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Old 01-05-2012, 05:53 PM   #1
beerice
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Default 85 Marathon 2pg Modifications

First off thank you to everyone in these threads who contribute, I spent better part of the last 3 days reading on how to get more POWER!

So far things I have already done to the cart with the help of my father(mechanic)

We lifted and painted it
Re-upholstered the seat and backs
Bored the engine - we did this because we scored something?!?! Not sure
Replaced the Ignition system with stock replacement
Replaced Fuel filter
Replace battery cable
Complete carb replacement

What I want to do for sure:
Add the cold air intake
Add 1" shorter belt

Maybe:
I might BBQ the muffler but I am not seeing issues as of yet.

The Questions I have are:
Would replacing the already brand new ignition with HEI improve power?
Do they make piston kits for an over sized bore?
Lastly, spark plug are they shallow or deep plugs. I have a shallow in there now and in the winter up north here it may take 2 minutes with full choke before it fires.

Also if you guys have any other ideas for improving power, let me know.
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Old 01-05-2012, 07:07 PM   #2
Ghall
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Default Re: 85 Marathon 2pg Modifications

Welcome to the forum!
Is it 2 stroke or 4?
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Old 01-05-2012, 08:32 PM   #3
sharse36
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Default Re: 85 Marathon 2pg Modifications

2 stroke look at the heading marathon 2pg motor

I seen piston for .25 and .50 over size.
I put the HEI on my cart and it starts a lot better especially if it is cold
The right plug is a NGK- BP5HS
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Old 01-05-2012, 09:43 PM   #4
beerice
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Default Re: 85 Marathon 2pg Modifications

2 Stroke

Thanks for the plug info, I am thinking .50 should work.... going to test the compression this weekend if it is above 100psi then I think it is good without the rebuild.... I think.

Another question.... will the Work House secondary clutch attach to this as simple rip and replace? I like the idea of increasing the spring tension too for more POWER!

It should be noted that I am trying my best to keep the engine in it. 244cc 2 stroke. I also heard I could possible modify a carb off of a 70's Polaris Snow Mobile and use it for more air/fuel. <- input on this would be nice.
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Old 01-06-2012, 07:15 AM   #5
sharse36
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Default Re: 85 Marathon 2pg Modifications

Form what I know is the clutch that is on the cart is the only one that you can put no it. On the spring you can shim the spring with big washers to give it more tension. I have a very week springin my driven clutch, I shimmed and stretched the spring and it did help. I can not find a replacement spring for the driven clutch.

On the motor remember that the motor spins backwards for reverse. So if you did replace the motor with a bigger motor you will not have reverse. Im not sure about the snowmobile carb if that would help or not.
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Old 01-06-2012, 09:13 AM   #6
Dave Box
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Default Re: 85 Marathon 2pg Modifications

Beerice, welcome to the wonderful world of the 2PG engine.

You can always get a little more power out of the engine but what ever you do to the clutch will have no impact on output. The most common and cheapest modification is to use a slightly shorter belt. This does not increase power or top speed but it does increase the low end torque and hence acceleration and hill climbing ability.

If you were feeling particularly adventurous you could try to emulate the modifications that EZGO made when they converted the 2PG to 3PG. In the main they changed the carburetor from the BV-18 to the larger BV-24. They also used a piston with two ports and that will fit the 2PG cylinder. Unfortunately they also incorporated two further mods that may prove to be cost ineffective for you. The first was a redesigned exhaust system. For a 2 cycle engine the exhaust has to be tuned and as part of the exhaust pipe is the expansion camber. For a nice explanation and a graphic click here
http://en.wikipedia.org/wiki/2_stroke
You should note how much raw fuel is driven into the expansion pipe and then sucked back before ignition.

However the real project killer is the differential. Mid 1989 EZGO rotated the engine 90 degrees.This rotation allowed for the differential to be changed from a hypoid gearing to a more efficient helical gear design, a change that persists to this day. With all of this the output (at the rear wheels) went from 9hp to 11hp.

That said a well maintained 2PG is a viable engine (of course I would say that I have one) and I can run rings around my 4 stroke buddies.

Have fun with your project and more fun driving your cart.

Dave
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Old 01-06-2012, 10:38 AM   #7
beerice
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Default Re: 85 Marathon 2pg Modifications

Thanks Dave, I was able to read the short history on the engines here a few days ago but thanks for the refresher. If I could get a jump from 9hp to 11hp with a few mods I sure would be in heaven. And when I say power I mean both torque and HP's. I am thinking though I am in the 7hp range at the moment.

As far as the the engine replacement... Ski Doo made one with an electric reverse that would sit in the 2PG chassis. This would be ideal for me just need to find one that is being sold cheap.

If I could also make my 2PG into more like 3PG that also would be nice. More carb and pits would give me more to work with. As far as the muffler. Having a buddy that owns his own exhaust shop, you can get pretty creative. Some thoughts would to take a Yamaha 250cc dirt bike exhaust and cut it apart to fit.

I of thinking of documenting my upgrades this weekend and throwing some pictures up in a new thread. Everyone has been so helpful and I know I enjoyed reading about other peoples mods when they had PICTURES!

I also found out that I am running a premix of 50:1(woops)

How much HP's will I gain with the cold air intake and cutting the mix fuel to 128:1 ? 1hp maybe 2hp?

Man if I can squeeze 3 hp with all these modifications out of this little 2pg that would be perfect.

Hopefully the weekend comes early.
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Old 03-14-2012, 04:57 AM   #8
panelbeatr
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Default

Anyone have anything further on exhaust mods?? I've got a 3PG and I'm wanting to install a powered bed lift and the horizontal muffler is in the way..
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