1978 ezgo marathon complete refurbish

[roundtable260]

1978 marathon stripped down to frame, in process of using phosporic acid to derust frame, will be converting to solid state, in infant stage will be adding a 4" lift kit also. will supply pics on this journey.. cut out rotten battery trays using bed frame to make and weld new battery trays.

[roundtable260]

[Michael Eddie]

Keep up the good work! Moving from the club car electric section to the pictures section for better visibility

[RideonTractor]

Awesome!!!!

[roundtable260]

[roundtable260]

leaf springs completely disassembled rust treated with phosphoric acid reassembled ready for paint, tie rod assy. degreased cleaned ready for paint, front king pins resealed and cleaned reassembled ready for paint

[roundtable260]

leaf springs completely disassembled rust treated with phosphoric acid reassembled ready for paint, tie rod assy. degreased cleaned ready for paint, front king pins resealed and cleaned reassembled ready for paint

steering arm cleaned and degreased

[roundtable260]

[cybercart]

Nice!

[roundtable260]

frame painted, lift kit, batteries, lots of work

[roundtable260]

[roundtable260]

need help decoding tag 1978? 780613 T57608

[golfcartg]

need help decoding tag 1978? 780613 T57608

I think you are correct, heres the info on ezgo serial numbers from Vintage Golf Cart Parts, INC - E-Z-GO Serial Number Guide

Locating and Deciphering your serial number and manufacturer's code

• Prior to 1976 the numbers are on a metal tag under the driver's seat on the fender skirt. From 1976 until 1993 the number is on a metal tag under the passenger side dash board. On 1994 and newer the manufacturer's code is found on a plate inside the glove box on the passenger side.
• The carts manufactured in the 1960s had the year at the end of the manufacture code. Here are a couple of actual examples: Model GX444-4, Serial # 11444GX1381, Mfg. #. 4114-1965G and this one: Model GX440, Serial # 4296X1570, Mfg. # 342-1968E. Carts made in the 1970s up until 1975 used a different dating matrix. The first number was the month of manufacture and the second number was the year. Here is an example of a 1972, Model: X440-2GE, Serial # 324X2047, Mfg # 432-2141G. Note the GE on the end of Model Number. This indicates an electric cart with a General Electric motor. For further help identifying electric carts use our General Electric Serial Number Guide here or located in the Miscellaneous Cart section to help determine the year of your cart. Find the General Electric Motor ID Tag on your motor and look in the lower left for the three letter identification code for the year of manufacture. Here is an example of another cart from the 1970s: Serial # 754X1653, Model #: X440-5GE. Note the GE on the end of the model number on this one as well. The motor on this one had a serial number code of DLN indicating that the motor was manufactured in April of 1975 and by the serial number the cart was manufactured in July (first number) of 1975 (second number). There is a great deal of additional information below to help you identify your year of manufacture.
• From 1976 until 1993 the number is on a metal tag under the passenger side dash board. The year of manufacture for these carts is found in the manufacture's code. The earlier carts used the first two numbers of the Manufacture Code but did not state it was the Manufacture Code on the metal tag. Here are several examples from actual carts: 760927 114994 which is a 1976 +++ 78O516-155671 which is a 1978 +++ 79A12-161603, which is a 1979 +++ 79J01-188254 which is a 1979 +++ 80H15-209210 which is a 1980 +++ 81C4-222441 which is a 1981 +++ 82C02-251539 which is a 1982. They used this numbering system up until 1983 when they went to the last two number scheme which they still use. Here are examples: FO283-290166 is a 1983 +++ H1284-332917 which is a 1984 +++ 4104-1585E which would be a 1985 cart +++ Here is another Manufacture Code: B1890 and Serial Number 576966. This is a 1990.
  
  SERIAL NUMBERS from 1976 to 1982
• 1976: 101050 to 115864
• 1977: 115865 to 135441
• 1978: 135442 to 161081
• 1979: 161082 to 189574
• 1980: 189575 to 216732
• 1981: 216733 to 244484
• 1982: 244485 to 275315

• From 1994 and newer the manufacturer's code is found on a plate inside the glove box on the passenger side. The arrangement of the Manufacturer's Code begins with a letter and the last 2 digits are the year. Example: J0195 is a 1995.

