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Old 07-02-2011, 06:34 PM   #1
EZGO 89 RED
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Default RZR "S" 800 engine in an 1984 EZ-GO Marathon

I'm starting a new thread about my 1984 EZ-GO Marathon that i am upgrading
i had an old thread kinda about this but it got to long and went dead.

http://www.buggiesgonewild.com/gas-e...s-modding.html

Here's what its got for upgrades so far:
-2009 Polaris RZR "S" 800 H.O. efi motor (55hp at the crank, with tons of low end torque)
-2008 Polaris Sportsman 500 H.O. transmission/rear differential combo (i research it and this will hold up to the 800 motor)
-1991 Yamaha Banshee front end (A-arms, frame, disc brakes, shocks) (im still in the process of mounting it to the golf cart
-full set of tires with rims to the Yamaha Banshee
-Steel plate dash i welded with switches and battery meter
-Sony radio also mounted in the dash

i will get some pics up of how the cart currently sits next week or so b/c for the time being im up at my cabin for the 4th of july
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Old 07-18-2011, 02:50 PM   #2
EZGO 89 RED
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Default Re: RZR "S" 800 engine in an 1984 EZ-GO Marathon

Sorry its taken so long to get some pics but here they are:
also i took the motor out today b/c i have yet to paint my swing arm and its getting rusty from sitting outside

here it sits with no front or rear end and no motor


heres the swing arm that i extended using solid round stock steel, i and thinking of scraping this and instead frame mounting the engine


here is the front dash with switches, radio, and battery gauge hard to see cause its black


heres is most of the engines wiring


here is the beast, the 2009 RZR S 800 H.O. motor


here is the pair of rear tires that i picked up with my front suspension


here is the front suspension, its from a 1991 Yamaha Banshee


heres a close up of one of the front a-arms on the front suspension
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Old 07-28-2011, 08:12 PM   #3
98 TUNNER
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Default Re: RZR "S" 800 engine in an 1984 EZ-GO Marathon

Good luck with the build. Thought you might be able to get some insite from my build witch is a very similar build.http://www.buggiesgonewild.com/membe...ject-cart.html
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Old 08-01-2011, 02:03 PM   #4
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Default Re: RZR "S" 800 engine in an 1984 EZ-GO Marathon

nice
i like how you have the rear independent suspension and the motor not swinging

i was going to have my motor and trans mounted to a swing arm but i had to really lengthen the swing to fit all the components and now i don't like how long it got

im thinkin of getting the rear components for a sportsman and then using them and making it similar to yours and also mounting the engine not in a swing arm
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Old 08-08-2011, 10:26 PM   #5
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Default Re: RZR "S" 800 engine in an 1984 EZ-GO Marathon

i have been getting my fuel pump mounted into the original ezgo plastic gas tank
im just waiting for a tool to build up and level a spot on top of the tank

after thats mounted then i just need fuel line/ fuel clamps and an air filter and i will be able to start and run the motor for a short amount of time b/c i still don't have a radiator yet
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Old 08-09-2011, 08:48 AM   #6
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Default Re: RZR "S" 800 engine in an 1984 EZ-GO Marathon

Lookin good!!

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Old 09-26-2011, 10:53 PM   #7
EZGO 89 RED
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Default Re: RZR "S" 800 engine in an 1984 EZ-GO Marathon

Got a radiator from my uncle who didn't need it, tested for leaks and its good

haven't really made any progress on the project b/c I don't have a wire feed welder or metal cutter or metal to work with

I'm going to see if I can borrow some tools from my high school and buy some of their metal, 1x1 thick wall, still need rear suspension waiting for good deal on ebay, probably gonna cost another $300, but can't really argue when the cart will have full independent suspension

need to pick up some Jb weld for making a flat spot on my stock gas tank to mount the fuel pump in

need to make a new header for the engine b/c of clearance issues and the old one i found out is warped about .497"

this cart is getting to be expensive, and i didn't even half to pay for the motor or transmission/rear differential

although the motor has costed me around $500 in parts like electronics, fuel pump, throttle body, and others

hopefully i will get some work done MEA weekend, but first i have to get those tools from my high school
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Old 10-12-2011, 04:11 PM   #8
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Default Re: RZR "S" 800 engine in an 1984 EZ-GO Marathon

my school didn't let me borrow the tools so instead im TAing for a metals class in 6 weeks and then i will have all the tools and materials there
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Old 10-24-2011, 10:22 PM   #9
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Default Re: RZR "S" 800 engine in an 1984 EZ-GO Marathon

I am getting some of my rear suspension in the mail this thursday according to fedex tracking

its the upper and lower rear a-arms with wheel bearing carriers and a few brackets with nuts and bolts for a 2007 polaris sportsman 500 efi

also sometime soon in the mail i will be getting my motor mount brackets and 2 of the vibration damperers

i might order my hubs sometime this week being as they are one sale (75%) off for $6.75 a piece plus $15 combined shipping

also needed are the 2 cv axles and the 2 rear shocks(about $37 including shipping in that price already)

i am making my plans for my new exhaust header so that i have better front engine clearence

this project is starting to get expensive but worth it
i think i have over $1000 into this project not including the motor or transmission (but including parts that attach to the motor and transmission ex throttle body, clutches, rear suspension)

in the end i will have an awesome golf cart with the full independent suspension.
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Old 10-26-2011, 08:33 PM   #10
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Default Re: RZR "S" 800 engine in an 1984 EZ-GO Marathon

Finally got my fuel pump/regulator mounted into the tank




side view of were i built up the surface of the tank to create a nice flat spot


top view with the bolts sticking out of the top the pumps flange


inside of the tank showing the fuel pick up and arm that measures fuel level, this doesn't work b/c of the mounting angle, I just wanted to make sure it would move up a little bit



fedex says that i will get my rear upper and lower arms for the rear suspension
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