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-   -   1988 gas EZ GO marathon 2pg (http://www.buggiesgonewild.com/gas-ezgo/154491-1988-gas-ez-go-marathon-2pg.html)

Jcrouch023 06-28-2019 04:18 PM

1988 gas EZ GO marathon 2pg
 
Hey all!

Got a question for you. My cart has been running great since doing a bunch of work. One of the things was replacing the starter generator.

Well, the other day my belt came off the S/G while I was driving and I could feel the difference for the last 100 yards or so while going home as it was just putting.

Today I put the belt back on and noticed it looks a little big for the new S/G pulley. Still fits decent and is enough to turn the clutch over, but now that Iíve put the belt in it just seems to spin the belt and clutch and wonít actually turn over the engine? Any thoughts to where I should start? Everything turns over by hand just fine so nothing is seized up.

Iím thinking either my clutch went out, or the bigger belt on the clutch is too lose? Kind of lost..please help!


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cart around 06-28-2019 05:44 PM

Re: 1988 gas EZ GO marathon 2pg
 
When you installed the starter belt, did you use a pry bar to put a little tension on the belt while tightening the bolts?

Jcrouch023 06-28-2019 06:29 PM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by cart around (Post 1630503)
When you installed the starter belt, did you use a pry bar to put a little tension on the belt while tightening the bolts?



No I sure didnít..I leaned the S/G a little towards the belt and then tightened it up. Should I try again with bolting S/G on first and then prying the belt onto it?


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Jcrouch023 06-28-2019 06:31 PM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by cart around (Post 1630503)
When you installed the starter belt, did you use a pry bar to put a little tension on the belt while tightening the bolts?



The S/G belt is still tight as hell, though. I canít even budge it with my fingers now that itís on. I just donít get why itís not spinning the the plastic (driven clutch?) and wheel?


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CP241 06-28-2019 07:04 PM

Re: 1988 gas EZ GO marathon 2pg
 
Can you grab the clutch and turn the engine by hand?

Jcrouch023 06-28-2019 10:04 PM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by CP241 (Post 1630516)
Can you grab the clutch and turn the engine by hand?



Yep I can! Thatís why Iím confused that the S/G belt isnít turning both over?


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CP241 06-28-2019 10:16 PM

Re: 1988 gas EZ GO marathon 2pg
 
Is your battery fully charged? Those 2strokes can take a lot to turn them over...

Jcrouch023 06-29-2019 08:50 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by CP241 (Post 1630572)
Is your battery fully charged? Those 2strokes can take a lot to turn them over...




Yeah itís fully charged. S/G belt and clutch are spinning fast like normal..for some reason the big belt isnít spinning this side at all.

https://uploads.tapatalk-cdn.com/201...18d3764be8.jpg


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Jcrouch023 06-29-2019 08:53 AM

Re: 1988 gas EZ GO marathon 2pg
 
Actually...is that belt upside down? Thatís how it was when I bought the cart, but why arenít the rigged edges facing down for grip?


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cart around 06-29-2019 09:03 AM

Re: 1988 gas EZ GO marathon 2pg
 
That belt is upside down.

Are you saying the engine is running, or not running?

Jcrouch023 06-29-2019 09:08 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by cart around (Post 1630635)
That belt is upside down.

Are you saying the engine is running, or not running?



I thought so..man the guy and small machine mechanic who worked on this before really did NOT know what they were doing. Is the only way to change this by removing the clutch? Iím guna have to suck it up and order one of those **** clutch removal tools.

The engine is not running know. It had been running just fine like this, until 2 days ago when the S/G belt popped off and it started running very slowly. I put it back on as soon as I got it back to the garage and not it wonít turn over it just spins and whirs like the clutch isnít engaging and grabbing the big drive belt.


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CP241 06-29-2019 09:25 AM

Re: 1988 gas EZ GO marathon 2pg
 
Sounds like the engine isnt running. The starter/generator is turning the motor but the S/G is not capable of turning the engine fast enough to engage the primary clutch and turn the drive (big) belt.

We need to determine e why the motor isnt running. Pull the spark plug out, rest the threaded part against something metal and spin the engine. Look for a fat blue spark. While it is out, Try dribbling a little gas down the spark plug hole (about a soda cap worth) and reinstall the spark plug and wire and see if it fires or sputters a little bit.

cart around 06-29-2019 09:26 AM

Re: 1988 gas EZ GO marathon 2pg
 
Let's do the belt first.
Pull the top of the belt up, and forward so it's sitting on the edge of the driven clutch. Then push the cart so the drive clutch turns. It will roll the belt off.

