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Gas EZGO Gas EZGO Marathon, Medalist, TXT and RXV.



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Unread 07-24-2013, 08:21 PM   #1
Not Yet Wild
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Join Date: Jul 2013
Location: Fishers, IN
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Default First Cart...Complete rebuild...need help

Picked up my first cart.
I think it's an 87 Marathon, but not sure.
Motor is locked up so I took it out to start the rebuild.
Bottom end is also bad so I need to rebuild the whole motor.
How do I get the clutch off...
Also the flywheel has two small screws...what are they for...do they need to come off?








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Unread 07-25-2013, 07:15 AM   #2
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Location: Savannah MO
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Default Re: First Cart...Complete rebuild...need help

Your setup looks a bit different than my 81, but those screws could be for the pulsar...? Not sure though. You need a clutch removal bolt. The exact size evades me at the moment. This thread may help.

1992 EZ-GO drive clutch removal
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Unread 07-25-2013, 01:41 PM   #3
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Default Re: First Cart...Complete rebuild...need help

Thanks...I'll go pick up the stuff to get the clutch off and see what I can do.
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Unread 07-25-2013, 08:15 PM   #4
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Default Re: First Cart...Complete rebuild...need help

You can make your own puller with a steel rod that fits into the clutch hole and is just long enough that you screw in bolt (same size as the threads on clutch end). Plan is to have a rod and a bolt that is now going to make the bolt have to seat in enough for good thread holding to push the rod against the crank shaft thus pushing off the clutch. Hope this is good enough of discription. Bolt will hit the top of the rod that is hitting the crank and as you thread the bolt in, it will force the clutch off the crank shaft. Make sure the rod is bigger than the female threads on the crank, but then if you are going to get another crank sooo....who cares.
Yes the screws are for the pulser. You will also need to have a puller to remove the flywheel .Take pics as you go along with this rebuild as they come in very handy on re-assembly. Your 2PG engine long block is cheaper than my 3PG was so go for the total crank, rod,bearings, piston, jug, rings and the seals rebuild.
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Unread 07-25-2013, 08:40 PM   #5
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Default Re: First Cart...Complete rebuild...need help

So just to be sure, I don't need to worry about the screws on the flywheel at this point? It will come off with the screws in place I assume?
Thanks for all the feedback. I will need lots of help along the way on this project.
Turned out to be more of a project than I expected....but what else is new..LOL
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Unread 07-29-2013, 11:19 AM   #6
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Default Re: First Cart...Complete rebuild...need help

Well I was able to get the flywheel and clutch off a couple of days ago.
Clutch did not want to go easy.....but I finally won that battle....
Now to get the crank case halves apart.
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Unread 07-29-2013, 03:30 PM   #7
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Default Re: First Cart...Complete rebuild...need help

Well I was able to get the case apart today.
Actually was a lot easier than I expected.
I was able to get it split slightly with a rubber mallet, then used ratchet tie down straps to pull it apart.
Is there anything I need to replace or look besides the full rebuild kit that I will be installing. (ordering that tonight).


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Unread 07-30-2013, 10:20 AM   #8
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Default Re: First Cart...Complete rebuild...need help

OK..I ordered the complete rebuild kit last night...should be here by the end of the week.
My question now is do I press the bearings into the case, or on the crankshaft first?
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Unread 07-30-2013, 11:09 PM   #9
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Default Re: First Cart...Complete rebuild...need help

Press them on the crank first lube the bearings with 2 cycle oil or bearing guard same as cam lube. Be sure to install the crank seals in the case halves before pressing the crank in the cases.


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Unread 08-02-2013, 04:53 PM   #10
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Default Re: First Cart...Complete rebuild...need help

All cleaned up and new parts arrived today.
Ready to start putting the puzzle back together.
Anything I special I need to be aware of?
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