I am doing a top end rebuild of my 1988 Marathon 2PG that was gifted to me a couple of years ago. I have used this forum to learn and resolve any issues I’ve had with it and just so you know, I’ve never done this before and am new to working on engines. That said, I research and read as much as I can and my mechanic friends have told me me that I’m capable of doing a rebuild and offered their assistance should I get stuck but they don’t know these engines, what parts are available, etc. like you guys do so I thought I’d ask you the questions and use their help in executing your answers should I need it. Being new to this, my biggest problem is understanding the lingo so please forgive my ignorance if I use the wrong terminology.
So the engine quit turning over and after a compression test that barely registered any compression at all, I came to the conclusion that I either needed to replace the engine or rebuild it. Obviously, I decided to rebuild so I managed to pull the engine and discovered that the piston had a chunk break off and there was a ring missing from it. Surprisingly, the cylinder was not scarred or worn but I purchased a rebuild kit with a new cylinder just to be safe. I have gotten as far as attempting to remove the old piston so I can put the new one on but I can’t get the pin out. The manual says to slide out the pin after removing the spring clips (pg H11) but it’s not coming out. I’ve read that the crankshaft rod assembly is no longer available and I’ll damage it using force to get it out. So my question is, is there anything besides the spring clips holding it in or any tricks to getting it out easily? I did check to see what kind of play there was with the rod and the is a little side to side but no up and down.
Also, I didn’t remove the gasket before removing the spring clips (lesson learned) and part of it crumbled while I was doing so. I’m afraid some pieces may have fallen down into the case. Will blowing it out with an air compressor be sufficient to remove any pieces that may have gotten down in there or do I need to take it apart to check?
I really appreciate any help you’re willing to give and the patience you must have to deal with such inexperience and the time you give to help so many people restore their old carts. I can’t tell you how many times people have suggested that I buy a new or newer one when they look at my little beat up cart. That is not even a consideration for me since mine was given to me and has sentimental value that cannot be replaced. It is the reason I took on such an overwhelming project and have actually enjoyed doing it so far, even though it’s a bit scary not knowing what I’m doing. Learning new things keeps the mind young or so I keep telling myself when I find myself questioning my sanity in attempting to do this…