Helpful hints to identify your car:

• First car was made in 1954.
• First 4 wheel cart came out in 1968.
• In 1980 the top was extended from 48 inches to 54 inches, and the supports were changed from round to square. The X leg top was discontinued.
• E-Z-GO Spirit was first built in 1986, a 2 seater, wrap around windshield and front bumper, with recessed head and tail lights.
• E-Z-GO Liberty was first built in 1986, the same as the Spirit, but a 4 seater.
• E-Z-GO Fleet was first built in 1986 and is the common golf course model.
• E-Z-GO Freedom was first built in 1988 and included the lights.
• From 1986-1/2 to 1994-1/2 the carts had two separate seat backs and no hand hold on the top. It had a plastic front bumper and a metal body. This is a Marathon Model.
• From 1994-1/2 to 1999 the steel bodied carts were the Medalist model. They had a single seat back with a hand hold in the top and a medal body.
• From 1996 and newer they made the plastic body cart named the TXT Model. This cart also had a single seat back.

Additional hints to identify early gas carts:

• From 1971 to 1975 E-Z-GO used a 175cc 2-cycle 17-CES 1PG Robin engine. This engine had four head bolts. It was painted blue. It had an internal starter generator. In 1976 they came out with the model EC25-DS 244c Robin engine made by Fugi Heavy Industries. This engine had six head bolts. It was painted black. It still had an internal starter/generator that was kept until mid 1980. In mid 1980 they came out with a Hitachi brand external starter/generator with modifications to the engine and clutch. This model EC25-2PG engine was used until 1988. In 1981 they came out with electronic ignition. 1983 was a single year model easily identified by having the muffler lying down behind the engine rather than standing up. In 1984 they went back to the stand up muffler near the drivers side of the cart.

Additional hints to identify early electric carts:

• Prior to 1971 electric E-Z-GOs used solenoid switching for speed control using five solenoids. Some of the very earliest carts from the early fifties used seven solenoids, four for forward and reverse and three for speed control. From 1971 to early 1982 they used a combination of a rectangular shaped speed control board with a single solenoid mounted on top in conjunction with a group of three resistors. In late 1982 they changed the board to one with a corner cut off with the resistors attached to the trailing edge of the board. This was a one year only. In 1983 they moved the resistors to the rear. The resistors were mounted on a board with leads setting the resistors off to the side. They kept this design until 1985 when the came out with resistors mounted down the center of the board. They kept this design until 1994 when they changed over to electronic motor speed control.

Find the GE serial number from your electric motor. It is on a metal plate and is usually on the lower right. The serial number is three letters ending in an N. Look up this three letter code in our General Electric Motor Dating Guide located in the Miscellaneous Carts section of this Golf Cart Reference Library.
From 1965 until June of 1971 E-Z-GO used a G.E. motor with a spiral cut output gear which was part of the armature. The differential had a large square flange where the motor bolted up. The opposite end of the motor had a male keyed output shaft where the single band drum brake attached. These carts had tapered keyed axles. In July of 1971 to October of 1975 they used a ten spline internal hub output shaft motor with an external shaft on the other end for the single band brake drum. These motors were either GE of Prestolite. The differential had a small square motor mounting flange from July of 1971 to May of 1975. From July of 1971 to May of 1972 they used equal length tapered keyed axles. From June of 1972 until October of 1975 the axles had ten spline hubs which were either round or clover leaf style.

