lifted club cars - lifted ezgo
Home FAQDonate Who's Online
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Gas EZGO
Gas EZGO Gas EZGO Marathon, Medalist, TXT and RXV.



Post New Thread  Reply
Thread Tools Display Modes
Unread 05-13-2017, 01:05 PM   #1
Gone Wild
 
Dabble Inn's Avatar
E-Z-GO
 
Join Date: Jun 2016
Posts: 476
Default 85 Marathon 244cc Engine Rebuild

This all started when I was removing the clutch to work just on it, But at that point is when I noticed a ton of horizontal play in the crankshaft mainly at the fan side. Never noticed it before as the starter belt must have been holding it up tight lol, But it ran ok too other then a bit sluggish off the line. Hence the reason I was looking into changing out the drive clutch spring to a stiffer one, I still may do that since I believe it engages too early (1000-1200rpm). Maybe I'm wrong but I'm thinking that's more of where a 4-cycle should be engaging???

Anyway, when I tore it apart things got worse. Much worse... Not only were the two steel starter mounts broke but the third one that bolts to the case flange has broken the entire flange off the case (pic below) UGHHH!!

I have a buddy that can weld aluminum so hopefully he can handle this one but wow what a surprise, And I'm sure a new case is impossible to find.

I also decided to buy a complete rebuild kit even though it still has 115lbs compression, And I'm getting the kit that includes a new crankshaft too. It's the only way to replace the lower rod bearing, Seems to me it'd be dumb not to replace that bearing too at this point.

I just ordered the rebuild kit but they're on back order so won't see it till the end of the month, Ughh!!

I'll keep y'all posted as I go
Attached Images
File Type: jpg 9.jpg (225.4 KB, 0 views)
File Type: jpg 11.jpg (200.7 KB, 0 views)
File Type: jpg 12.jpg (211.4 KB, 0 views)
File Type: jpg 13.jpg (260.1 KB, 0 views)
File Type: jpg 14.jpg (228.9 KB, 0 views)
Dabble Inn is offline   Reply With Quote
Alt Today
BGW

Golf car forum Sponsored Links

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum
   
Unread 05-14-2017, 12:08 AM   #2
Getting Wild
 
Join Date: May 2016
Posts: 122
Default Re: 85 Marathon 244cc Engine Rebuild

Can you do me a huge favor and measure the connecting rod center to center (crank to wrist pin)? I didn't measure mine when it was apart, and I would love to figure out some engine data. Also, if all those parts are going in the scrap heap I would love to take them in the name of science (and I pay shipping of course). I am trying to build the ultimate 2pg engine, with math proven modification. It would be nice to have a scrap jug and crank to experiment with!
clr.R4tch3t is offline   Reply With Quote
Unread 05-14-2017, 09:43 AM   #3
Gone Wild
Yamaha
 
Join Date: Jun 2015
Location: NW Iowa
Posts: 1,659
Default Re: 85 Marathon 244cc Engine Rebuild

If you have a ezgo dealer close the cranks are pressed together and can be disassembled and new lower rod bearings can be installed also it's cheaper to figure out what size piston you have and buy an oversized and take it to a machine shop and have them bore it out
Spicyunicorn is offline   Reply With Quote
Unread 05-14-2017, 11:57 AM   #4
Gone Wild
 
Dabble Inn's Avatar
E-Z-GO
 
Join Date: Jun 2016
Posts: 476
Default Re: 85 Marathon 244cc Engine Rebuild

Yes I considered doing that with the crank as I do have a Bombardier dealer with a shop that I have had a crank repaired in the past on a snowmobile engine rebuild, But after seeing this crank (junk) it has to be replaced.

I also considered buying an over-sized piston and having the jug bored, or even just re-using this set as it still has 115lbs compression. Then decided for the little bit of money it takes I'll just go with new everything..

I've had this buggy for 17 years now and ran it hard without having to do any engine repair till now. It deserves a fresh rebuild lol
Dabble Inn is offline   Reply With Quote
Unread 05-14-2017, 12:48 PM   #5
Gone Wild
 
