20 years so I have some mechanical knowledge but this will be an adventure. We got a good deal on an old 1989 EZGO electric so we bought it, trailered it home and started the project. I will attempt to post as many pics as possible during the build. Any advice is more than welcome. I know from searching the threads that there is a ton of experience in here. Looking forward to it. Enjoy!!
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Unread 07-11-2019, 09:06 PM   #2
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Default Re: 1989 EZGO Marathon Father/Son Rebuild Project .

Since you are starting with a "clean slate", it's the perfect time to ditch that archaic resistor system, and go 48v. The old system used just as much power to go 5 mph, as it did to go top speed (lame 12mph, and slow up a hill), please put that idea of keep it stock out of your head. So much efficiency gains have been made since then... Stock golf carts were designed to go "hole to hole" for 18 holes, at slow speeds carrying 2 people & 2 bags of clubs. Not very exciting, right?

So, do you see the idea of lifting it, with bigger tires? Do you want speeds faster than 12mph? Want speed on the streets, not offroad? Just what do you want it to do? The possibilities are only limited by a budget cap. Keep in mind that 30 mph speeds with a big lift & huge tires will cost $$.

Within a budget, every desire has a tradeoff, max speed will typically come at a loss of torque for offroading, and vise-versa. I have built several electric carts that want to yank the front wheels off the ground, anything can be done. It's a matter of what you desire, and budget.

First thing is to set the goal points you desire. We can get almost anything done after a set goal is in place. Let us know your goals, and how you will be using it. We can go wild AF, or whatever "in the middle" between that and stock. (I'm just guessing 12mph stock is not how you found this place, but I could be wrong).
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Unread 07-16-2019, 09:44 PM   #3
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Default Re: 1989 EZGO Marathon Father/Son Rebuild Project .

Sounds like fun. I just picked up an 89 marathon too. Slightly different tho. New batteries and a kit from scottieb (solenoid, fnr, and controller) This is a great site with lots of information. Have fun
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Unread 07-17-2019, 08:41 AM   #4
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Default Re: 1989 EZGO Marathon Father/Son Rebuild Project .

I am looking to upgrade to a controller system, probably 48V system sometime in the near future. I think it will make a huge difference. We finished painting the frame and battery tray this week. I just ordered a new ignition, solenoid, and board for the resistor. I need a recommendation on a good deal on a new front seat assembly (wood,seat and cover). Does anyone have a suggestion?
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Unread 07-17-2019, 08:52 AM   #5
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Default Re: 1989 EZGO Marathon Father/Son Rebuild Project .

We painted the frame and battery tray this week. Starting to put it back together next week.9.jpg

10.jpg
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Unread 07-18-2019, 11:16 AM   #6
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Default Re: 1989 EZGO Marathon Father/Son Rebuild Project .

Try the site sponsors on this page. If not, try an upholstery shop around your area. (Boat shops)
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Unread 07-18-2019, 11:35 AM   #7
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Default Re: 1989 EZGO Marathon Father/Son Rebuild Project .

Quote:
Originally Posted by Danjackson View Post
I am looking to upgrade to a controller system, probably 48V system sometime in the near future. I think it will make a huge difference. We finished painting the frame and battery tray this week. I just ordered a new ignition, solenoid, and board for the resistor. I need a recommendation on a good deal on a new front seat assembly (wood,seat and cover). Does anyone have a suggestion?
I am not sure about a marathon seat, or what all you need, but lots of guys end up having to rebuild the wood part of the seat. Half sheet of ply and you are good. Foam can be sourced at an arts and craft place and cut with a hot knife or an electric knife. Again, not sure what all you need. I think up to par will sell you a whole seat too. If not them, just google golf cart seats/seat covers and you'll find some good options. Having it custom done at an upholstery place may get pricey.

Last edited by TheNewGuy; 09-14-2019 at 07:50 AM.. Reason: non sponsor
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Unread 08-03-2019, 03:38 PM   #8
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Default Re: 1989 EZGO Marathon Father/Son Rebuild Project .

I need some motor help. The cart is running now but it is a doooogggg up a hill. I also hear some grinding from the motor as i let off of the gas. Ant suggestions? The motor is also getting hot to the touch. Is this normal?

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Unread 09-06-2019, 08:24 AM   #9
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Default Re: 1989 EZGO Marathon Father/Son Rebuild Project .

I just bought a 4" drop axle lift from sgc. When we tried to install, the lower shocks would not mount. I have attached pics. Could anybody tell me if I am doing something wrong, or is the axle incorrect. The instruction manual is not really telling me much. It also doesnt have any pictures.

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Unread 09-06-2019, 08:28 AM   #10
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Default Re: 1989 EZGO Marathon Father/Son Rebuild Project .

Looks like the axle might be facing the wrong direction. Most of the drop axle installs have the shock mounting tab facing the rear of the cart.
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