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Unread 11-13-2016, 09:11 AM   #1
Not Yet Wild
E-Z-GO
 
Join Date: Nov 2016
Location: Hedgesville, WV
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Default 1983 Marathon Struggles Uphill

Hello all, this is my first post to your forum.

I just bought a 1983 E-Z-Go Marathon with a 2 cycle 9hp 244cc Robin engine and belt drive. This is my first cart. This cart has always been a privately owned cart and seems to have had good maintenance and care throughout its life.

I have rebuilt the starter/generator, replaced the battery, cables, spark plug and put fresh gas/oil mix in it. The cart starts and runs pretty well now.

My problem is that it really struggles going up a moderately steep hill, especially with 2 adults onboard. It seems to have no problem hitting top speed. I suspect that there is a problem with the clutches not operating properly. The belt seems to be not new, but OK.

I have no experience or knowledge about this type of clutch system and could use all the help I can get about removal, inspection, maintenance and reinstall of this system.

If I understood it better I'm sure that I could insure that it is functioning properly.

Any help or documentation is appreciated. Thanks for your assistance.
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Unread 11-13-2016, 11:39 AM   #2
Test before replacing
E-Z-GO
 
Join Date: Aug 2013
Location: Ohio side of the Pennsylvania border.
Posts: 1,617
Default Re: 1983 Marathon Struggles Uphill

Put yours up on blocks like this video, and watch that the drive clutch squeezes together, and the belt rides all the way to the top. The driven clutch should open up, and the belt rides to the bottom.

https://www.youtube.com/watch?v=fuJIW-zhMJ0

The belt should be 1 3/16" wide. Anything less than an inch is junk.

This is a manual for an 85. Your exhaust is different. The rest of the engine is the same.

Mix gas at 128:1

Disconnect the governor, and you should easily hit 15 mph. Sometimes 17 mph.

EDIT: I also just read your other question. If you could find an 88 donor cart for cheap, or free, it would be worth a try. You would need the muffler mounts from the engine mount.

You would need a carburetor, exhaust mounts, a head pipe, and muffler. If you could even find new ones, they would cost more than what your cart is worth.
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File Type: pdf 85-EZGO(2) (1).pdf (6.71 MB, 0 views)
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Unread 11-14-2016, 10:54 AM   #3
Not Yet Wild
E-Z-GO
 
Join Date: Nov 2016
Location: Hedgesville, WV
Posts: 18
Default Re: 1983 Marathon Struggles Uphill

Thank you both for the video link and the manual. Very much appreciated. The video was an excellent help in understanding how the clutch works.

After watching the video and looking in the manual, am I correct in understanding that the clutch should NOT engage when the engine is at idle and only engage when the throttle is advanced? Mine starts moving as soon as you hit the accelerator and never disengages.

Also, my sincere thanks for doing the work to maintain this forum.
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Unread 11-14-2016, 06:31 PM   #4
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Default Re: 1983 Marathon Struggles Uphill

It's a fine line, but yes. I can feather my throttle to make it idle without engaging the clutch. Mine is an 87.

My brother has an 83 that acts like yours. It wants to engage instantly. Changing the front cradle bushing helped. I don't know if he changed the rear ones yet. Molylube, or graphite spray also helps on the clutch shaft. It needs to slide easily.
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Unread 11-14-2016, 08:02 PM   #5
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Location: West Virginia
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Default Re: 1983 Marathon Struggles Uphill

My experience with 2 strokes (73 Harley cart and dirt bikes) have been that engine compression and timing plays a big big part in performance. Just throwing this out there. GOOD LUCK!!!
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Unread 11-15-2016, 09:04 AM   #6
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Default Re: 1983 Marathon Struggles Uphill

Thanks Guys,

I jacked up mine in the shop last night and ran it. The clutches aren't moving AT ALL, no matter how fast or slow I run it. Me thinks we've found the problem!

So, I think my next move is to pull the belt, both clutches, disassemble and clean/repair/replace/lubricate as necessary. Reinstall and put a new belt on.

Any heads up on doing this is appreciated.

Thanks for everything,

Chuck

PS: I do have the rebuild kit for the fuel pump and will be pulling the carb for a good cleaning as well.
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Unread 11-15-2016, 09:06 AM   #7
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Default Re: 1983 Marathon Struggles Uphill

I also wanted to let you know that I did a compression test on it and it runs around 105 to 110PSI, so I'm pretty sure that the top end is OK.
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Unread 11-15-2016, 09:19 AM   #8
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Default Re: 1983 Marathon Struggles Uphill

That's a good compression. The engine usually comes out to remove the drive clutch. Some guys have been able to tilt it up for clearance.

Clutch bolt size 83 EZGO gas cart

Here is the home made clutch puller thread. ^ You will get best results using an impact.
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Unread 12-29-2016, 01:04 PM   #9
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Default Re: 1983 Marathon Struggles Uphill

OK,

The engine is out. I made the hoist adapter and it worked well.

[IMG]IMG_0890.JPG[/IMG]

I've replaced the air filter, both fuel filters, rebuilt the fuel pump, pulled and cleaned the carburetor.

The driven clutch seems to be fine.

Now that I can get to the drive clutch, I've pried it open to look inside and I don't see any type of counter weight mechanism that I would have expected.

[IMG]IMG_0912.JPG[/IMG]

Since there was no cover on this clutch, should I assume that the counter weights have left for parts unknown and that I now need to purchase a new drive clutch for this cart?

If so, I've found a new aftermarket clutch at Blockbuster Golf Cars for $206.66, see link below:

[URL="http://blockbustergolfcarts.com/driveclutche-z-gogas2cycle1976-88.aspx"]

Is this a good price or should I look elsewhere?

Again, my thanks for your advice.

Chuck
Attached Images
File Type: jpg IMG_0890.jpg (185.2 KB, 0 views)
File Type: jpg IMG_0912.jpg (118.6 KB, 0 views)

Last edited by WVCartMan; 12-29-2016 at 01:26 PM.. Reason: Add correct image attachments
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Unread 01-01-2017, 06:57 AM   #10
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Default Re: 1983 Marathon Struggles Uphill

There are 3 pucks in the clutch that slide up & down in the ribs you see. It's most likely ok. The cove can be removed but I forget how I removed it to clean mine someone may know.

LOU
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