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Old 05-16-2017, 05:12 PM   #1
yogi827
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Unhappy 91 ezgo marathon oil tank cracked

my `91 ezgo marathon 2cycle has a cracked oil tank and of course you can not get one anymore so i have to remove the tank and oil injection system. my question is does anyone have a step by step process i can follow so i can make sure i remove everything and also not lock up my motor. i know to use a 6mm bolt or screw to plug the top of intake but how long of one. any help would be much appreciated thanks in advance
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Old 05-16-2017, 05:41 PM   #2
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Default Re: 91 ezgo marathon oil tank cracked

Just long enough to seal the intake. You don't want it hanging down in to disrupt the flow.
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Old 05-16-2017, 08:31 PM   #3
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Default Re: 91 ezgo marathon oil tank cracked

Ok thanks. Any tips on what I actually need to remove or plug after removal of oil tank and pump etc?
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Old 05-16-2017, 11:15 PM   #4
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Default Re: 91 ezgo marathon oil tank cracked

Unbolt the pump from the fan cover. Pull the hoses from the tank to the pump and the pump to the intake. Remove the cable from the carb to the pump. Remove the tank. That should be it. It is a fairly simple system (that often fails). Premix is much easier and gives you some peace of mind.

And while you are in there removing useless junk, go ahead and remove the governor if it is still hooked up. Haha
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Old 05-17-2017, 07:00 AM   #5
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Default Re: 91 ezgo marathon oil tank cracked

Thanks for the info. Yep governor is definitely coming off lol!!! Gonna try and knock it out this weekend
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Old 05-17-2017, 07:53 AM   #6
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Default Re: 91 ezgo marathon oil tank cracked

I'd say that oil tank did you a favor, 3/8" to 1/2" long for the plug bolt will be fine. And yeah get rid of that governor too, I took mine off after the first 15 minutes I owned it when I realized how easy it was. Wish my Yamaha G1 was as simple to remove, I still haven't done that one yet and it's waaay to slow
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Old 05-17-2017, 03:28 PM   #7
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Default Re: 91 ezgo marathon oil tank cracked

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Originally Posted by Dabble Inn View Post
I'd say that oil tank did you a favor, 3/8" to 1/2" long for the plug bolt will be fine. And yeah get rid of that governor too, I took mine off after the first 15 minutes I owned it when I realized how easy it was. Wish my Yamaha G1 was as simple to remove, I still haven't done that one yet and it's waaay to slow
G1 is easy take the arm off the top of the rearend and drill out the "d" in the arm place it back on hook of the cables and tack weld a washer on top of the shaft so the arm moves freely and wa-la you have a 20+ mph golf cart
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Old 05-17-2017, 06:20 PM   #8
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Default Re: 91 ezgo marathon oil tank cracked

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Originally Posted by Spicyunicorn View Post
G1 is easy take the arm off the top of the rearend and drill out the "d" in the arm place it back on hook of the cables and tack weld a washer on top of the shaft so the arm moves freely and wa-la you have a 20+ mph golf cart
Well....... I was right there with ya easy peasy all the way up to the word welder, LOL..

I've heard of hooking the two cables together but haven't came up with a way to do that either, Thanks though
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Old 05-18-2017, 10:14 AM   #9
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Default Re: 91 ezgo marathon oil tank cracked

Another option it's connecting throttle cable directly to carb
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Old 05-19-2017, 08:49 AM   #10
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Default Re: 91 ezgo marathon oil tank cracked

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Originally Posted by Spicyunicorn View Post
Another option it's connecting throttle cable directly to carb
Thank you, I looked it over and think I may have found a way to do that semi easily. Maybe I'll start a thread on it so as not to derail this one
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