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Old 09-28-2010, 08:44 AM   #1
SamCarroll
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Default Marathon Engine troubleshooting

I posted this in my other thread but the title doesnt match anymore so i wanted a new thread with this new problem.

Ok so heres the deal, i replaced the fuel pump and nothing changed. I took off the oil container cleaned out the lines leading to the engine and found the filter flow was backwards. I fixed that and replaced with new oil. I noticed on top of the carb where the throttle piece is it connects to where the oil goes into the engine. Now whenever i give it gas the engine tries to start but no oil has come passed the filter. I may need to replace the filter but the way the cable is set up confuses me and it very well could be wrong. Its like it pushed the cable which doesnt lift the switch on the engine to what looks like allow oil.

The engine backfired a bunch of times and barely didnt start a few other times. its close, and hopefully figuring this last step will help me get it running.

Heres pics I took of the engine and everything i was explaining. Hope this helps.



no oil passed the filter


Whole engine compartment.
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Old 09-28-2010, 09:56 AM   #2
Dave Box
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Default Re: Marathon Engine troubleshooting

Do you really want to continue with the oil injection system? Most guys disconnect the whole thing and simply mix oil and gas and pour that into the tank.

Looking at your connections you appear to be missing a spring. The throttle cable should go through the arm and then have a spring between the carb lever and the end stop nipple. The reason for the spring is so that when he overspeed govenor kicks in it will act against the spring to close the throttle. It looks like someone did not understand this and just put a load of slack in the governor cable. Your governor is currently about as much use as a chocolate fireguard.
The connection to the oil pump is a mess. You are missing a rod and connector, I don't think it will work like that and if it doesn't work you starve your engine of oil and you can guess what will happen next. It is your cart and your decision but I urge you to disconnect the oil line, cut it off about two inches from the elbow and seal it with a screw and some mastic. Now drain your fuel lines to remove the pure gas. Mix one ounce of 2 stroke oil to a gallon of gas and shake vigourously. Add this to your tank, now wrap a shop towel around the filler cap and blow hard to prime the pump.
Start her up and enjoy your cart. In the fullness of time you might care to remove the oil reservoir and the oil pump.
BTW in my opinion a sensible adult driver does not need the governor. Just keep an eye on your speed especially downhill.
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Old 09-28-2010, 10:22 AM   #3
BrewCityMusic
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Default Re: Marathon Engine troubleshooting

Another thing, I could be way off here (help me out guys) but in the last pic it looks like someone rerouted the pulsar cable over the top of the engine and wound the excess around the cables going to the starter/generator (see what I'm talking about?) ... Couldn't that significantly alter the AC pulse or ? resulting in inconsistant spark - I mention it as I had to install a cable stay when I mounted my HEI module on the frame rail and when the pulsar wires would rub up against it, the cart would run really rough, like the module was screwing with the pulsar signal ...

Again, I could be way off base here but figured I'd mention it
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Old 09-28-2010, 10:34 AM   #4
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Default Re: Marathon Engine troubleshooting

ill gladly do premix instead. im new to carts so i was just using what was there but thats easy enough. i can try that when i get home.

what do you suggest i do with that cable and how should i run it for the best way possible?

thanks for the help.
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Old 09-28-2010, 10:37 AM   #5
Dave Box
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Default Re: Marathon Engine troubleshooting

Well spotted Brew City. You need to change your log in to Eagle Eyes
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Old 09-28-2010, 11:42 AM   #6
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Default Re: Marathon Engine troubleshooting

Sam, one other thing I just noticed is the the grounding point on your chassis looks kind of corroded. It might be worth taking it apart and hitting it with a file, sandpaper, wire brush or whatever. If you have a bad ground the engine will try to ground through anything else for example the choke cable, this might result in a weak or intermittant spark
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Old 09-28-2010, 12:57 PM   #7
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Default Re: Marathon Engine troubleshooting

LOL - I was just thinkin about all the time people have spent helping me solve MY problems, so I sat and stared at the pic and tried to trace everything to see what might have been out of place!

(And yeah, that ground point IS notoriously problematic, I believe it was one of MY issues that you pointed out, Dave!)

As to the routing, being as your Ignitor is low on the firewall, the best bet is a fairly direct route along the swingarm - I shortened my Pulsar wires by about 20" when I replaced it, I have NO idea why EZGO designed the setup with like 30" of cable ... Just make sure you have some slack for swingarm travel, etc
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Old 09-28-2010, 01:27 PM   #8
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Default Re: Marathon Engine troubleshooting

Don't mean to step on toes but the spring on the throttle is also used to keep the throttle closed until you press the pedal far enough away from the microswitch so that you can run at very low speed with very little pedal travel and not turn the microswitch on and off, it also closes the throttle completely to prevent backfires. I thought my cart was surging but I was actually turning it on and off while trying to go very slow and it backfired like crazy, installed and squeezed the spring, set the cable stop and voila backfire gone and and could practically crawl.

Good catch BCM
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Old 09-28-2010, 01:29 PM   #9
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Default Re: Marathon Engine troubleshooting

Oh and dump the oil injection, plug the hole on top of the carb, pre-mix like @Dave said and drive on knowing the engine is lubricated.
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Old 09-28-2010, 02:11 PM   #10
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Default Re: Marathon Engine troubleshooting

Im so pissed i have to work till 4 because i want to do everything you all said and get my cart running lol. Im so excited for it to run and you guys have helped a ton. Ive been meaning to clean the ground because it looked bad to begin with. Right on you guys. Ill report back with my findings after i work on it. Hopefully itll be positive.
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