88 Marathon EZGO uns & Dies

Orchard Worker · 12-25-2009, 08:16 PM

I am new on this forum ,I need a little direction here,Any Ideas with this problem, It will take off and run for a short while then dies and the spark plug is wet, Cart was running pretty good when I first purchased it ,
I might have put 10 hours total on it before this started to occur.
Things already replaced:
New Coil
New Carburetor ( Does anyone have the adjusting specs?(I installed it as-is)
Many New Spark Plugs
Spark plug wire,
New Fuel Pump
new Fuel Filters
Cleaned out Plastic Tank,
New Fuel Hoses
New Battery
I am thinking the Compression may be low? Can this be checked with a standard type Auto Compression gauge?

Workstead · 12-25-2009, 08:31 PM

Welcome Orchard Worker.

You sure can use an auto compression tester, as long as the threads fit. If you get about 120 pounds you're OK as far as compression goes.

I'm in the middle of a top end rebuild on my 92 Marathon because of low compression. I just got the top end off today and the piston is scored so badly I'm surprised it didn't fuse itself to the cylinder wall. Looks like the oil wasn't getting to the cylinder. I'm going to mix my oil with the gas, from now on.

Check your compression and while you have the plug out crank the engine with the threads of the plug grounded and see what kind of spark you are getting, if any. From what you say it seems to be getting gas to the plug but it's not firing.

When an engine won't run it's either not getting gas, spark or compression, (for the most part).

Clem

ruredy · 12-25-2009, 08:45 PM

Yes, use an auto type tester for the compression.
You should check and make sure your choke is opening all the way, also need to have a clean air filter. If filter is dirty or there's some type of restriction it'll act like it's choked and feed to much gas. not sure about that model carb and or adjustment. maybe someone with one can help out here on that.
Also as workstead has pointed out, check and make sure you have spark. will a new plug get it running till it fouls out again?

Orchard Worker · 12-26-2009, 10:10 PM

At first I didnt I have any spark, I replaced the coil and spark plug and Spark plug wire with new, I have good spark. and still no start, I have to get a hold of a Compression gauge and thats my next step. Thanks for the replies,

Orchard Worker · 12-27-2009, 07:26 PM

Here is an Update:
This cart is a 1987 EZGO with the 244cc
Model #EC25-2PG
Eng Motor #87-08750

I completed the compression test the first test ,compression was 95lbs,
I tried it 5 or 6 more times each time compression climbed a little, the last test it was at 115lbs.,(Not high enough) I ended up removing the motor from the frame today, I removed the the upper Head compression cap ,& I removed the cylinder, I noticed on one side of the cylinder head it was heavier with oil than the other side, I started to remove the Cyl.bolts and they were barely tight, I think the piston is suppose to have a very slight amount of play in the cylinder if someone can confirm or deny that I would appreciate it.
There was about 1/8" any direction. I removed the Cylinder head and then proceeded to remove the Piston, I noticed that the Piston had two cracks at the skirt.
( see attached) I also attached an image of the Clutch assembly,I didnt have any issues with it when the cart was running so I think Im ok there.
If anyone knows what I should look for I would appreciate it.
Where can I find the Cylinder head Piston, Gaskets ?
I also need the gaskets under the Carb for the Intake.
The Cart still has the Original Mikuni Oil Injection pump and it was obviously working well with all the oil on that one side of the outside of the cylider head. I think I will leave it on the cart. My thinking on the Piston Cracks is the head bolts came loose on that one side, which allowed the piston to move just enough to cause it to crack at the skirts only on the same side.
I didnt see any bluing or burns in the cylinder but i did notice that the cylinder wall was scored .
Thanks for the ear..
OW

scottyb · 12-27-2009, 08:11 PM

Looks like you found the problem. Since you are saving $ doing this yourself you can splurge a little on OEM parts

Click on the shop Ezgo Link in the upper Right of most bgw pages.......

sabercat · 12-27-2009, 11:48 PM

Quote:

Originally Posted by scottyb

Looks like you found the problem. Since you are saving $ doing this yourself you can splurge a little on OEM parts

Click on the shop Ezgo Link in the upper Right of most bgw pages.......

yup! looks like you'll need a piston and a set of rings and some gaskets. glad to hear you found the issue, some of these old 2 strokes are hard to fix.