Once the belt is off of the driven clutch, you will have room to maneuver it between the engine, and plastic dust cover at the end of the clutch. It will then have plenty of room to remove it from the drive clutch. Turn it inside out, and reinstall using the reverse procedure. Loop it on the drive clutch first, get most of it on the driven clutch, and then push the cart to roll it on.

Jcrouch023 06-29-2019 09:32 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by CP241 (Post 1630640)
Sounds like the engine isnt running. The starter/generator is turning the motor but the S/G is not capable of turning the engine fast enough to engage the primary clutch and turn the drive (big) belt.

We need to determine e why the motor isnt running. Pull the spark plug out, rest the threaded part against something metal and spin the engine. Look for a fat blue spark. While it is out, Try dribbling a little gas down the spark plug hole (about a soda cap worth) and reinstall the spark plug and wire and see if it fires or sputters a little bit.



So I just did all of that. When I took the spark plug out I am getting a nice blue spark and also the engine turns over like it should when Itís out.

Added a cap full of gas in the hole and put the plug back in and it does the same spinning and whirring sound and doesnít turn over.


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Jcrouch023 06-29-2019 09:33 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by cart around (Post 1630641)
Let's do the belt first.
Pull the top of the belt up, and forward so it's sitting on the edge of the driven clutch. Then push the cart so the drive clutch turns. It will roll the belt off.

Once the belt is off of the driven clutch, you will have room to maneuver it between the engine, and plastic dust cover at the end of the clutch. It will then have plenty of room to remove it from the drive clutch. Turn it inside out, and reinstall using the reverse procedure. Loop it on the drive clutch first, get most of it on the driven clutch, and then push the cart to roll it on.



Thank you for this! I will get changing this now! This probably explains why it would slow down a bit on hills huh? The belt was probably slipping when it tried to work harder?


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Dabble Inn 06-29-2019 10:38 AM

Re: 1988 gas EZ GO marathon 2pg
 
I doubt the drive belt was always inside out, perhaps when the s/g belt came off it got caught in the drive belt and flipped it over somehow. Strange things can happen.........

By the way; those teeth on the belt don't grab anything, it's the sides of the belt that do the grabbing

Jcrouch023 06-29-2019 10:56 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by Dabble Inn (Post 1630654)
I doubt the drive belt was always inside out, perhaps when the s/g belt came off it got caught in the drive belt and flipped it over somehow. Strange things can happen.........



By the way; those teeth on the belt don't grab anything, it's the sides of the belt that do the grabbing



Yeah maybe that happened..not really sure. I just know I took pics and put it back exactly how it was lol.

I did realize that after I posted it, my bad.

But, still, why is this thing only turning over when I take the spark plug out?


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Dabble Inn 06-29-2019 10:59 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by Jcrouch023 (Post 1630642)
So I just did all of that. When I took the spark plug out I am getting a nice blue spark and also the engine turns over like it should when Itís out.

Added a cap full of gas in the hole and put the plug back in and it does the same spinning and whirring sound and doesnít turn over.


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Ok wait a minute;
It turns over with the spark plug out, but doesn't with it in? I'm beginning to wonder if the clutch is spinning on the crankshaft with all this spinning and whirring sounds, is the main center bolt of the drive clutch still there and tight?

Let's check spark again but only this time leave the plug in so it'll have resistance from compression and use another plug from wire to block, if it still has good spark then the engine indeed is turning

Jcrouch023 06-29-2019 11:10 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by Dabble Inn (Post 1630658)
Ok wait a minute;

It turns over with the spark plug out, but doesn't with it in? I'm beginning to wonder if the clutch is spinning on the crankshaft with all this spinning and whirring sounds, is the main center bolt of the drive clutch still there and tight?



Let's check spark again but only this time leave the plug in so it'll have resistance from compression and use another plug from wire to block, if it still has good spark then the engine indeed is turning



Yeah itís turning right over like it wants to start up, but obviously it canít because the spark plug isnít it..weird?!

Yeah the main center bolt is still there and itís tight enough to where I canít twist it with my hand or anything. I can push the clutch back and forth with my hand and do notice that the washer seems a little wobbly. I hope my clutch didnít just go bad? The guy at the golf cart shop said I would have to replace it down the road and showed me the little grooves from wear.

So I put another plug in and this time it didnít spark or turn over when I left the other plug inside.


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cart around 06-29-2019 11:20 AM

Re: 1988 gas EZ GO marathon 2pg
 
Put the battery on a charger. When the belt came off you were draining battery power while driving. It is weak.

