questions before I get in too deep.

JohnnyG67

While mech. inclined and have built my fair share of buggies and go-karts, golf carts are new to me. Got a 84 Marathon for camp for $350. I don't have a big budget as The girl and me are saving for a wedding in the fall.It needs a cosmetic do over lol. I put new piston/rings and a battery in it. It runs, goes, starts, forward/reverse everything is all there. It needs a lot of wires replaced and cleaned up (lil rat nesty looking).The brakes are in need of adjustment. just shy of 1/8" meat left on the shoes and from what I can tell by parts pics that's not much less than new. 1st, when adjusting the turnbuckle under the cart I noticed the two cables in the "equalizer bracket aren't equal. I have the shoes adjusted to the drums with a lil bit of drag and that seem to be ok but now the brake pedal is a lot higher and the hill brake takes a bit of oomph to engage. Is there any way to adjust the pedal hill brake engagement point? 2nd. Upon inspecting the rear undercarriage there is a bushing on each side of the cart forward of the rear axle that goes in front of the spring/shock plate and both of them are wasted. One seems to be attached to a motor mount on pass side and the other to some subframe x member. The driver side seems like the x member has shifted a tad (I can tap it back) and the two bolts on either side of the shock are loose and have been for some time it seems. I can't seem to find these bushings. Before I go at a old tire sidewall with a hole saw to make my own are they still avail. As for the bolts, if they are hogged out I can always go up a size in bolt... I'm hearing the nickel and dime train coming and wondering if I should keep at it or....
John

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BGW

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JohnnyG67

I'm assuming these bushings that carry the subframe allow for some extra articulation in the rear end? so not a rigid swing-arm but one that will pivot a little side to side? If that's the case I'm afraid making bushings from used tire sidewall will be too rigid? Anyone?

Cheezygo

Those are engine mounts and they are available.
The brake cables have an adjustment under the drivers floorboard but you need to adjust the shoes up with the adjusters inside the drums first.

Cheezygo

Have a look here for service manuals. http://http://www.buggiesgonewild.com/ezgo-gas-tech/

JohnnyG67

Thank you sir! Found a manual and by the looks of it the prev. owner had the brakes all adjusted wrong. Will call around for the bushings... Now to tackle the rewire... Dang why so much wiring for a gas cart? Was redone at one point and there's a lot of butt connectors and splices to work thru...

sccowboy

The "excess" wiring is because the cart has to turn the starter both clockwise and counter-clockwise to run the engine fwd or backward. That's how you get reverse in the 2 cycle carts. The wires reverse current flow to the starter.

This is for a late 80s and up 2 stroke but it should help you figure it out. Note the white and black arrows near the direction selector which indicate the current flow.

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JohnnyG67

Thank you!. Of all my strong points for some reason wiring is NOT one of them. I don't know why, but wiring gets me all freaked out lol. Although from the last rewire that was done all the colored wires were swapped out making it trickier. It all works (minus rev. buzzer and governor((removed) Just trying to clean it all up. Whoever did it left an inch or so of the orig wire colors at their respective sources (for the most part) and butt connected new wires in between.

rvkersh

The rear end is loose on the swing arm. You need to tighten or replace the bolts each side of the shock mount. You can see in the photo that it is sliding for and aft on the arm.

JohnnyG67

Good eyes rvkersh! That's one of the things I was trying to describe in the initial post. From what I can tell it's has been moving for some time. Those bolt heads have sunken in a bit. I have a ton of grade 8 hardware left over from my other projects. Soon as I can find the bushings I'm going to it all at once. I have a feeling I'm going to be going up a size on those bolt diam. Pass side is good tho.

rvkersh

Larger bolts won't hurt a thing. Those motor mounts are fairly simple as well.