1989 EZGO Marathon Electrical Problems

jonnymoon5

I have a 1989 ez go marathon with many problems that i need to know if they're repairable and what i need to do to repair them

First off, it seems like the speed controller is dead or broken. It goes from 0-full speed theres no in between

Secondly, the batteries hold little to no charge

Finally, it makes this weird grinding noise when i'm driving

Any help would be GREATLY appreciated

Thanks

BGW

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pggroves

Attached Images

Marathon Controller Wiring Diagram.jpg (53.8 KB, 54 views)

jonnymoon5

the batteries are 3 2009 deka and 3 2008 i believe energizer

this is my first cart so i'm still learning parts on the engine and drive system. where are the castle nuts and what in the brake drums should i be looking at

thanks
-Jm5

pggroves

OK
For the batteries:
Start by checking individual battery voltages and also check each cell's specific gravity. Post results here and someone can identify any problem areas if you need it. Check voltages while charging. Especially at beginning of charge and near end of charge cycle. Note amps at each time as well.
Grinding noise:
The brake drums are splined to mate to the splined ends of the axle shaft. Remove the rear wheel and you'll see the castle nut. It also may just be worn out brake shoes scraping against the drum. Either way, you need to tear down and inspect.

Of course, if any of this is outside your comfort level and you're in Texas (within a reasonable commute) then let me know and I can take that problem child off your hands.

jonnymoon5

the battery part was fixed. i replaced the energizer batteries. one was melting so i replaced the whole set and it holds a charge. the brakes are only working on one side so i adjusted it and its still making the noise. it's out of my ideas so i'm taking it to a repair shop. thanks for the help

tbrian76

I had an 89 EZGO also and had to replace the coils and solenoid. I also had the problem with going in high speed also and noticed that the wiper contacts were welded together from electrical arcing as the wiper assembly traveled across them. I took a hacksaw blade and filed in between the contacts to break the weld. Works great now and it fixed the speed problem. Hope that helps.

jonnymoon5

woah digging up a dead topic much? problems been resolved

tbrian76

Good news. Are you saying that someone else had the same issue? I guess I missed it in the thousands of posts I checked, none of which referred to welded contacts on the wiper board. Probably the most inexpensive fix I've had. All the reading just blurred together after a while. Even though, it's great to have a resource when you need help. I can't seem to find too many mechanics around my area that have much experience with carts. Nice to find a community of knowledgable and enthusiastic cart supporters.

jonnymoon5

i figured out that my issue was a solenoid issue, not the board. but it was replaced during the resto and she's working like a champ now. just wish the charger was working that good

scottyb

It is always good to have these repairs resolved and documented ~ It makes for more useful archives.....