[roundtable260]

I think you are correct, heres the info on ezgo serial numbers from Vintage Golf Cart Parts, INC - E-Z-GO Serial Number Guide

Locating and Deciphering your serial number and manufacturer's code

• Prior to 1976 the numbers are on a metal tag under the driver's seat on the fender skirt. From 1976 until 1993 the number is on a metal tag under the passenger side dash board. On 1994 and newer the manufacturer's code is found on a plate inside the glove box on the passenger side.
• The carts manufactured in the 1960s had the year at the end of the manufacture code. Here are a couple of actual examples: Model GX444-4, Serial # 11444GX1381, Mfg. #. 4114-1965G and this one: Model GX440, Serial # 4296X1570, Mfg. # 342-1968E. Carts made in the 1970s up until 1975 used a different dating matrix. The first number was the month of manufacture and the second number was the year. Here is an example of a 1972, Model: X440-2GE, Serial # 324X2047, Mfg # 432-2141G. Note the GE on the end of Model Number. This indicates an electric cart with a General Electric motor. For further help identifying electric carts use our General Electric Serial Number Guide here or located in the Miscellaneous Cart section to help determine the year of your cart. Find the General Electric Motor ID Tag on your motor and look in the lower left for the three letter identification code for the year of manufacture. Here is an example of another cart from the 1970s: Serial # 754X1653, Model #: X440-5GE. Note the GE on the end of the model number on this one as well. The motor on this one had a serial number code of DLN indicating that the motor was manufactured in April of 1975 and by the serial number the cart was manufactured in July (first number) of 1975 (second number). There is a great deal of additional information below to help you identify your year of manufacture.
• From 1976 until 1993 the number is on a metal tag under the passenger side dash board. The year of manufacture for these carts is found in the manufacture's code. The earlier carts used the first two numbers of the Manufacture Code but did not state it was the Manufacture Code on the metal tag. Here are several examples from actual carts: 760927 114994 which is a 1976 +++ 78O516-155671 which is a 1978 +++ 79A12-161603, which is a 1979 +++ 79J01-188254 which is a 1979 +++ 80H15-209210 which is a 1980 +++ 81C4-222441 which is a 1981 +++ 82C02-251539 which is a 1982. They used this numbering system up until 1983 when they went to the last two number scheme which they still use. Here are examples: FO283-290166 is a 1983 +++ H1284-332917 which is a 1984 +++ 4104-1585E which would be a 1985 cart +++ Here is another Manufacture Code: B1890 and Serial Number 576966. This is a 1990.
  
  SERIAL NUMBERS from 1976 to 1982
• 1976: 101050 to 115864
• 1977: 115865 to 135441
• 1978: 135442 to 161081
• 1979: 161082 to 189574
• 1980: 189575 to 216732
• 1981: 216733 to 244484
• 1982: 244485 to 275315

• From 1994 and newer the manufacturer's code is found on a plate inside the glove box on the passenger side. The arrangement of the Manufacturer's Code begins with a letter and the last 2 digits are the year. Example: J0195 is a 1995.

Helpful hints to identify your car:

• First car was made in 1954.
• First 4 wheel cart came out in 1968.
• In 1980 the top was extended from 48 inches to 54 inches, and the supports were changed from round to square. The X leg top was discontinued.
• E-Z-GO Spirit was first built in 1986, a 2 seater, wrap around windshield and front bumper, with recessed head and tail lights.
• E-Z-GO Liberty was first built in 1986, the same as the Spirit, but a 4 seater.
• E-Z-GO Fleet was first built in 1986 and is the common golf course model.
• E-Z-GO Freedom was first built in 1988 and included the lights.
• From 1986-1/2 to 1994-1/2 the carts had two separate seat backs and no hand hold on the top. It had a plastic front bumper and a metal body. This is a Marathon Model.
• From 1994-1/2 to 1999 the steel bodied carts were the Medalist model. They had a single seat back with a hand hold in the top and a medal body.
• From 1996 and newer they made the plastic body cart named the TXT Model. This cart also had a single seat back.

