Two problems, muffler and clutch

Stone

I have been battling two problems since buying this 1986 Marathon and while I have gotten a lot of help here I want to pose a couple questions to see if I can fix them myself.

Bare with me while I provide a little background.

1. The exhaust pipe keeps breaking and I can only conclude that it's due to vibration. I jacked it up and looked everything over and found one problem.....the driven clutch sheave toward the front was bent all to hell (see picture), even more concerning was how easily I could bend it back.......could this be why I don't have low end torque...... is the sheave just bending away from the belt? I bent it as straight as I could to get me through the rest of deer season and will repair the clutch later. Anyone ever see this sheave weakened to the point where you can bend it by hand?

2. Izzy (that's her name) is loud and since I will be completely redoing the exhaust in the off season, I would like to hear from you guys who have experimented with quieting the muffler. I have read that proper back pressure is critical but someone has to have tried some things. I plan to replace the motor mounts and have a 2" stainless pipe made and insert a flex pipe (to absorb vibration) since I can't find a replacement exhaust pipe anywhere.

Attached Images

Driven clutch.jpg (172.3 KB, 0 views)

BGW

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Skoal82

I'm fixing a g2 for a friend and the drive clutch is worn out
It vibrates the whole engine bad and cause of that the exhaust has either fallen off or broken right at the flange 3 times
Welded a few times to get throu the summer and now it is time for a me clutch or rebuild
You should not be able to bend the clutch Sheave by hand I would have to say it is worn out
Maybe put up a post in the classifieds looking for a used clutch and exhaust
Also 2 strokes are a lot more picky when it comes to back pressure I would try to find a replacement

Mr. Mike

Stone I'm parting out an entire 1990 EZGO Marathon 3pg. I have it in the for sale section. I'm not 100% sure but I'm pretty sure that most of the parts were the same. Maybe somebody can verify that. The exhaust is in great shape. Primary and secondary both appear to be working properly. The cart runs good it just needed too many things to make it right as far going and stopping so I decided to just part it out.

Stone

PM sent

Stone

I don't want to add confusion but I guess I'm going to........Can you replace just the front sheave?

racin161

Sure you can if you can find a used one. Most of the time the bushing is worn out which causes it to cock sideways. Maybe a member has a clutch they don't need

LOU

Stone

I wonder if some of you guys who like to think things thru would give me your thoughts on this? The front sheave on the driven clutch is apparently well worn and it is flimsy. Could this be the reason I am not getting low end torque? If the belt is trying to move 1100 pounds of cart and people and the sheave flexes out of the way it makes sense to me that I will never get low end torque because the belt will just drop down into the driven clutch.

Your thoughts?

TomStark

That is possible. Try running with the seat off and looking at the clutch and see what it is doing.
Tom

racin161

Yes if the bushing is worn out it will not slide or move as intended. Try to give it a good cleaning then lube it with anti seize keep in mind this is just a short term fix. I've been there !!!!
LOU

Stone

It's the sheave that is worn out. The outer perimeter of the sheave is weak and it bends very easily. I hope I can find one from an otherwise damaged driven clutch.