Jcrouch023 06-29-2019 11:27 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by cart around (Post 1630663)
Put the battery on a charger. When the belt came off you were draining battery power while driving. It is weak.



The battery has been on a charger since then. I have a trickle charger and I always plug it in when Iím done using it just for good measures. I have a CD deck and amp and subwoofer in it and LED neon lights so I always want to make sure itís full charged.


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Dabble Inn 06-29-2019 11:42 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by Jcrouch023 (Post 1630661)
Yeah itís turning right over like it wants to start up, but obviously it canít because the spark plug isnít it..weird?!

Yeah the main center bolt is still there and itís tight enough to where I canít twist it with my hand or anything. I can push the clutch back and forth with my hand and do notice that the washer seems a little wobbly. I hope my clutch didnít just go bad? The guy at the golf cart shop said I would have to replace it down the road and showed me the little grooves from wear.

So I put another plug in and this time it didnít spark or turn over when I left the other plug inside.


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Was anything spinning?

Jcrouch023 06-29-2019 11:47 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by Dabble Inn (Post 1630669)
Was anything spinning?



With the plug left in the engine, and a new plug against metal, the clutch was doing the spinning and whirring thing still but no noise at all from the engine.

If I remove the spark plug and put it against metal the engine turns and sounds normal, minus the firing up.


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Dabble Inn 06-29-2019 11:54 AM

Re: 1988 gas EZ GO marathon 2pg
 
I'm thinking the clutch is slipping on the crankshaft

CP241 06-29-2019 11:57 AM

Re: 1988 gas EZ GO marathon 2pg
 
Can you do a compression test?

Jcrouch023 06-29-2019 02:29 PM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by Dabble Inn (Post 1630672)
I'm thinking the clutch is slipping on the crankshaft



Thatís what it seems like. Doesnít seem to be spinning the rod. Could that mean the clutch is shot? Or just mess around with tightening that bolt?

I canít do a compression test at the moment I donít have the right tool here. But the cart has been running great and the motor had just been rebuilt before I did all the other work.

Iím just so confused as to what the heck removing the spark plug could possible do and why it turns over when I do?

CP241 06-29-2019 03:41 PM

Re: 1988 gas EZ GO marathon 2pg
 
I'd just ask for a compression test just to rule it out.
Clutch not being tight does make sense. When the spark plug is out theres no resistance/compression so the engine turns easy. With plug in, the clutch has to overcome the compression of the motor. Tighten that bolt on the end of the clutch. If it turns easily then its definitely loose.

Jcrouch023 06-29-2019 03:54 PM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by CP241 (Post 1630714)
I'd just ask for a compression test just to rule it out.
Clutch not being tight does make sense. When the spark plug is out theres no resistance/compression so the engine turns easy. With plug in, the clutch has to overcome the compression of the motor. Tighten that bolt on the end of the clutch. If it turns easily then its definitely loose.



Itís definitely the clutch. Threw a wrench on it and the bolt is moving around. Doesnít seem to be getting any tighter, though? Itís not loose enough to move by hand but just keeps spinning with the wrench.


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Jcrouch023 06-29-2019 03:59 PM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by Jcrouch023 (Post 1630715)
Itís definitely the clutch. Threw a wrench on it and the bolt is moving around. Doesnít seem to be getting any tighter, though? Itís not loose enough to move by hand but just keeps spinning with the wrench.


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Never mind I got it to tighten up! Just had a long ways to go apparently. Sure as **** it fired right up!

Now if I can get this drive belt back on..UGH! Thereís hardly any room to stretch it back over the pulley and itís hot and humid as hell today lol. Just want to drive it down to the lake and jump in!!


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Jcrouch023 06-29-2019 07:30 PM

Re: 1988 gas EZ GO marathon 2pg
 
So I got the belt on the right way and tightened clutch up, and it fired right up.

Drove it down the road up a hill and noticed the bolt was loose again and my S/G belt popped off.

Is my clutch going bad? Or is it just hard to get the clutch bolt tight enough without using an impact wrench?

Think Iím going to get a little smaller belt for the S/G as the pulley is a little thinner than the old S/G and have my neighbor try using his impact wrench on it?


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Jcrouch023 06-30-2019 07:42 AM

Re: 1988 gas EZ GO marathon 2pg
 
Now that it happened again..nothing is spinning or turning over, not even the S/G belt.

Battery is fully charged from overnight..can still turn over the engine by hand. Could the clutch have completely went out or should the S/G belt at least be turning still?