DOOmsman · 12-28-2009, 11:17 AM

The piston top looks like it was very lean and it got hot be sure and torque the cyl base bolts in stages. I like a cheap 12 inch beam with inch pounds and maybe you can splurge on a crows foot adapter

Workstead · 12-28-2009, 11:24 AM

Quote:

Originally Posted by DOOmsman

The piston top looks like it was very lean and it got hot be sure and torque the cyl base bolts in stages. I like a cheap 12 inch beam with inch pounds and maybe you can splurge on a crows foot adapter

DOO,

What is the advantage of the crows foot adapter if you can get to the nut with a socket?

Clem

DOOmsman · 12-28-2009, 11:53 AM

None but a torque wrench is thicker than a ratchet and it looks like the base studs are in under the cylinder. If you use a crow foot there will be an adjustment to the torque amount because of increased leverage.

12-25-2009, 08:16 PM	#1
Orchard Worker Not Yet Wild Join Date: Dec 2009 Posts: 13	88 Marathon EZGO uns & Dies I am new on this forum ,I need a little direction here,Any Ideas with this problem, It will take off and run for a short while then dies and the spark plug is wet, Cart was running pretty good when I first purchased it , I might have put 10 hours total on it before this started to occur. Things already replaced: New Coil New Carburetor ( Does anyone have the adjusting specs?(I installed it as-is) Many New Spark Plugs Spark plug wire, New Fuel Pump new Fuel Filters Cleaned out Plastic Tank, New Fuel Hoses New Battery I am thinking the Compression may be low? Can this be checked with a standard type Auto Compression gauge?

12-25-2009, 08:31 PM	#2
Workstead Getting Wild Join Date: Nov 2009 Location: Jonesboro, AR Posts: 94	Re: 88 Marathon EZGO uns & Dies Welcome Orchard Worker. You sure can use an auto compression tester, as long as the threads fit. If you get about 120 pounds you're OK as far as compression goes. I'm in the middle of a top end rebuild on my 92 Marathon because of low compression. I just got the top end off today and the piston is scored so badly I'm surprised it didn't fuse itself to the cylinder wall. Looks like the oil wasn't getting to the cylinder. I'm going to mix my oil with the gas, from now on. Check your compression and while you have the plug out crank the engine with the threads of the plug grounded and see what kind of spark you are getting, if any. From what you say it seems to be getting gas to the plug but it's not firing. When an engine won't run it's either not getting gas, spark or compression, (for the most part). Clem Last edited by Workstead; 12-25-2009 at 08:35 PM.. Reason: Typo

12-25-2009, 08:45 PM	#3
ruredy Born Wild Join Date: Mar 2007 Location: Clover SC. Posts: 5,552	Re: 88 Marathon EZGO uns & Dies Yes, use an auto type tester for the compression. You should check and make sure your choke is opening all the way, also need to have a clean air filter. If filter is dirty or there's some type of restriction it'll act like it's choked and feed to much gas. not sure about that model carb and or adjustment. maybe someone with one can help out here on that. Also as workstead has pointed out, check and make sure you have spark. will a new plug get it running till it fouls out again?

12-26-2009, 10:10 PM	#4
Orchard Worker Not Yet Wild Join Date: Dec 2009 Posts: 13	Re: 88 Marathon EZGO uns & Dies At first I didnt I have any spark, I replaced the coil and spark plug and Spark plug wire with new, I have good spark. and still no start, I have to get a hold of a Compression gauge and thats my next step. Thanks for the replies,

12-27-2009, 08:11 PM	#6
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: 88 Marathon EZGO uns & Dies Looks like you found the problem. Since you are saving $ doing this yourself you can splurge a little on OEM parts Click on the shop Ezgo Link in the upper Right of most bgw pages.......

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12-28-2009, 11:17 AM	#8
DOOmsman Gone Wild Join Date: Jul 2008 Location: Reddick IL Posts: 11,220	Re: 88 Marathon EZGO uns & Dies The piston top looks like it was very lean and it got hot be sure and torque the cyl base bolts in stages. I like a cheap 12 inch beam with inch pounds and maybe you can splurge on a crows foot adapter

12-28-2009, 11:53 AM	#10
DOOmsman Gone Wild Join Date: Jul 2008 Location: Reddick IL Posts: 11,220	Re: 88 Marathon EZGO uns & Dies None but a torque wrench is thicker than a ratchet and it looks like the base studs are in under the cylinder. If you use a crow foot there will be an adjustment to the torque amount because of increased leverage.

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