Yesterday I finally took the engine into Billy’s. Unfortunately when I asked him about turnaround time he got really evasive and said it was hard to say as this is the season of limited parts availability. Oh yea there was also this storm back east witch would also limit part availability. So hopefully the engine will be done before the years out but its hard to say.
Ugh. I ran the botom end up to Hawg’s last week so we could press out the fly wheels a generaly asses the stat of the bottom end. First I want to say sorry that I dont have any pictures. The subject completly sliped my mind. durring this whole process. What I will say though is that the proccess was rather enlightning and edjucational. To Hawgs I took the left case , fly wheels, and the gouged piston. The first thing Hawg did was to look at the piston and say “look how the ware goes at an angle to vertical.” Damn he knows what hes talking about. 🙂 So after some shit shooting and finding tools we got the flywheel pressed out of the case.
We found some interesting things. First the connecting rods had been pushed over into the thrust washer left thrust washer to the pint that it had gouged into it. Can it be fixed ??? Then we found that the connecting rods were vary difficult to get off of the drive crank pin. But we did get them off. What we found after we got the flywheels apart was nothing liess then disappointing. First the right flywheel was bored, drilled for balancing, at the top, neer the crank pin. This is a NO NO as it weakens the wheel and leads to cracking. Next we found that the borring holes on the left wheel were drilled out then refilled with lead. In of of itself is not bad but when ist is just half assed into the hols it leads to the lead falling out of the holes. As in this case. We speculate that it was the leaching lead the lead to the connecting rods feeling so gummy and hard to pull off the crank pin. Lastly we found that the crank pin and bearings were pitted and there for no good.
So last Tuesday the 12th, since there closed on Mondays (hours are helpful on the webpage). I took my engine up to the machine shop and Billy said my cam was shot as well. Now I’m looking at not only a $1200 top end rebuild but a bottom end as well. The parts alone for the bottom end is in the $1000 rang just for the fly wheels. So in about three more weeks I hope to hear from Billy about a quote on the engine rebuild.
Now fortunately I have time to check the trans and swing arm as well as rewire marlin.
I’ve been gone for a few days on a family visit so I didn’t get anything done on marlin until today. Actually it was Monday that I got to work. I first got the primary cover off and found that I needed a compensator wrench. After some calls to Hawg I found out that I needed a jam bar to keep things from moving. I accomplished this with a 3/8ths extension. After that I was able to get the compensator sprocket off then the clutch hub. After that I needed one more call to Hawg to find out I had to take the battery out so I could reach the two nuts that hold the starter to the inner primary. But mission accomplished and I got the inner off. Next came the four nuts and bolts that hold the engine to the frame. As you can see I got them out too. 
Next step is to have the real work done. I think I’ll farm that out to someone who can do the job.
Got the rear jug off. its beautiful inside. it is also .01 over bore. I dont see a more size on the front piston. They do seam to be a matching make of piston. I’ve got a call in to a local (ish) machine shop, that comes highly recomended by Hawg, for a sleeving and boring to match out the cylinders.
Got a quote for the repairs to the cylinder.
I’m very depressed. I got the front cylinder off tonight and found disaster. There is a deep gouge in the cylinder wall and the piston id shot. A C clip broke and scrubbed a lot of metal out of my engine. You can see the broken clip here 
and the damage here.
Don’t forget this is only the front cylinder. It was the rear cylinder that had the compression issues in the past.
I spent several hours today taking Marlin appart. Unscrewed the headers, took off the carb, removed the tank, and seat. One thing I noticed was oil in the intake manifold ports. I then took off the front head. 5 bolts and and lot of swearing. Since I dont know what I’m looking for I guess I’ll keep going.
Last night I decided to drain the oil. Then this morning I was going to refill and head up to the swap meet. When I pulled the filleter out of the oil tank I noticed some particulate mater on the rim. Upon further inspection it looks to be metal fillings. SHIT! Well long story short I talked to Hawg and based on the noise the push rods were making he figured it was at least one tappet going out. So this after noon I started pulling them apart. 
Now I’m no expert but I’m pretty sure the tappets are in good shape. There is no play that I can tell in them. So the next guess is maybe a piston is disintegrating. Again SHIT. But at least I’m checking all this be fore something catastrophic happens.