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Old 06-12-2013, 01:19 PM   #1
PartTime
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Default Marathon 84' rebuild

Ok, just startin to take things apart, and found that there was only one mtr. mnt. bolt in. Also seen where drive clutch??pulley is bent. There is no damage to mtr. although i will be getting the rubber replaced that is worn-out for these mnts. The bolt that came out where the clutchspring is,was a course thread. How do i take this off?In order to replace the bent pcs. I don't know the names of all the parts, but you can see in these pics. Txs. to BrewCityMusic and PibullJoe & RG and bgw, i have all the parts i need for the 5" lift and wheels spacers,shorter driver belt and the HEI (bwd)coil and mod. ignition sys.. Going to run w/22-11-8s and completely redo the front-end w/new ball joints, bearings and races. Just need to know where is best place to get them? Anywho, it gets hot here really early (110) heat index by noon.Already had heat stroke(2yrs ago) So i get up @ 5am and start until ??. Will work on it some more tomorrow. Txs in advance for any and all advise. Nap-time for the PartTime, HappyTrails.
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Old 06-12-2013, 06:27 PM   #2
Heliarc
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Default Re: Marathon 84' rebuild

If you really want to get that bent clutch off, you're going to have to unbolt your rear end and pull it out otherwise the clutch isn't going to clear the rest of the workings. Besides that though once you take out the bolt in the center the clutch will slide off. What I would do if it were mine would be to get a hammer and wood block or dolly and try to massage that part back into shape. Your belt doesn't ride on that bent part very much so if it's working alright, just try and straighten it. I'm pretty sure that sucker is expensive to replace so a few minutes with a hammer might save you a cool hundo.

FYI, the clutch that is on the engine is the drive clutch, or primary clutch. The one on the rear end is the driven, or secondary clutch. Looks like you got a nice Comet for the drive clutch. Also, the drive clutch is a taper lock. You'll need to either buy a puller or make one to get it off. And you might just want to do that so you can change your crank seals since this is a pretty old cart and chances are they're shot. If your seals go bad it makes the cart run lean and it'll burn it up after a while. Best to spend a few bucks now instead of garfing your engine and spending a whole lot more later.

Stay cool down there.
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Old 06-12-2013, 07:50 PM   #3
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Default Re: Marathon 84' rebuild

You can get the drive clutch off by first removing the bolt holding it on. Then you'll see that the drive clutch is threaded. I sprayed pb blaster in mine and ran a bolt down in the threads. The bolt bottoms out against the end oh the crank and pops the clutch off. I'm not sure what size the threads are but I'm certain they were fine threads.
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Old 06-12-2013, 11:11 PM   #4
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Default Re: Marathon 84' rebuild

Hey thanks Heliarc n Ryan, i wasn't for sure about the clutch. About what type it is, so its a comet. And i'am prob. just goin to straightin the bent part-out and clean everything up a bit. This cart runs pretty good, goin to do afew mods. to it. Nothing to elaberate. ignition,shorter belt, brakes,new front-end,5"lift,taller rubber,replace all mounts,do some maint. etc.. But will post pics. as i go.Txs again
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Old 06-13-2013, 10:55 AM   #5
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Default Re: Marathon 84' rebuild

Looks like you're setting up to do the HEI mod on the ignition. Good move.
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Old 06-13-2013, 11:08 AM   #6
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Default Re: Marathon 84' rebuild

Yes sir, don't know what to do about carb. I was thinking about using diff. style air filter(open). Then if i do that, it will get alot of air. So carb. will have to be rejetted, i suppose. Still up in the air on it.
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Old 06-19-2013, 10:56 PM   #7
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Default Re: Marathon 84' rebuild

Parts are in and i've completely redone the rear brakes. Installed the Monroe 31125s on the rear, however the angle of the springs are set to far forward on the top end. Will have to grind tacks off of the upper bracket n reweld.No problem. Opened up the axle cover plt. and every thing looks like new. Going to clean and reseal W/high temp.(red)Rtv. And ad 80-90, The old smelt and felt like reg. 30w.Kinda burnt. Added the 4" whl. spacers(2")per side, to the rear. Locked down w/blue loc-tight. Will add pics. tomorrow after fishing trip, its going to be around 60 deg. this evening, so hopefully crappie will be bitting n the morning.

Going to order some new motor mts. also tomorrow. I think local dealer has them for around $10 buxs @. The mtr. only had one bolt in holding it in, when i got it so. Going to have to find out what size it is, metric/sae?? and how long. Have not seen description no where in the parts manual. Can you tell that i'am working from back to front on this project? Anyways, got to add the lift on the front-end after i get home. I know i will be changing the bearings and races, the other parts look and feel good,except 1 rubber boot on tie-rod end. Not sure , but i have to take the long shaft off and put the lift on. Then put long shaft(w/t.rds)under leafsprings, right? Any how will post pics. ltr. txs to all (bgw) for your help so far.
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Old 06-20-2013, 02:00 AM   #8
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Default Re: Marathon 84' rebuild

Good fishing and good luck on that cart!
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Old 06-20-2013, 03:23 PM   #9
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Default Re: Marathon 84' rebuild

Put the lift on, man what an angle, swingarm was level. Going to try movin top bracket back, and cut pipe the same length, but at diff. angle. Then add plt., and tack it off, to see how its gonna work.
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File Type: jpg 84'E-Z-GO[GAS] 081.jpg (175.6 KB, 0 views)
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Old 06-21-2013, 03:58 AM   #10
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Default Re: Marathon 84' rebuild

By Yiminy, I'd say it's a bit off. Shouldn't be a big issue to move that top spring perch though. I'd definitely spring for some vice clamps or C-clamps though instead of having to tack it, finding out you don't like it with some weight on it, then you have to grind and retack. If you can clamp it you can experiment and find the sweet spot pretty easy.
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