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-   -   1970 to 1990's Marathon explained - Manual (https://www.buggiesgonewild.com/showthread.php?t=105501)

Dave Box 05-01-2015 07:00 AM

1970 to 1990's Marathon explained - Manual
 
As Scowboy says it is the 3PG and it generates 11 hp. It also benefits from a more efficient differential. Here is a short history of the engine.

-In 1976 the so-called '2pg'--a 244cc, Fuji Heavy Industries/Robin Engine--with an internal starter generator (st/gen), became standard. Repair parts are still available except for the crankshaft assembly, the voltage regulator/starter relay and the internal st/gen stator & field.

-In 1980, an external, Hitachi brand starter generator was introduced and the engine was modified. The crank bearings, drive clutch, point set & condenser, voltage regulator and the engine frame all changed.

-1981 ushered in an electronic ignition system, which did away with the golf carts point set & condenser altogether, and the point activator lobe on the crankshaft soon went away too. Except for the addition of an oil injection system, this engine went virually unchanged until 1989 when the 3pg golf cart engine replaced it. Although the two engines are similar, many parts are very different.

-1983 was the oddball year for the 2pg engine. The muffler was placed behind the engine and it layed down instead of standing up. The '83 golf cart had a different engine frame, muffler & exhaust stack. It only lasted one year though...lots of problems.

In '84 the E-Z-GO golf cart went back to the old exhaust system & stand-up muffler on the driver side of the car.

1988 was the last full year of the 2pg engine. A larger golf cart carburetor and another change to the muffler & exhaust system were implemented trying to get more power for the car. The st/gen bracket also went through several changes as the incresed power caused the original bracket to break apart.

In mid-year 1989, (early '89 models had the 2pg engine) E-Z-GO changed to the '3pg' engine, leaving the old 2pg to history. The '3pg' engine has the spark plug turned upward, and the whole engine is rotated such that both clutches face the driver side of the golf cart. 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. The lay-down style golf cart muffler for the '3pg' engine is in front of, and slightly above the engine. The piston is about the only part that works in either engine. The crankshaft & clutches, the exhaust system, the carburetor, air intake & control cables all changed.

1992 is the generally accepted date that the twin-cylider 4-cycle engine became the standard power plant but in fact the 3pg engine can be found in golf carts as late as 1994.

francesc1 10-13-2015 03:19 PM

Re: 1970 to 1990's Marathon explained
 
great post!
i have a cross between late 79 and early 80
marathon 2pg
it has the external starter generator.
ran great for the longest time.
i bought it from a member in our trailer park who has since passed.
fuel is ok new points filters and spark plug new
carb cleaned pump is pumping
this is the last of its kind in our park
could the seals be bad?

Doody 03-03-2016 07:04 PM

Re: 1970 to 1990's Marathon explained
 
I have a 86 marathon that I'm rebuilding the top end it has the 2pg engine and I'm trying to figure out if it's better to use the two port 3pg piston instead if some one can shine some light on this that would be grate

TomStark 03-05-2016 07:38 PM

Re: 1970 to 1990's Marathon explained
 
Quote:

Originally Posted by Doody (Post 1249253)
I have a 86 marathon that I'm rebuilding the top end it has the 2pg engine and I'm trying to figure out if it's better to use the two port 3pg piston instead if some one can shine some light on this that would be grate

I do not know, but would bet it is best to use the 2pg piston in the 2pg and 3pg piston in the 3pg. No idea if there is any gain to be made by using the 3 in the 2, but willing to bet it is miniscule at best. I think there is a lot more to gain by making sure the port timing is correct for your use, and that the ports are aimed correctly, maybe give a little more compression, etc.
Tom

kip_66 04-26-2016 12:09 PM

Re: 1970 to 1990's Marathon explained
 
Quote:

Originally Posted by Dave Box (Post 1148973)
As Scowboy says it is the 3PG and it generates 11 hp. It also benefits from a more efficient differential. Here is a short history of the engine.

-In 1976 the so-called '2pg'--a 244cc, Fuji Heavy Industries/Robin Engine--with an internal starter generator (st/gen), became standard. Repair parts are still available except for the crankshaft assembly, the voltage regulator/starter relay and the internal st/gen stator & field.

-In 1980, an external, Hitachi brand starter generator was introduced and the engine was modified. The crank bearings, drive clutch, point set & condenser, voltage regulator and the engine frame all changed.

