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Gas EZGO Gas EZGO Marathon, Medalist, TXT and RXV.



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Unread 08-12-2016, 08:25 PM   #1
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Default Ezgo palace shaft?

I am currently resealing a 94 ezgo marathon. It has a 295cc. Cam seal blew out of head and was leaking oil everywhere. I put all new seals on it crank balancer shaft gasketts ect.... I put it back together and it's binding in the bottom end every time it reaches tdc. With the side cover off rolls over with no issues. Put the side cover back on and it binds every time at tdc again. Upon further inspection the crank gear looks like it has a couple dents on the teeth along with the balancer shaft. Like somthing went through them. I can assure you it was not like this when he backed it off the trailer I heard no strange noises. Rolling it over by hand upon re assembly there is a very loud clunk every time it reaches tdc. I try to mark these things when I split the case but the balancer shaft was stuck to the side cover when I removed it. Is it possible that they re timed the balancer shaft a couple teeth so that the bad teeth didn't mesh up?
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Unread 08-12-2016, 08:25 PM   #2
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Default Re: Ezgo palace shaft?

The cart was running fine with no strange noises 10 minutes before tear down.
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Unread 08-12-2016, 08:26 PM   #3
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Default Re: Ezgo palace shaft?

And now with the motor re assembled just with the starter gen turning it over you can hear the clunk very well .
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Unread 08-12-2016, 08:29 PM   #4
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Default Re: Ezgo palace shaft?

I checked and re checked the timing on b/s and crank and it's clearing everything and looks good other than the gear teeth on both sides
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Unread 08-12-2016, 08:54 PM   #5
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Default Re: Ezgo palace shaft?

I guess you could only flip it 180 because it would still have to stay in time
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Unread 08-12-2016, 09:51 PM   #6
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Default Re: Ezgo palace shaft?

Double check the cam timing. Could be hitting the valves at tdc.

You did not pull the rods? If you did did you mark both caps to make sure they went back exactly as they were?
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Unread 08-13-2016, 08:18 AM   #7
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Default Re: Ezgo palace shaft?

Correct I did not pull rods. Always mark the way the came out. U found out what it was this morning. Only have 8 extra hours into this thing. It was the head gaskett hitting I caliper it and it's to small. Everything g about this motor is 295cc so my guess is they over bored it
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