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Gas EZGO Gas EZGO Marathon, Medalist, TXT and RXV. |
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04-03-2021, 05:42 PM | #21 |
Not Yet Wild
Join Date: Sep 2020
Posts: 53
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Re: 1984 ezgo marathon starting issues
Alright I have the motor tore down. Before I removed the jug I did move the piston back and forth to see if I had play in it and I did. But fortunately the psiton and cylinder look good I saw no scratches or scores. my only concern was that if I run my finger through the bore I can feel a little difference like a lip but only in one spot about a 3/4 of an inch long from side to side. I don't have my calipers at home to check everything right now. my question is can i hone out the cylinder and or does it need to be bored out. The piston does say ez on the top and reg. Other than those issues everything else seems to be in order and working. while I have it apart are there any other parts or anything i should check also.
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04-03-2021, 07:53 PM | #22 |
Test before replacing
Join Date: Aug 2013
Location: Ohio side of the Pennsylvania border.
Posts: 3,491
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Re: 1984 ezgo marathon starting issues
This is where a good set of T gauges would come in handy to measure the entire cylinder bore. I would be tempted to throw a set of rings in it, but I don't care if I have to take it apart again. Your mileage may vary.
The 85 manual here has the cylinder bore specs. You might want to see how close you are. Pistons are sold .25 MM over size, and .5 mm over size. If a quick hone isn't good enough, then I would buy the entire jug kit with gaskets, and all. https://buggiesgonewild.com/showthre...=105501&page=3. $235 for everything you need including gaskets and peace of mind is a pretty good deal. |
04-05-2021, 11:37 AM | #23 |
Not Yet Wild
Join Date: Sep 2020
Posts: 53
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Re: 1984 ezgo marathon starting issues
I decided to but a complete jug and piston setup. What are things I need to watch for when reassembling the motor or things that will make it easier to reassemble.
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04-05-2021, 03:39 PM | #24 |
Test before replacing
Join Date: Aug 2013
Location: Ohio side of the Pennsylvania border.
Posts: 3,491
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Re: 1984 ezgo marathon starting issues
Install your new crankshaft seals with loctite, and stake them in three places.
The piston goes in with the side port facing the intake. The rings go in bevel side up with the ends wrapped around the little alignment pins in the ring grooves. It's a good idea to measure ring end gap in the cylinder before installing them on the piston. The manual has the tolerance. |
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