-1981 ushered in an electronic ignition system, which did away with the golf carts point set & condenser altogether, and the point activator lobe on the crankshaft soon went away too. Except for the addition of an oil injection system, this engine went virually unchanged until 1989 when the 3pg golf cart engine replaced it. Although the two engines are similar, many parts are very different.

-1983 was the oddball year for the 2pg engine. The muffler was placed behind the engine and it layed down instead of standing up. The '83 golf cart had a different engine frame, muffler & exhaust stack. It only lasted one year though...lots of problems.

In '84 the E-Z-GO golf cart went back to the old exhaust system & stand-up muffler on the driver side of the car.

1988 was the last full year of the 2pg engine. A larger golf cart carburetor and another change to the muffler & exhaust system were implemented trying to get more power for the car. The st/gen bracket also went through several changes as the incresed power caused the original bracket to break apart.

In mid-year 1989, (early '89 models had the 2pg engine) E-Z-GO changed to the '3pg' engine, leaving the old 2pg to history. The '3pg' engine has the spark plug turned upward, and the whole engine is rotated such that both clutches face the driver side of the golf cart. 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. The lay-down style golf cart muffler for the '3pg' engine is in front of, and slightly above the engine. The piston is about the only part that works in either engine. The crankshaft & clutches, the exhaust system, the carburetor, air intake & control cables all changed.

1992 is the generally accepted date that the twin-cylider 4-cycle engine became the standard power plant but in fact the 3pg engine can be found in golf carts as late as 1994.

Dave,
I am hoping you can help me.. I have a 1989 EZGO Marathon. What function has to take place to get the rear end to go in reverse? Mine is a project cart that I am trying to rebuild and it is missing alot of pieces.. There is a little stub on top of the differential, is that the forward reverse mechanism? If not, how does the cart go into reverse?

TomStark 04-26-2016 03:58 PM

Re: 1970 to 1990's Marathon explained
 
Quote:

Originally Posted by kip_66 (Post 1267617)
Dave,
I am hoping you can help me.. I have a 1989 EZGO Marathon. What function has to take place to get the rear end to go in reverse? Mine is a project cart that I am trying to rebuild and it is missing alot of pieces.. There is a little stub on top of the differential, is that the forward reverse mechanism? If not, how does the cart go into reverse?

If you have a 2 stroke, and 89 should be a 3pg 2 stroke, you go in reverse by starting the engine up backwards. Only 4 strokes have any sort of reverse.
Tom

simmons87 06-10-2016 03:49 PM

Re: 1970 to 1990's Marathon explained
 
i have a 80 ezgo 2pg rear axles are shot its the key one looking to replace can anyone help me out

krp 10-09-2016 05:01 PM

Re: 1970 to 1990's Marathon explained
 
I have a 1990 Maraton Freedom with the 3PG engine. The service manual refers to "early" and "late" 1990 models. There are differences in the wiring for "early" and "late" models. This is critical since I have electrical problems. How can I tell if my cart is "early" or "late"?

WVCartMan 11-13-2016 09:44 AM

Re: 1970 to 1990's Marathon explained
 
I have a 1983 2PG, based on what I read above, would it be a good idea to replace the stock carb and exhaust on this cart with the carb and exhaust from a 1988 2PG to get the added horsepower? Or would this create more problems than it's worth?

Thanks

WVCartMan 11-30-2016 10:13 AM

Re: 1970 to 1990's Marathon explained
 
Dave Box,

One more question about my 1983, when you say "It only lasted one year though...lots of problems." for the 1983, what "...lots of problems." are you referring to? Is there something more than the carb/exhaust that I should be looking for?

Thanks for the help

aleminx 11-12-2018 05:56 AM

Re: 1970 to 1990's Marathon explained
 
I have a 96 (94 maybe?) Tuff truck I believe it's called. Would that qualify as a marathon? Has the 295 but a diamond plate exterior and originally came with a dump bed. Uses the 4 bolt steering mount... Parts are sometimes tough to cross reference. Great post!

Gully 06-11-2019 04:03 PM

Re: 1970 to 1990's Marathon explained
 
Hi there. Does anyone have a link to a manual for a 1988 EZ GO ? Thanks

cart around 06-11-2019 05:36 PM

Re: 1970 to 1990's Marathon explained
 
1 Attachment(s)
Here.

JonnyPhenomenon 07-09-2019 01:30 PM

Re: 1970 to 1990's Marathon explained
 
Quote:

Originally Posted by cart around (Post 1624577)
Here.

THANK YOU FOR THIS!

Seriously man, I've wasted the better part of my day trying to track this down.

