1988 1993 E-Z-GO Marathon Service Manual

The 1988-1993 E-Z-GO Marathon Service Manual provides comprehensive maintenance, repair, and troubleshooting information for E-Z-GO Marathon golf carts manufactured between 1988 and 1993. This manual covers gasoline and electric models, including engine systems, electrical systems, brakes, steering, suspension, and chassis components. Below are key sections for specifications, maintenance procedures, troubleshooting, and repair instructions.

1. General Information 2. Specifications 3. Periodic Maintenance 4. Engine Service 5. Electrical System 6. Brake System 7. Steering & Suspension 8. Troubleshooting 9. Wiring Diagrams 10. Safety Precautions

General Information

This manual applies to E-Z-GO Marathon models produced from 1988 through 1993, including both 2-stroke and 4-stroke gasoline engines, as well as 36-volt electric models.

Model Type	Description
Gasoline Models	2-stroke and 4-stroke engines with various displacement options
Electric Models	36-volt DC motor with resistor speed control
Chassis	Steel frame with leaf spring suspension
Brakes	Mechanical drum brakes standard
Steering	Rack and pinion steering system
Transmission	Forward/Reverse transmission with neutral position
Battery (Electric)	Six 6-volt batteries in series
Fuel System	Gravity feed fuel system with mechanical pump
Ignition System	Battery ignition with points or electronic ignition
Charging System	Generator or alternator depending on model

Specifications

Overall Length: 91 inches
Overall Width: 47 inches
Overall Height: 66 inches
Wheelbase: 69.5 inches
Ground Clearance: 5.5 inches
Curb Weight: 550-750 lbs (depending on model)
Payload Capacity: 800 lbs
Turning Radius: 11 feet
Top Speed: 12-15 mph
Engine Options: 2-stroke (244cc, 285cc) and 4-stroke (295cc, 350cc)
Electric Motor: 36V DC series wound motor
Battery Capacity: 180-225 Ah

Periodic Maintenance

Regular maintenance is essential for optimal performance and longevity.

Daily: Check tire pressure, battery water level (electric), fuel level
Weekly: Clean battery terminals, check brake operation
Monthly: Lubricate steering components, check wheel lug nuts
Every 3 Months: Change engine oil (gas), check brake adjustment
Every 6 Months: Clean air filter, check spark plug, inspect brakes
Annually: Complete tune-up, inspect suspension, check all fasteners

WARNING! Always disconnect battery before performing electrical work. Use jack stands when lifting cart.

Engine Service

Gasoline engine maintenance and repair procedures.

Oil Change: Drain oil when warm, refill with SAE 30 weight oil
Spark Plug: Gap at 0.030 inches, replace annually
Air Filter: Clean foam filter in soapy water, re-oil with engine oil
Carburetor Adjustment: Set idle speed to 1200 RPM, mixture screw 1.5 turns out
Compression Test: Should read 90-120 psi for healthy engine
Fuel System: Check for leaks, clean fuel filter, inspect fuel lines
Cooling System: Clean cooling fins, ensure proper airflow

CAUTION! Engine components may be hot. Allow to cool before servicing.

Electrical System

Battery, charging, and electrical component service.

Component	Specification	Test Procedure
Battery	36V total (six 6V batteries)	Check specific gravity: 1.225-1.280
Charger	Automatic shutoff	Verify automatic shutoff at 42-45V
Motor	Series wound DC	Check brushes: replace if less than 1/2"
Solenoid	36V continuous duty	Listen for click when pedal depressed
Controller	Resistor coil type	Check for burned or broken resistors
Forward/Reverse	Heavy duty switch	Test continuity in both positions

Brake System

Mechanical drum brake adjustment and service.

Park cart on level surface, chock wheels
Loosen equalizer lock nut on brake rod
Adjust brake rods until slight drag is felt when rotating wheels
Tighten lock nuts and test brake operation
Brakes should hold cart on 15-degree incline
Replace brake shoes if lining is less than 1/16" thick

WARNING! Always test brakes on level surface before operation.

Steering & Suspension

Steering system adjustment and suspension maintenance.

Steering Play: Should not exceed 1/4 turn at steering wheel
Tie Rod Ends: Check for excessive play, replace if worn
Wheel Bearings: Pack with grease annually, adjust preload
Leaf Springs: Inspect for cracks or sagging
Shock Absorbers: Replace if leaking or no damping action
Alignment: Toe-in setting: 1/8" to 1/4"
Tire Pressure: 15-20 PSI for standard tires

Troubleshooting

Symptom	Possible Cause	Corrective Action
Cart won't start (Gas)	No spark, fuel issue	Check spark, fuel flow, compression
Cart won't move (Electric)	Dead batteries, solenoid	Check battery voltage, solenoid operation
Poor performance	Worn belts, low compression	Check drive belt, compression test
Battery won't charge	Bad batteries, charger issue	Test individual batteries, check charger output
Brakes dragging	Misadjusted brakes	Adjust brake rods for proper clearance
Steering wander	Worn components, alignment	Check tie rods, adjust toe-in
Electrical shorts	Damaged wiring	Inspect wiring harness, repair damaged sections

Wiring Diagrams

Complete wiring schematics for all 1988-1993 Marathon models.

Gasoline models with points ignition
Gasoline models with electronic ignition
Electric models with resistor speed control
Lighting kit installation diagrams
Accessory wiring for horns, turn signals

Note: Always disconnect main negative battery cable before working on electrical system.

Safety Precautions

Essential safety procedures for service and operation.

Always use jack stands - never work under cart supported only by jack
Disconnect battery before performing electrical work
Wear safety glasses when working with batteries
Use proper tools for all repair procedures
Test drive cart in safe area after repairs
Keep hands clear of moving components
Ensure parking brake holds on inclines

WARNING! Gasoline is highly flammable - no smoking during fuel system service.