Additional hints to identify early gas carts:

• From 1971 to 1975 E-Z-GO used a 175cc 2-cycle 17-CES 1PG Robin engine. This engine had four head bolts. It was painted blue. It had an internal starter generator. In 1976 they came out with the model EC25-DS 244c Robin engine made by Fugi Heavy Industries. This engine had six head bolts. It was painted black. It still had an internal starter/generator that was kept until mid 1980. In mid 1980 they came out with a Hitachi brand external starter/generator with modifications to the engine and clutch. This model EC25-2PG engine was used until 1988. In 1981 they came out with electronic ignition. 1983 was a single year model easily identified by having the muffler lying down behind the engine rather than standing up. In 1984 they went back to the stand up muffler near the drivers side of the cart.

Additional hints to identify early electric carts:

• Prior to 1971 electric E-Z-GOs used solenoid switching for speed control using five solenoids. Some of the very earliest carts from the early fifties used seven solenoids, four for forward and reverse and three for speed control. From 1971 to early 1982 they used a combination of a rectangular shaped speed control board with a single solenoid mounted on top in conjunction with a group of three resistors. In late 1982 they changed the board to one with a corner cut off with the resistors attached to the trailing edge of the board. This was a one year only. In 1983 they moved the resistors to the rear. The resistors were mounted on a board with leads setting the resistors off to the side. They kept this design until 1985 when the came out with resistors mounted down the center of the board. They kept this design until 1994 when they changed over to electronic motor speed control.

Find the GE serial number from your electric motor. It is on a metal plate and is usually on the lower right. The serial number is three letters ending in an N. Look up this three letter code in our General Electric Motor Dating Guide located in the Miscellaneous Carts section of this Golf Cart Reference Library.
From 1965 until June of 1971 E-Z-GO used a G.E. motor with a spiral cut output gear which was part of the armature. The differential had a large square flange where the motor bolted up. The opposite end of the motor had a male keyed output shaft where the single band drum brake attached. These carts had tapered keyed axles. In July of 1971 to October of 1975 they used a ten spline internal hub output shaft motor with an external shaft on the other end for the single band brake drum. These motors were either GE of Prestolite. The differential had a small square motor mounting flange from July of 1971 to May of 1975. From July of 1971 to May of 1972 they used equal length tapered keyed axles. From June of 1972 until October of 1975 the axles had ten spline hubs which were either round or clover leaf style.

thank you brother

[roundtable260]

[roundtable260]

purple flake 2 coats clear coat

[golfcartg]

Nicely done on the purple flake, the color choice adds a nice touch. The overall effect is coming together nicely. Metal flake never lost its luster. It’s like the "classic rock" of paint, timeless and always cool

[roundtable260]

[roundtable260]

Many hours to get to this point assembly next week let paint cure for 4 days, 4 coats flake 4 coats clear, all brackets screws bolts ect. Have been painted

[roundtable260]

[roundtable260]

Adhesion promoter and white vinyl spray paint did nice job on seats cushions, purple flake on seat backs and white seat brackets adds nice contrast

[roundtable260]

[roundtable260]

steering installed, fenders, power wiring, curtis controller, 0-5k accelerator pot box, solenoid, precharge resistor and diode, rear basket, run tow switch (200 amp circuit breaker), have to finish control wiring install batts test this week..

[roundtable260]

and ezgo logo

[golfcartg]

Great choice going with the solid state conversion, did you use the harness from a donor cart or are you making a harness yourself if you don't mind me asking?

[roundtable260]

Great choice going with the solid state conversion, did you use the harness from a donor cart or are you making a harness yourself if you don't mind me asking?

hey brother, i am using wires from original wiring just have to modify a bit, curtis controller has manual with schematics its not to bad at all

[roundtable260]

Great choice going with the solid state conversion, did you use the harness from a donor cart or are you making a harness yourself if you don't mind me asking?

i will include close up pics of all the electric system and schematics after testing

[Michael Eddie]

Lookin good

[roundtable260]

[roundtable260]

Roof supports and marine vinyl top

[roundtable260]

[roundtable260]

Done can't get rubber molding on just not capable and do not know how, that was a tough project

[Michael Eddie]

This came out nice, thanks for sharing.

Looks like you have a little extra room for some larger wheel options, are you thinking about upgrading?

[roundtable260]

Maybe larger wheels