Thats the Genuine Article right there... E-Z-Go Gasoline Powered Golf Car Owner's Operation And Service Manual NO. 23839-G1 for model Year 1988

fantastic!

Someone add this to the sticky!

rib33024 07-09-2019 03:01 PM

Re: 1970 to 1990's Marathon explained
 
Quote:

Originally Posted by JonnyPhenomenon (Post 1633788)
THANK YOU FOR THIS!

Seriously man, I've wasted the better part of my day trying to track this down.

Thats the Genuine Article right there... E-Z-Go Gasoline Powered Golf Car Owner's Operation And Service Manual NO. 23839-G1 for model Year 1988

fantastic!

Someone add this to the sticky!



JonnyPhenomenon This Thread with the manual in it. Is in the Sticky's, That is where you found it. :mrgreen: Welcome

Firefighter316 08-16-2019 08:16 PM

Re: 1970 to 1990's Marathon explained - Manual
 
Anybody have or know where I can find or get a internal armature for 1979 ezgo golf cart


Sent from my iPhone using Tapatalk

brads1986 04-09-2020 02:14 PM

Re: 1970 to 1990's Marathon explained
 
Thanks so much for sharing this! I just entered to world of Marathon ownership & have hunted high and low for an '88 manual.

jakesnake27 04-09-2020 02:42 PM

Re: 1970 to 1990's Marathon explained
 
Quote:

Originally Posted by brads1986 (Post 1705432)
Thanks so much for sharing this! I just entered to world of Marathon ownership & have hunted high and low for an '88 manual.

:thumbup:

:sign3: to BGW

IMKCMAC 05-23-2020 08:09 PM

Re: 1970 to 1990's Marathon explained - Manual
 
What is the model no. for the 4cyl. motor that started in 1992? I have a 1992 Marathon?

newtjl 05-24-2020 06:02 PM

Re: 1970 to 1990's Marathon explained - Manual
 
Its a 295 cc Robin Engine. The manual is here https://products.jacobsen.com/img/manuals/27615-g01.pdf

Beadyeyez 08-08-2020 12:27 PM

Re: 1970 to 1990's Marathon explained - Manual
 
I have a 1987 Marathon and I'm finding it next to impossible to find any manuals for it. Lots of 88 and later but no luck for the 87. Aside from paying $100+ for the parts and service copies...any tips on where a guy could find them? Even just a few clutch specific pages

Sent from my SM-G973W using Tapatalk

cart around 08-08-2020 04:08 PM

Re: 1970 to 1990's Marathon explained - Manual
 
2 Attachment(s)
The only differences between the 87, and 88, are the carburetor, exhaust, and front cowl. Use the 85 manual for everything except the wiring. The 87 has an extra microswitch that the 85 doesn't.

ldj1002 08-24-2020 08:49 AM

Re: 1970 to 1990's Marathon explained - Manual
 
It looks like the solenoid is activated all the time the limit switch is closed. Does that make the starter generator in the start mode all time also?

cart around 08-24-2020 09:23 AM

Re: 1970 to 1990's Marathon explained - Manual
 
Quote:

Originally Posted by ldj1002 (Post 1753445)
It looks like the solenoid is activated all the time the limit switch is closed. Does that make the starter generator in the start mode all time also?

Yes. As the engine gets up to speed, the starter begins to generate power. It then becomes the generator.

cart around 10-30-2020 08:56 AM

Re: 1970 to 1990's Marathon explained - Manual
 
This link is for the 2 stroke 3pg manual. 1989 to I think it ended in 1994.
Each chapter is broken down into pdf files. I would suggest downloading all of them, and saving locally in case this link ever disappears. https://app.box.com/s/3habgxrtgz

EZ Gone..... 12-05-2020 09:56 AM

Re: 1970 to 1990's Marathon explained - Manual
 
Thanks for the manuals!!!! Now time to buy parts....

jakesnake27 12-05-2020 01:51 PM

Re: 1970 to 1990's Marathon explained - Manual
 
Quote:

Originally Posted by EZ Gone..... (Post 1787046)
Thanks for the manuals!!!! Now time to buy parts....

:sign3: to BGW

sippi5 05-09-2021 05:05 AM

Re: 1970 to 1990's Marathon explained - Manual
 
so i have a 1976 ezgo 2 cycle, does that mean it has the 244cc with internal

cart around 07-02-2021 06:36 PM

Re: 1970 to 1990's Marathon explained - Manual
 
Compare your manual to this one, and let us know if it's the same.
https://app.box.com/s/3habgxrtgz


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