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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 12-31-2015, 08:37 PM   #1
tyoungenator
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Default 89 Marathon overheating

My dad has a 1989 marathon 36 volt that seems to be overheating at the resistor assembly. We rebuilt the assembly today and discovered that a coil was broke. We cleaned it up and put it back together and it runs. However, after 5 minutes or so that resistor assembly gets real hot and begins to smoke. I'm worried it might start cooking the wires.

That batteries are new. They are deep cell. Do we need to buy another resistor plate assembly or is the problem elsewhere?

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IMG_0300.jpg
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Old 12-31-2015, 08:54 PM   #2
crash test dummy
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Default Re: 89 Marathon overheating

repaired ? how ?
photo 2 ... you are missing the #1 cable
your wiring digram


coils need a complete coil to work correctly

yes a broken or shortened coil will get hot
at full throttle coils are by passed at #4 cable

also when disconnecting battery pack , do it at the battery pack negative ( BR- )
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Old 01-02-2016, 08:13 PM   #3
tyoungenator
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Default Re: 89 Marathon overheating

Thanks for the response and the info. The repair consisted of the following...
Cleaned up all the bolts on the assembly in pic #2
The coil that has the thinnest wire was broke at the bolt and we reconnected it to the bolt by creating another loop at the end of the coil and attaching it to the bolt. We may have lost an inch of that coil.
Added washer above and below the board in pic #2 where the #1 wire attaches and attached #1 wire to it.

Additionally, I don't know if this is related, the go pedal seems to be sticking. Not the pedal itself but something in the mechanism. It will go forward at a pretty fast pace without having to push the pedal. After tapping the pedal a few times it will respond by slowing down.

I just noticed in the 1st pic. while checking individual batteries one of the connections broke. We cleaned all of them and replaced the end on the one that broke.
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Old 01-02-2016, 08:39 PM   #4
crash test dummy
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Default Re: 89 Marathon overheating

the sweeper arm is sticking
check to see if a burnt area is on the contacts
see if swiper arm is groved
replace if needed



http://www.buggiesgonewild.com/elect...er-issues.html
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Old 01-04-2016, 07:20 AM   #5
tyoungenator
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Default Re: 89 Marathon overheating

Thanks. I'll check it out. Do you think that could be related to the overheating?
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Old 01-04-2016, 07:36 AM   #6
crash test dummy
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Default Re: 89 Marathon overheating

yes it could ... if sweeper arm is stuck it will get hot on coils
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over heating, resistor coil, resistor group assembly
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