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Old 08-19-2015, 06:25 PM   #1
SkysTheLimit
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Default 1989 marathon project...

Hello everyone! Started breaking the cart down after a few issues. After replacing battery,plug, wire new gas oil and voltage regulator I was able to get it to fire up. With some starts, stops and 1 ride around the block I decided to park it and pull it apart. I have read about some of the common issues. One was choke related(keeping it pulled to run). Inconstanties in turning over. Etc etc.... The biggest factor was a significant oil leak. At this point I pulled battery and removed oil tank. Plan on bypassing oil pump and premixing. Motor is out and being heavily cleaned and examined. I will share some of the photos of current state.
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Old 08-19-2015, 06:31 PM   #2
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Default Re: 1989 marathon project...

More images need to resize....
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Old 08-19-2015, 06:35 PM   #3
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Default Re: 1989 marathon project...

More
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Old 08-19-2015, 06:37 PM   #4
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Default Re: 1989 marathon project...

Inside
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Old 08-19-2015, 06:41 PM   #5
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Default Re: 1989 marathon project...

Took intake off to look
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Old 08-19-2015, 06:55 PM   #6
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Default Re: 1989 marathon project...

Those are some great detailed pictures. This is going to be interesting to watch.
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Old 08-19-2015, 07:35 PM   #7
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Default Re: 1989 marathon project...

Quote:
Originally Posted by cart around View Post
Those are some great detailed pictures. This is going to be interesting to watch.
It's interesting to start! I'm a novice. I spent some time looking before taking apart. I have literally been segregating nuts/bolts in bags and doing photos to trace steps. Trying not to go to far without semi researching the next steps. At this point I'm trying to determine what needs to be replaced motor wise. Judging from the amount of oil settling into fan shroud I'm assuming there may be a leak from that general area. Piston didn't feel gouged or scratched but diefitnely needs a cleaning..... Rings looked to be needing replacement. I'm hoping I can just tear it down replace rings, gasket seals etc etc...
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Old 08-30-2015, 11:28 PM   #8
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Default Re: 1989 marathon project...

Cracked piston...
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Old 08-30-2015, 11:32 PM   #9
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Default Re: 1989 marathon project...

At this point....all electrical is out, have to pull clutch/flywheel, replace crank seals... Inbetween things just a ton of cleaning.
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Old 08-31-2015, 03:28 PM   #10
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Default Re: 1989 marathon project...

That cracked piston is not your problem. Don't get me wrong, it is junk and needs to be replaced, but look at the scoring on that piston. Were the rings real tight in that area, and maybe took some effort to get out of the grooves? It looks like there was not enough oil in the fuel. Of course, it could also be that there was plenty of oil, but your leaking crank seals allowed air in making the engine lean. Also, all the crud that was around the fan can't help engine cooling, and air cooled engines tend to run hot anyway. 400+ degrees is not unheard of in an air cooled engine.
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