Dabble Inn's Avatar
E-Z-GO
 
Join Date: Jun 2016
Posts: 476
Default Re: 85 Marathon 244cc Engine Rebuild

Quote:
Originally Posted by clr.R4tch3t View Post
Can you do me a huge favor and measure the connecting rod center to center (crank to wrist pin)? I didn't measure mine when it was apart, and I would love to figure out some engine data. Also, if all those parts are going in the scrap heap I would love to take them in the name of science (and I pay shipping of course). I am trying to build the ultimate 2pg engine, with math proven modification. It would be nice to have a scrap jug and crank to experiment with!
The rod center to center measures 4.75"ish, didn't get a mic on it just used a tape but that's very very close. The crank is pretty much junk so yes you can have it, Someone before me must have had problems with a clutch as it appears they removed it with a cut-off wheel or something lol. There's a couple nasty cuts in the taper where the clutch lives (pic)..... I'm keeping the jug and piston for a buddy.
Attached Images
File Type: jpg 16.jpg (62.1 KB, 0 views)
Dabble Inn is offline   Reply With Quote
Unread 05-14-2017, 10:38 PM   #6
Getting Wild
 
Join Date: May 2016
Posts: 122
Default Re: 85 Marathon 244cc Engine Rebuild

I have seen worse... I worked on a Passat last week, the owner just bought it from a 'VW mechanic'. Previous owner used sticks to plug ruptured turbo coolant hoses. Hahahaha let me know what I would owe you to send it to 80819. Thanks!
Attached Images
File Type: jpg IMG_20170509_150029.jpg (95.7 KB, 0 views)
clr.R4tch3t is offline   Reply With Quote
Unread 05-15-2017, 09:39 AM   #7
Gone Wild
 
Dabble Inn's Avatar
E-Z-GO
 
Join Date: Jun 2016
Posts: 476
Default Re: 85 Marathon 244cc Engine Rebuild

OMG! I know a lot about the Mcguyver thing but that doesn't even qualify LOL. Funny how some people use the title 'mechanic' so loosely, A 'real mechanic' would never do that. Unless of course in an emergency to get ya home type thing lol, But then fix it right and certainly not sell it like that LOL....

Anyway, shipping isn't as bad as I thought it'd be. Luckily for you we're somewhat in the same part of the country, From what I found on USPS it would be somewhere between $14 & $20ish depending on what box it fits in. That's using the ole 'if it fits it ships' method....

Just one thing though, I won't let it go until I have a new one in hand. Just in case
Dabble Inn is offline   Reply With Quote
Unread 05-15-2017, 08:26 PM   #8
Getting Wild
 
Join Date: May 2016
Posts: 122
Default Re: 85 Marathon 244cc Engine Rebuild

Perfectly reasonable to me. You can send me a PM when that time comes. Hopefully your parts come soon! I hate waiting on parts..
clr.R4tch3t is offline   Reply With Quote
Unread 05-16-2017, 08:58 AM   #9
Gone Wild
 
Dabble Inn's Avatar
E-Z-GO
 
Join Date: Jun 2016
Posts: 476
Default Re: 85 Marathon 244cc Engine Rebuild

Ok I'll let ya know, Yeah ain't nothin' worse than waiting for parts. Except for when they tell ya it's on back order, UGHH!!

I was fully expecting this to be a smooth, easy and quick rebuild. I know there's always surprises but when ya order a complete kit that should minimize the problems down to just the case itself, And it did. FFS LOL.....Of course it could be worse
Attached Images
File Type: jpg 13.jpg (260.1 KB, 0 views)
Dabble Inn is offline   Reply With Quote
Unread 05-17-2017, 07:34 PM   #10
Gone Wild
 
Dabble Inn's Avatar
E-Z-GO
 
Join Date: Jun 2016
Posts: 476
Default Re: 85 Marathon 244cc Engine Rebuild

Looks like the parts are going to arrive one at a time, Today I got one exhaust and two intake gaskets. *Sigh*

It's showing another box on Monday, that'll be the reed valve gaskets. *Double sigh*

And today they said there's an extended delay on the crankshaft and piston from the rebuild kit, Won't be in til June 1st. *%$#@#$@%&*
Dabble Inn is offline   Reply With Quote
Reply
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Gas EZGO


Thread Tools
Display Modes


Similar Threads
Thread Forum
1987 marathon top end overhaul or engine rebuild? Gas EZGO
1989 Marathon 2PG Engine Rebuild- In over my head - Please help Gas EZGO
85 Marathon Engine Rebuild Gas EZGO
1988 marathon 244cc robin 2pg engine Gas EZGO
82 244cc top end rebuild Gas EZGO


All times are GMT -5. The time now is 11:19 PM.


Club Car Electric | EZGO Electric | Lifted Golf Carts | Gas EZGO | Used Golf Carts and Parts

Powered by vBulletin® Version 3.8.6
Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.
Content Relevant URLs by vBSEO ©2011, Crawlability, Inc.