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Dabble Inn 06-30-2019 09:57 AM

Re: 1988 gas EZ GO marathon 2pg
 
Ok let's do this one more time;
Tighten the clutch bolt to 55ft lbs, loosen the s/g adjustment bolts and put the belt back on. Then tighten the adjustment bolts while prying it over tight with a big screwdriver or whatever you have.

As far as nothing turning over now? Check the fuse

Jcrouch023 06-30-2019 10:01 AM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by Dabble Inn (Post 1630850)
Ok let's do this one more time;

Tighten the clutch bolt to 55ft lbs, loosen the s/g adjustment bolts and put the belt back on. Then tighten the adjustment bolts while prying it over tight with a big screwdriver or whatever you have.



As far as nothing turning over now? Check the fuse



I found the problem. The S/G cable came disconnected from the solenoid. Put that back on and had my neighbor use an impact wrench this time since I couldnít get it tight enough by hand.

Seemed to have done the trick. Seemed to go a little smoother than it had been up the hills, too.


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Dabble Inn 06-30-2019 10:20 AM

Re: 1988 gas EZ GO marathon 2pg
 
YES, Success!!

Jcrouch023 07-01-2019 08:39 PM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by Dabble Inn (Post 1630857)
YES, Success!!



Yesssss!! Finally!!


It still puts up hills when I got a full load riding on the cart but Iím thinking thatís not going to get any better until I just replace the clutch.

I can live with it for now though as it goes pretty dang fast on flat surface.

Cheers!


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Jcrouch023 07-06-2019 06:53 PM

Re: 1988 gas EZ GO marathon 2pg
 
Got another question. Earlier in the post we talked about how the drive belt was upside down. Well, I put it on the correct way after I noticed it. Drove it a time or two and itís been driving fine, but noticed the belt is upside down AGAIN! So, it must be flipping over somehow when I drive? Iím thinking itís when I go up a steep hill. It really seems to struggle with the hills. Clutch has remained tightened and the cart goes very fast on flat grounds but struggles uphill a little, especially if I have 2 or more riders with me.

Any ideas to why this is happening? Could it be a sign of my clutch going out and slipping while going up hills, and also flipping the belt?

Everything else is practically brand new that Iíve replaced and it just had the engine rebuilt and I changed crank seals myself.


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cart around 07-06-2019 08:48 PM

Re: 1988 gas EZ GO marathon 2pg
 
The only way a belt is going to do that is if it's twisted on installation. I would say it's happening when you work it between the frame, and the end of the driven clutch. Look at it real good before you install it on the driven clutch.

CP241 07-06-2019 09:45 PM

Re: 1988 gas EZ GO marathon 2pg
 
I agree. I dont even know how it would be possible for it to turn itself inside out. Unless perhaps it was driven for so long upside down that it has worn itself backwards and somehow flipping...

It should be tapered on both sides with the clogged side being narrow and the solid side being wider.

Dabble Inn 07-07-2019 12:54 PM

Re: 1988 gas EZ GO marathon 2pg
 
Wow inside out again, Hmmm.......

Wonder if the clutches are mis-aligned with each other, But can't think of a reason why if everything is bolted down tight. The engine is bolted down tight right?

How old is the belt? I'd get a new one and see what happens, This one may be worn since being inside out so much

Jcrouch023 07-07-2019 01:16 PM

Re: 1988 gas EZ GO marathon 2pg
 
Quote:

Originally Posted by Dabble Inn (Post 1633014)
Wow inside out again, Hmmm.......

Wonder if the clutches are mis-aligned with each other, But can't think of a reason why if everything is bolted down tight. The engine is bolted down tight right?

How old is the belt? I'd get a new one and see what happens, This one may be worn since being inside out so much



Yeah I donít understand whatís going on. Engine is bolted down tightly. Clutches donít appear to be mid-aligned from looking at them.

Belt very well could be worn down. Not sure how old it is since it was on the cart when I bought it over winter and fixed it up.

The belt definitely wasnít twisted or anything when I put it on, though. I couldnít get it on easily as it was too tight so I literally removed engine and tilted the clutch in to get it on. So I made sure it was all good before putting it back together.

Just wanted to confirm if my clutch was going bad if it was a possibility with that and the struggling up hills with more than 1 passenger. I feel like thatís when it flips when it starts working hard to get up those I feel like I could feel some slipping. But, again, that could just be the belt. Maybe Iíll order one of those high performance ones and see before replacing the expensive clutch. Just worries me that the EZ GO dealer mechanic said my clutch would go out sometime down the road as it had some wear in it.


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