1986 EZGO Marathon Rear Suspension Parts and Bushings: A Complete Guide

If you own a 1986 EZGO Marathon golf cart, you know it’s a reliable workhorse. But after decades of use, the rear suspension parts and bushings are likely worn out. Replacing them restores ride quality, handling, and safety. This guide covers everything you need to know about the rear suspension system on a 1986 EZGO Marathon—what parts wear, what bushings you need, and how to choose the right replacements.

Common Rear Suspension Issues on the 1986 EZGO Marathon

The 1986 Marathon uses a simple leaf spring rear suspension with shock absorbers. Over time, the following components fail:

• Leaf springs: Sag or break, causing a rough ride and poor load support.
• Shock absorbers: Leak or lose damping, leading to bouncing and instability.
• Bushings: Rubber or polyurethane bushings crack, harden, or disintegrate, resulting in clunking noises and loose handling.
• Spring shackles and bolts: Rust seizes the bolts, making removal difficult.
• Axle pivot bushings: On the rear axle, these allow the axle to articulate; when worn, the cart sways.

Replace these components as a set to avoid chasing down problems one by one.

Rear Suspension Parts List for 1986 EZGO Marathon

Leaf Springs

The 1986 Marathon uses a single leaf spring per side, measuring about 25 inches long. OEM part numbers vary, but aftermarket springs are widely available. Look for springs rated for standard load (around 500 lbs per spring) or heavy-duty if you carry extra weight. Verify the spring eye diameter—typically 5/8 inch inner diameter for the front eye and 1/2 inch for the rear shackle.

Shock Absorbers

The rear shocks on a 1986 Marathon are about 10.5 inches extended and 6.5 inches collapsed (eye-to-eye). They mount with studs on top and bottom. Replacement shocks should match these measurements. Gas-charged shocks improve ride quality over OEM hydraulic units.

Spring Shackles and Bolts

The shackles connect the rear of the leaf spring to the frame. Stock shackles are stamped steel. Upgrade to cast aluminum or steel shackles for longer life. Bolts are 1/2 inch diameter grade 5 or better. Use new bolts, lock washers, and nuts—don't reuse rusty hardware.

Bushing Kit

A complete bushing kit for the 1986 Marathon rear suspension includes:

• Spring eye bushings (2 per spring, outer diameter ~1 inch, inner diameter ~5/8 inch)
• Shackle bushings (4 total, for both ends of two shackles)
• Shock absorber bushings (often include sleeves)
• Axle pivot bushings (2 per side, if equipped)

Choosing the Right Bushings: Rubber vs. Polyurethane

OEM bushings are rubber. They are soft, quiet, and absorb vibration. However, rubber degrades in sunlight and oil, and can compress over time, leading to sloppy handling. Polyurethane bushings are harder and last much longer. They provide tighter suspension control and resist chemicals. The tradeoff is more road noise and vibration transmitted into the frame.

When to use rubber: If you want a quiet, factory-like ride and don’t mind replacing every few years. When to use polyurethane: For improved handling, longer life, or if you drive off-road. Many owners prefer polyurethane for durability.

Make sure any bushing kit you buy is specifically for the 1986 EZGO Marathon. The axle pivot bushings can be tricky—some aftermarket kits omit them. Check if your axle has pivot points (most Marathon solid rear axles do not have pivots; they use a solid axle with leaf springs. The axle pivot bushings are actually for the rear of the spring where it attaches to the axle housing. Clarify with the seller.)

Step-by-Step Replacement Guide

Replacing rear suspension parts on a 1986 Marathon is a medium-difficulty job. You’ll need a jack, jack stands, wrenches, pry bar, penetrant oil (like PB Blaster), and a bushing press or large C-clamp.

1. Safety First

Chock the front wheels, jack up the rear frame, and place jack stands under the frame not the axle. Never crawl under a cart supported only by a jack.

2. Remove Wheels and Tires

Remove the rear wheels to access suspension components.

3. Support the Axle

Place a second jack under the rear axle to relieve spring tension.

4. Unbolt the Shocks

Remove the top and bottom shock bolts. Note that some shocks have studs and nuts.

5. Remove Spring Shackle Bolts

Soak shackle bolts with penetrant oil. Use a wrench or socket—these bolts are often rusted. Remove the shackle plates and bushings.

6. Remove the Front Spring Eye Bolt

At the front of the spring, remove the bolt that attaches to the frame. The spring will now be free.

7. Disassemble and Replace Bushings

Press out old bushings using a bushing driver or socket. Lubricate new bushings with rubber grease (for rubber) or polyurethane lubricant (for polyurethane). Press them in squarely.

8. Install New Springs and Hardware

Bolt the front eye loosely, install the shackle at the rear, and attach the shocks loosely. Tighten everything only after the cart is back on the ground and the suspension is under load.

9. Torque Bolts

Final torque: spring eye bolts 20-25 ft-lbs, shackle bolts 15-20 ft-lbs, shock bolts 15-20 ft-lbs. Use thread locker on critical bolts.

10. Test Ride

Drive slowly and listen for clunks. Re-torque after 50 miles.

Where to Find Quality Parts

Avoid cheap, unbranded kits that use soft metal or wrong-size bushings. Stick with reputable aftermarket suppliers that specialize in golf cart parts. Look for:

• Leaf springs with a weight rating appropriate for your use.
• Bushings marked as SAE grade 5 hardware or better.
• Kits that include all necessary bushings, washers, and sleeves.

Many online retailers offer complete rear suspension overhaul kits for the 1986 Marathon. Compare prices and read the included components carefully.

Final Recommendation

For most 1986 EZGO Marathon owners, a complete replacement of leaf springs, shock absorbers, and bushings is the best investment. It restores the cart’s ride to like-new condition and prevents further wear to tires and steering components.

• If you use your cart on smooth pavement and want minimal cost, choose OEM-style rubber bushings.
• If you drive over rough terrain or carry heavy loads, upgrade to polyurethane bushings and heavy-duty springs.
• Replace all hardware bolts with new, zinc-plated ones to avoid future seized bolts.

Do the job yourself with basic tools and a weekend afternoon. Your 1986 Marathon will thank you with a smooth, quiet ride for years to come.

Remember: When ordering, verify your cart’s serial number to ensure compatibility. The 1986 EZGO Marathon rear suspension parts are specific to that year; later models may differ. Always consult a repair manual or a knowledgeable dealer if you’re unsure.

By tackling rear suspension maintenance now, you’ll avoid costly repairs down the road and keep your classic EZGO running strong.