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Old 06-19-2012, 07:49 AM   #1
PhilR
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Default 1984 Marathon 2PG ?'s

Hi, New to the forum and new to carts. My wife and I just picked up a 1984 Marathon 2pg. It runs but not great and needs some TLC. I'm getting a new NGK plug, air filter and making a new plug wire today. I'm also going to check compression to make sure of the cylinder health. I pulled the carb off last night and cleaned the need and seat but I need to pull it again and clean all the jets and other passages that I found in another thread. My real question is the fuel pump. I pulled the outlet line off and cranked the engine over and it bubbled a little but not a steady stream.....that doesn't seem right to me. I work on cars all day and can check fuel pressure but I'm not sure if there is a spec for pressure or flow for this cart. So any help there would be great. From other threads I have read I think I might be better off just buying a new carb as the one on there has the inlet fitting JB wleded on and the throttle and choke shafts have excessive play IMO. Also is there a clutch kit for this thing to get rid of some lag....I'm used to my modded Polaris ATV clutch and this thing is annoying . Is there a way to make it idle when you are off the gas as well? Thanks for the help and I hope to learn a bunch here and maybe repower this cart with a 3 cyl Diesel over the winter.....I am a diesel guy to the bone FYI

Phil
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Old 06-19-2012, 08:51 AM   #2
Dave Box
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Default Re: 1984 Marathon 2PG ?'s

Hello Phil and welcome to the forum.
The very first thing to do (as you have realized) is to take a compression reading. Compression is far more important with a 2 stroke as piston blow by will seriously affect your crankcase pressure which is essential to
a) operate your fuel pump (hmmm this is starting to add up)
b) transfer fuel from the crankcase to the cylinder.
Although the engine will run at quite low pressures as a rule of thumb you should consider anything less than 100 psi as a signpost to a rebuild.

When cranking the engine you should see a healthy series of spurts from the pump, a trickle or a dribble will not do. It is possible that the pump has lost prime and you can re-pressure it by removing the line to the carburetor and blowing into the tank until you see fuel blowing out of the line. It is also possible that the pump needs cleaning (or replacing). It is an easy job to pull the pump and take it apart. Before you do draw a line down the outside of the pump to ensure that you get the top on with the correct orientation. Look very carefully at the plastic diaphragm if it has the slightest crack or puncture it will not work. A rebuild kit is almost the same price as a new pump which should be ~$33.
I had the same issue with my carburetor and I replaced it with great results. A target price should be ~$100.
You can make it idle by simply shorting out the microswitch or the throttle arm which is in the engine bay under the driver's side. It's your cart and it's your call but personally I like the additional safety of knowing that the engine dies when I am not in the cart.

Good luck with the compression test. Let us know what transpires.

Dave
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Old 06-19-2012, 09:27 AM   #3
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Default Re: 1984 Marathon 2PG ?'s

I forgot to say I put some compressed air in the tank and got fuel all the way through the line......that's how I primed the new filter LOL. I guess it is a safety issue bypassing the switch and with my wife and sister in law operating it to I need all the safety features possible. I'll check the compression after work. I read through some other threads with your posts about air leaks at the carb mounting flange and rear crank seal so I'll check that stuff too. I was looking up parts and agree it is better to just replace the pump and I think if that is bad I'm just going to get a carb too.
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Old 06-19-2012, 11:59 AM   #4
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Default Re: 1984 Marathon 2PG ?'s

Well I went home at lunch and did a compression check.....my gauge showed just at 100 psi. So it's at the bottom of the spec...not really surprised with the age of this thing. I'll go through the carb and stuff tonight and see what happens as well.
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Old 06-19-2012, 08:54 PM   #5
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Default Re: 1984 Marathon 2PG ?'s

Got it running tonight. New plug, wire, fresh fuel and a little love to the carb and she fired up. I found and fixed a huge exhaust leak. The flange on the head was missing a nut and had no gasket. New gasket and some studs and she's quiet now too. I still think I'm going to order a carb and put it on as those shafts are loose and have to be leaking air past.
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Old 06-20-2012, 06:11 AM   #6
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Default Re: 1984 Marathon 2PG ?'s

Good job Phil, well done

Dave
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Old 06-20-2012, 06:35 AM   #7
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Default Re: 1984 Marathon 2PG ?'s

Thanks. I have a question about the drive belt. I read through the thread in the tech section about a shorter belt but I didn't see a pn listed for my cart. Anyone know the pn for the 1" shorter belt for the my 84? I have access to napa/gates and autozone/Dayton belts.
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Old 06-20-2012, 06:45 AM   #8
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Default Re: 1984 Marathon 2PG ?'s

Your OEM belt is 45 inches. I used the Dayco HP3004 at 44 1/8th which has worked very well for me.

Dave
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Old 06-20-2012, 07:03 AM   #9
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Default Re: 1984 Marathon 2PG ?'s

Thanks Dave......I will check with my commercial sales guys and see what they can get for me. Where is the best place to get the carb and fuel pump? Quality/Service is number one but price is important too.
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Old 06-20-2012, 07:16 AM   #10
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Default Re: 1984 Marathon 2PG ?'s

Autozone ordered the belt for me.....I'll have it tomorrow.
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