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Unread 01-28-2020, 07:24 PM   #1
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Default 85 Marathon Starter/Generator hot to the touch

Hi, I purchased a 85 marathon, which I did a complete Motor rebuild. Everything went smooth except for the flywheel removal, which took 5 days of Cussing, Beer, and a lot of reading in this forum. It started right up, and I have run about 1/2 tank of break in fuel (40:1) thru it at not more than 1/2 throttle. I am not familiar with Golf carts, and was wondering if the Starter/Generator should be hot to the touch after driving 20 min or so. If this is not normal, what should I be looking at? Thanks for any help.
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Unread 01-31-2020, 06:21 PM   #2
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Default Re: 85 Marathon Starter/Generator hot to the touch

Anyone knows if this is normal?
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Unread 01-31-2020, 07:34 PM   #3
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Default Re: 85 Marathon Starter/Generator hot to the touch

Shouldn’t be gettin hot... a little warm maybe... might want to check the brushes and bearings
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Unread 02-01-2020, 06:34 AM   #4
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Default Re: 85 Marathon Starter/Generator hot to the touch

Thanks timber, I looked at 3 of the brushes thru the plug holes (could not get to the bottom one, and did not remove S/G), and they looked like they were new, with plenty sticking above the holders/seat. I did not take the end off, but the pulley spins freely, and smooth. I have been going thru and cleaning all connections, and looking at insulation for cracks, wear spots. I then went for a 30 min ride, and it appeared to not be as warm as before. The big wires appear to be original (35 yrs. 0ld), and I think I will replace for peace of mind.
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Unread 02-01-2020, 09:07 AM   #5
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Default Re: 85 Marathon Starter/Generator hot to the touch

Is the starter/generator underneath the muffler like in the 3pg? That would cause quite a bit of heat...
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Unread 02-01-2020, 01:41 PM   #6
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Default Re: 85 Marathon Starter/Generator hot to the touch

No, the 85 muffler stands upright under the driver
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Unread 02-03-2020, 07:44 AM   #7
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Default Re: 85 Marathon Starter/Generator hot to the touch

I must have a short somewhere. After diving around for an hour or so I parked the cart and S/G felt warm. 1 hour later I check it, and it still was warm, motor and exhaust were room temperature. I disconnected battery cable and it cooled off in 10 mins. reconnected and it stayed cool to the touch. Any Ideas?
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Unread 02-03-2020, 08:50 AM   #8
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Default Re: 85 Marathon Starter/Generator hot to the touch

It doesn't make any sense, but there are two places I would check for a short. One would be the wire going from the hot side of the key switch to the microswitch for the backup buzzer. That is located on the driver's side of the FnR switch.

The other place would be the voltage regulator. No, scratch that. The only way it could be the voltage regulator is if it is wired to the wrong side of the solenoid.

The only thing that could supply power without the pedal being pushed is the wire for the backup buzzer.

This is the 85 manual, and wiring diagram.
Attached Files
File Type: pdf 85-EZGO(2) (1).pdf (6.71 MB, 0 views)
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Unread 02-10-2020, 07:07 PM   #9
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Talking Re: 85 Marathon Starter/Generator hot to the touch

Update: OK, I think I have it figured out. I checked/cleaned all connections, and when I got to the DF stud on the S/G, the stud itself was loose (it could wobble and slide 1/8 to 1/4") from the S/G housing, and I think it was shorting out to the housing. I centered it, tightened it down, and now it only gets slightly warm after 30 min. of driving. If it changes, I will let you know. Thanks for the help.
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