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Old 03-14-2015, 11:09 AM   #1
Mac1978
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Default Need help with a Marathon issue

I have been chasing a ghost in my 93 Marathon 295 for a while, and I just can't find it. Cart runs fantastic until I get to a certain hill, then falls flat on its face. It used to climb hill fine with 4 adults, then 3, then 2, then.... After it acts up, it won't run right for a while, then runs like new again. I figured that maybe it was worn out and just losing compression, so I decided to check it at the very moment that it would act up, and it's 170/170. I have adjusted valves several times, new fuel pump, new carb, new ignitor, new coil, new voltage regulator, etc. could it be a goofy clutch problem, or the generator breaking down at temp? Any input is greatly appreciated!
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Old 03-14-2015, 08:01 PM   #2
Mattm
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Default Re: Need help with a Marathon issue

I've had a problem with my driven clutch for a while, it runs great up hills some times then other times it just sucks. I'd say possibly a clutch, just cause it sounds like what mine is doing and I know that is my problem.
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Old 03-14-2015, 09:42 PM   #3
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Default Re: Need help with a Marathon issue

Is the engine still revving when it falls on its face? If so, then you may have a clutch problem. Measure the width of your belt first though. It should be 1 3/16 " wide. If it is more narrow, then the clutches can't grip it properly when under a load.
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Old 03-14-2015, 10:37 PM   #4
Mac1978
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Default Re: Need help with a Marathon issue

After it does this, you can only pump the throttle slightly to get it to go a few yards at a time.
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Old 03-15-2015, 06:10 AM   #5
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Default Re: Need help with a Marathon issue

So lets clarify, the engine itself loses rpms and power? Or does it seem to stay revved up. You could remove the seat and lay a 2x6 across the engine bay. Drive to that hill and see what the clutches are doing. As it encounters the incline you should see the belt on the front "drive" clutch move toward the inner diameter. That means the rear "driven" clutch is closing the drive and pulling the drive clutch open.

If all that is doing what it's supposed to do, then we can move to the engine and start figuring out what its doing.
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Old 03-15-2015, 08:59 AM   #6
Mac1978
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Default Re: Need help with a Marathon issue

Ok, cool. I'll do that this afternoon and report back. It seems like it is being bogged down, though.Thanks for the help!
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Old 03-16-2015, 07:33 PM   #7
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Default Re: Need help with a Marathon issue

Looks like I have a driven clutch issue. Any way to overhaul it?
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Old 03-17-2015, 07:40 AM   #8
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Default Re: Need help with a Marathon issue

Ok, first, what's the width of your belt. Second, what is the driven doing? There are plastic buttons in the driven that slide on ramps. They become worn and can cause it to stick and not open and close smoothly.
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Old 03-17-2015, 08:14 AM   #9
Mac1978
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Default Re: Need help with a Marathon issue

Belt is 1.25. It acts like its bogging down going uphill and fouling the plugs
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Old 03-17-2015, 09:03 AM   #10
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Default Re: Need help with a Marathon issue

Your belt is 1 1/4"? If that is correct,then that is a 1/16 larger than stock. Did you remove the seat and use a 2x6 to sit on then observe the driven clutch to make sure it is opening when you encounter the hill?

Page J2 and J3 of this manual:
http://products.jacobsen.com/img/manuals/605586.pdf

detail CVT clutch operation and also how to service it.
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