Found an 85 EZ-GO Marathon gasser

Plato_99

Hello! About 2 weeks ago a neighbor gave me an 85 Marathon for free. It was one of the neighbors husbands projects he was going to work on before he died suddenly. It was covered with weeds and leaves but is in relatively decent shape. Towed it home, aired up the tires, changed the gas, flushed out the gas lines, replaced the battery and it fired right up. I'm in the process of going through it to see what it needs to get it into shape. All I want it for is to pull carts and a tree sprayer and carry yard tools in my yard, not going to use it for woods travel.

So far I replaced the carb with a new one, replaced the fuel lines, air filter, spark plugs and gas filters, cleaned all the ground connections, removed the oil injection, did an HEI upgrade, fabbed & installed a rear hitch, and steam cleaned all the gunk and grease off everything. Runs but not good.

This morning I did a compression test and it reads 90lbs, was hoping for app 130, looks like a motor job is needed. Going to start looking into that this week. Want to compare prices for me doing the motor job as opposed to a shop doing the work. I'm comfortable doing motor work, but I've learned over the years that sometimes it pays to let someone who knows what they are doing do the work. The deciding factor will be the cost of the parts and me doing the work as opposed to a shop doing it, if it's close I'll have the shop do it, if not I'll buy the parts and do it myself.

In the meantime I ordered 4 new knobby tires, as the tires it came with are all dry rotted and leaking air badly. Motor mounts are shot, looks like an easy replacement. Once it's running good I'm going to paint it with a military cammo pattern.

Great site here! Lots of info!! Hope I can contribute.

BGW

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Night

Sounds like you have a good plan and know what you are doing. I look forward to seeing you here.

Mark

Plato_99

Lol. I sound like I know what I'm doing?? Lol I know that I know enough to be dangerous!!

Crawled around under the rear portion this morning.

Rear shocks are both broken, need to add shocks to the list.

All 3 motor mounts are totally disintegrated, need to add motor mounts to the list.

Here's where it stands so far:

1. Need to rebuild motor, top end and bottom end.
2. 4 tires - knobbies on order. $70 each, come with rims, $280 total.
3. Rear shocks needed, broken in half
4. Motor mounts needed, totally disintegrated
5. Seats need to be replaced, totally disintegrated
6. Replaced carb. $123
7. Replaced air filter, fuel filter, spark plug. $17
8. Removed oil injection hardware & tank.
9. Ignition HEI upgrade. $45
10. Purchased cammo paint for body. $25
11. Muffler needs to be replaced (good enough for now)
12. Cleaned out fuel tank
13. Replaced all fuel lines $5
14. Fabricated and mounted rear hitch
15. Removed governor
16. Disconnected backup buzzer
17. Cleaned-up motor to chassis ground connections
18. Eliminated key switch, replaced with toggle switch

Haven't looked at the front end yet. I'll do that within the next hour.

I'll start posting pics of this projects progress soon as I figure out how to do it (I'm not a computer person). I have been taking pics as I've been going on.

Plato_99

Checked the front end. Looks OK. Nothing appears to be worn, bent or broken. King Pins are a little sloppy but I think grease may tighten them up, close enough for right now.

As it stands this is what it needs:

1. Need to rebuild motor, top end and bottom end. (Immediate need)

2. Motor mounts needed, totally disintegrated. (Immediate need)

3. 4 tires - knobbies on order. $70 each, come with rims, $280 total.
4. Rear shocks needed, broken in half (good enough for now but before list items #5 & 6)
5. Seats need to be replaced, totally disintegrated (good enough for now)
6. Muffler needs to be replaced (good enough for now)

When I have the motor out I'll disassemble the clutch and check it out, but it appears to be ok. I'm familiar with these clutches from my snowmobiles & 4-wheelers so I don't see any problems fixing it up if it needs any work.

Rear end seems fine. I'll pull the pumpkin cover off sometime and check it out inside but everything feels and sounds ok.

Next step is to start looking for the best prices on the internet for motor rebuild kits. Anyone have any suggestions?

Anyone know a good supplier, any supplier to not deal with?

Is a rebuild kit a rebuild kit?

Any differences in kits or anything I should watch out for and make sure I get when I order ? I'd like to order everything all at once and have everything ready for when I pull the motor.

Dave Box

It sounds like you have a great plan in place. The engine rebuild kits are all made by the same manufacturer in India where they are in great demand for those tuktuk taxis. Your target price should be less than $400. I would look to the sponsors of this forum however you should first read this thread for a cautionary tale

http://www.buggiesgonewild.com/gas-e...-question.html

particularly posts 10 and 15.

Lots of people here will have lots of tips for you when you do the rebuild and I will start the ball rolling with my top tips.

Get a bunch of zip lock bags and a sharpie. As you break it down put the parts in a bag and label them.

The piston must go in with the port facing the input. If you turn it around the engine will run but barely, it is very hard to work out why if you get it wrong.

The complete engine kit comes with new crankshaft seals. Glue them in with some Loctite blue bearing seal. If you rely on the push fit they will fall out.

Use a thin bead of sealant on the crankcase halves. I like mega grey because it matches the metal tone.

If you get stuck shout out, everyone here loves a story with a happy ending.

Good luck
Dave

Plato_99

Thanks for your reply! I'll take all the advice & tips I can get!!!

If that's your buggy in your avitar it looks great. I thought about using that cammy film on my buggy but it seems kinda expensive. I called the company that sells the stuff a week or so ago and they estimated I would need about $350 worth of film! Flat cammo colored spray paint cost me about $25. It's still a possibility though, depends on how I feel about my buggy after I rebuild the motor.

Dave Box

Thank you for the compliment, I got my camo here

http://www.everythingcarts.com/p-147...body-wrap.aspx

I searched the four corners of the internet and this seemed to be the best, although sadly I see they have increased their price by $20 since I bought. Such is life.

Dave

Plato_99

Hey Dave! Is your cart an 85? Looks exactly like mine so I'm assuming it is. I see you have a lift kit on it, where did you get it or is it home made? I would like to lift my cart but I haven't been able to find any kits anywhere. I'm supposed to pick up new tires for my cart this week but if I lift it I could put bigger tires on it. I'd want to find a lift kit before I buy tires.

Thanks again!

Dave Box

It's actually an 86, not that there is any difference. Here is the kit that I used and I have to say for a cheapy it worked out well.

http://www.ebay.com/itm/EZ-GO-Gas-Go...464c3b&vxp=mtr

I used Fox tires 22 x 11 x 8. They are fine but I would advise you that 2 ply tires have a lot of sway in the sidewalls so you may consider spending a little more and getting 4 ply.

Dave

rjc799

Wow, that was inexpensive.

I have an '87, glad I am not the only one having issues finding parts.