1987 EZGO Marathon motor studs broke

sooner310 · 06-19-2015, 12:09 AM

I am a newbie needing a little help. I bought 1987 EZGO PC4x for great cheap price of $300. Added some new batteries and it started running but not as fast as expected. I have good voltage across batteries (replaced all cables with 4 gauge), solenoid, resistor coils. After cleaning the wire posts, I noticed it was moving a bit faster. The only posts not cleaned were the ones on the motor itself. I tried to remove the rusted bolt(two cables I had not replaced) and that is when the stud/bolt started turning freely. I knew it was bad when the cart would not move. Pulled the motor to find the connectors were broke from the studs. My question is should I have these re-welded or look for a new motor? If I get a new motor, can someone point me to the correct motor? I would like to upgrade to a lift kit and bigger tires with time. Any guidance would be greatly appreciated.

cgtech · 06-19-2015, 04:16 AM

Sounds like you may have caused expensive damage (twisted-off the wires inside the motor, not fixed with a "solder-it-up job"). Consider taking the motor to a "starter/generator/alternator" rebuild shop. They may be able to fix it for less than a new motor. If you have the "resistor coil" motor controller setup i think you may have, the stock system is not a great setup for a "beefed-up" motor without significant upgrades.

sooner310 · 06-19-2015, 10:23 AM

It is all stock with the resistor coil controller. I will check out a starter shop to see what can be done. Outside of a conversion kit to electronic controller, how could I upgrade to a motor with more torque?

biggie1976 · 06-19-2015, 12:24 PM

Quote:

Originally Posted by sooner310

It is all stock with the resistor coil controller. I will check out a starter shop to see what can be done. Outside of a conversion kit to electronic controller, how could I upgrade to a motor with more torque?

ScottyB sells a conversion kit for it. And Many motor manufacturers out there.

slowfozzy · 01-13-2017, 04:14 PM

What did you end up doing? I think I might have the same issue myself, in the middle of a rebuild and not sure if my studs have spun off or not.

01-13-2017, 05:20 PM

Quote:

Originally Posted by slowfozzy

What did you end up doing? I think I might have the same issue myself, in the middle of a rebuild and not sure if my studs have spun off or not.

you too can find a shop to do a rebuild

87ezgo87 · 01-28-2017, 06:10 PM

My stud broke too on my 87 marathon, just can't get the motor off. How many bolts are there? I can get to 3 at 9, 12 and 3 o'clock. Is there one on the bottom (6 o'clock)? If so how do you get to it?
Thanks!

yurtle · 01-30-2017, 02:40 PM

When removing or replacing the motor cables, you need to use two wrenches, one to hold back the stud and the other for removing the nut.

06-19-2015, 12:09 AM	#1
sooner310 Not Yet Wild Join Date: Jun 2015 Posts: 2	1987 EZGO Marathon motor studs broke I am a newbie needing a little help. I bought 1987 EZGO PC4x for great cheap price of $300. Added some new batteries and it started running but not as fast as expected. I have good voltage across batteries (replaced all cables with 4 gauge), solenoid, resistor coils. After cleaning the wire posts, I noticed it was moving a bit faster. The only posts not cleaned were the ones on the motor itself. I tried to remove the rusted bolt(two cables I had not replaced) and that is when the stud/bolt started turning freely. I knew it was bad when the cart would not move. Pulled the motor to find the connectors were broke from the studs. My question is should I have these re-welded or look for a new motor? If I get a new motor, can someone point me to the correct motor? I would like to upgrade to a lift kit and bigger tires with time. Any guidance would be greatly appreciated.
sooner310 Not Yet Wild Join Date: Jun 2015 Posts: 2

06-19-2015, 04:16 AM	#2
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: 1987 EZGO Marathon motor studs broke Sounds like you may have caused expensive damage (twisted-off the wires inside the motor, not fixed with a "solder-it-up job"). Consider taking the motor to a "starter/generator/alternator" rebuild shop. They may be able to fix it for less than a new motor. If you have the "resistor coil" motor controller setup i think you may have, the stock system is not a great setup for a "beefed-up" motor without significant upgrades.

06-19-2015, 10:23 AM	#3
sooner310 Not Yet Wild Join Date: Jun 2015 Posts: 2	Re: 1987 EZGO Marathon motor studs broke It is all stock with the resistor coil controller. I will check out a starter shop to see what can be done. Outside of a conversion kit to electronic controller, how could I upgrade to a motor with more torque?
sooner310 Not Yet Wild Join Date: Jun 2015 Posts: 2

01-13-2017, 04:14 PM	#5
slowfozzy Not Yet Wild Join Date: Apr 2016 Location: Kingsland, GA Posts: 44	Re: 1987 EZGO Marathon motor studs broke What did you end up doing? I think I might have the same issue myself, in the middle of a rebuild and not sure if my studs have spun off or not.

01-28-2017, 06:10 PM	#7
87ezgo87 Not Yet Wild Join Date: Jan 2017 Posts: 1	Re: 1987 EZGO Marathon motor studs broke My stud broke too on my 87 marathon, just can't get the motor off. How many bolts are there? I can get to 3 at 9, 12 and 3 o'clock. Is there one on the bottom (6 o'clock)? If so how do you get to it? Thanks!
87ezgo87 Not Yet Wild Join Date: Jan 2017 Posts: 1

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01-30-2017, 02:40 PM	#8
yurtle Gone Mad Join Date: Oct 2009 Location: Buford, GA Posts: 8,988	Re: 1987 EZGO Marathon motor studs broke When removing or replacing the motor cables, you need to use two wrenches, one to hold back the stud and the other for removing the nut.

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