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



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Old 09-15-2014, 12:28 PM   #1
burbs84
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Default 1988 EZGO Marathon Engine Swap...Newbee here!

Hey guys Ive been reading and researching for about a.week now and everything I find redirects me to this sights. I know this is the right place to be.

Anyways I picked up a 1988 Gas Freedom Marathon for $50 Last week. Theres a few missing parts cosmetically and some engine components like the generator, oil tank and who knows what else. I ripped the 2 stroke out and plan on putting in a 16hp motor like the predator 420cc turn key or The duromax turn key engine. I would like to have something that recharges the battery. A v twin would be nice but costly for me. I do have some questions though. These motors turn counter clockwise if Im correct and the axle that is in there seems to be opposite. Idk if the axle will even work. Im new to this stuff so bare with me! My idea was to use a torque converter and a gearbox for reverse. I also thought of using a live axle from mfg supply with the sprockets and all that. I plan on using the original gas tank. Can you guys help me start off this project right?? Thanks in advance!
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Old 09-15-2014, 01:25 PM   #2
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Default Re: 1988 EZGO Marathon Engine Swap...Newbee here!

You'll have to start with a 93-up 4-stroke style rear end, You're going to need a new driven clutch for it too (the 88 won't work) - from there, You'll need a starter/generator with the correct rotation along with a mount of some sort and adapter pulley that works with whatever clutch You decide to run on the Predator ... Throw in the engine, a cradle, ignition, and a ton of misc "figure it out as You go" parts and it's not an easy task.

Might be a lot easier and cheaper to keep and fix up that 88 2PG. That's their "High Performance" 2-stroke (only available in 198 and will get you to 28mph nicely with a lift and bigger tires. Going to a 16hp Duro will gain You torque, but the top speed will be the same as both engines are limited RPM-wise in stock configuration.
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Old 09-15-2014, 02:26 PM   #3
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Default Re: 1988 EZGO Marathon Engine Swap...Newbee here!

Thanks for the reply and info! I thought about using the engine it came with but its older, its a 2 stroke which Im not that fond of and I like projects haha. So a live axle is not a good idea? I see where mine is welded in that it can be cut and I should have enough room for a hanger kit. I know I would lose my brakes in back so I would have to add a disc brake or whatever. My main concern with the axle was the gearing and sprokets. I feel like I have a lot more freedom of choice with a live axle, just dont know that it will hold up. Im not too worried about the fab work and what not, I can figure stuff out and work slowly. I plan on putting a lift and bigger tires on so I know that gains speed from what I read. Im only going to be using it for simple driving and occasional trail riding but nothing too extreme. Im guessing that the forward/reverse control cannot be used if i convert to one of the engines I listed? I like the idea of being able to start it and idle, shift into forward or reverse. like i said im new to this and learning as I go. I know its a lot of work and money but im determined to get it done!
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Old 09-15-2014, 03:52 PM   #4
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Default Re: 1988 EZGO Marathon Engine Swap...Newbee here!

If You swap to a 4-stroke-style rear end, You will have your F-N-R as well as a heck of an easier job getting the power from the motor to the rear end, as the clutch is oriented parallel with the cart as versus crossways such as the one You have now ... Comet makes clutches for the Predator/Lifan/390 clones (they require cutting the output shaft as well as tapping it if You're going to use a stock clutch) ...

I have driven in carts with a live axle, I wasn't a fan (the differential is important to handling and cornering at cart speeds, especially with the bigger tires and lift)

Were it ME, I'd be talking to Geoff at Vegas Carts (www.vegascarts.com - he's a site sponsor) - he does kits for the 390 clones, engines, turnkey, bolt-in conversions, etc for the 94-up Medalist/TXT - You'll have a little welding and whatnot into Your Marathon to fit the cradle, etc but it's still a good starting point, his products are proven AND economical, and I'll bet he has some Marathon pointers for You!
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Old 09-15-2014, 04:49 PM   #5
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Default Re: 1988 EZGO Marathon Engine Swap...Newbee here!

Ahhh that makes sense with the axles. Theres a million carts for sale by me but no luck on the 4 stroke axles. Everyone wants toomuch for junker carts. Guess ill have to be patient. I wasnt planning on using the factory clutch. I am going to check out that site and maybe make a phone call or 2 in the near future. Thanks for your help, got some thinking to do!
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Old 09-16-2014, 07:37 AM   #6
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Default Re: 1988 EZGO Marathon Engine Swap...Newbee here!

I think I just scored a 992cc Generac v twin engine for fairly cheap!
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Old 09-17-2014, 08:57 PM   #7
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Default Re: 1988 EZGO Marathon Engine Swap...Newbee here!

Now as far as the forward/reverse shift mechanism below the seat, will my 2 stroke shifter work with a motor swap and a 4 stroke rear transaxle? If not, what seems to be the best resolution? Ive seen the jakes shifters and I Like them but I see that they connect to your orriginal assmbly. Just wasnt sure if I had to switch mine out. If the pics show up, this is what I have currently.
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Old 09-18-2014, 09:19 AM   #8
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Default Re: 1988 EZGO Marathon Engine Swap...Newbee here!

Youll need the whole assembly from a 4-stroke - the one You have actually reverses the electrical to cause the engine to run backwards for reverse (that's how the 2-strokes were) - the 4-stroke assembly is just a set of cables that move a shifter arm on the transaxle (depending on the year of 4-stroke rear end You get, it will either be a single or dual-cable design, so best to buy it all together or get the rear end first, then the assembly you'll need)
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Old 09-22-2014, 08:05 PM   #9
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I just bought the stock motor from you on ebay. I just sold a cart with a snowmobile engine in it with the stock 2 stroke rear end in it. Well actually traded it for a yamaha g2 that I'm putting a vanguard v twin in. I had a hard time finding a 4 stroke rear end and when i could they were expensive and I really wanted reverse. I also have a 87 marathon with a cracked engine block that I'm putting the motor that I'm getting from you in. Good luck on your build.
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Old 09-23-2014, 09:35 PM   #10
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Default Re: 1988 EZGO Marathon Engine Swap...Newbee here!

I bet that think was quick! Small world. I will be shipping it out tomorrow. Sorry I have been really busy and trying to find something good to put it in at work is tough at times.

Sorry about the message that accidentally got sent to you. I bought a whole steering unit from the steering wheel to the steering gear box and now I have a problem. My cart didn't have that when I got it so I found one on ebay for a good price, purchased it... Half of it showed up. The seller said he packaged everything and it was all there. I thought he was lying but seeing the prices on the USPS tags, inspecting the boxes (seeing greasy finger prints on the patch tape job where the big hole was) and calling USPS led me to find out that it was "Damaged" upon receiving at my local USPS branch. Basically the whole gear box assembly is missing along with the 4 bolts. I have a shaft and steering wheel thats it. There was no insurance on the package because the seller didn't insure it. So, Im kinda f'd on it. I emailed the seller and asked if he can make the situation right and send me the other one he has since Im not the one who boxed it and didn't insure it. I purchased, I have the right to get my purchase (my belief). Ill see what he says.
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