Printable View
Like the title shows, taking on a new project just cause I have so much time on my hands. Was out for a sunday morning ride and she was purring like a kitten at 50 mph when all of a sudden she went to sleep never to awaken. Because I own a compressor, a few air tools, and a keen sense to know how things work I'm diving in. I back her into the garage plug the comp in and bam shes apart
The seat off , spark plugs exposed, should I continue? am I over my head already?
http://farm7.static.flickr.com/6183/...bb6a47fe_z.jpgDSCF0798 by docdrs, on Flickr
Oops , spark plugs removed, fuel rail removed, rave valves removed
.http://farm7.static.flickr.com/6078/...b16c9439_z.jpgDSCF0800 by docdrs, on Flickr
parts sitting on the floor not looking too bad, or is it?
http://farm7.static.flickr.com/6072/...f752aaeb_z.jpg
DSCF0802 by docdrs, on Flickr
Dirty and Chipped Rave valve.......could this mean trouble?
http://farm7.static.flickr.com/6072/...8c3e926e_z.jpg
DSCF0824 by docdrs, on Flickr
Head bolts loosened
http://farm7.static.flickr.com/6209/...d24e3564_z.jpg
DSCF0805 by docdrs, on Flickr
some cowling parts removed, head bolts out
http://farm7.static.flickr.com/6072/...132469ce_z.jpg
DSCF0806 by docdrs, on Flickr
Head removed
http://farm7.static.flickr.com/6072/...65a016ec_z.jpg
DSCF0813 by docdrs, on Flickr
Underside of head... look the same
http://farm7.static.flickr.com/6197/...ae6f9b37_z.jpg
DSCF0822 by docdrs, on Flickr
Top of cylinders, right one looks as tho it may have been a little hotter, or lean, but why???? Oh gratuitous pic of air tool to save my wrists undoing jug bolts
http://farm7.static.flickr.com/6064/...10cedfdc_z.jpg
DSCF0816 by docdrs, on Flickr
Jugs removed , uh oh what have I found
http://farm7.static.flickr.com/6210/...86b1e473_z.jpg
DSCF0817 by docdrs, on Flickr
A hole in the right piston and massaged rings , now i know why that rave valve looked knarled :(
Pistons removed and UH oh I dropped a wrist pin coller and some roller bearings as I removed the first piston :(
Where did they go? Into the crankcase.......most likely
http://farm7.static.flickr.com/6080/...c27b56e5_z.jpg
DSCF0818 by docdrs, on Flickr
http://farm7.static.flickr.com/6191/...8f0bc637_z.jpg
DSCF0820 by docdrs, on Flickr
Yep they were in the crankcase.....all parts accounted for 4 wrist pin collars and 72 roller bearings :)
http://farm7.static.flickr.com/6181/...7100d149_z.jpg
DSCF0825 by docdrs, on Flickr
The sleeve in the jug was scored, so off to the machine shop to get straightened, bored and oversized.....looks like .02 over so pistons are ordered and on their way..... should be here tomorrow for final sleeve honing and fitting .......hopefully I can start the reassemble process wednesday......maybe on the water for the weekend :) note on cleaning of the crankcase good oil flow was noted into the case so hopefully it was just old age that blew the piston
Nice work, i thought you were asking a question waiting for responce then i opened the thread and realised it was one of them questions your asked but really have no say in the matter. Its already been done LOL.
Nice work man. Im intrested to see how it all turns out.
so what'cha doing september 10th? I gotta pull the engine out of my 98 ford ranger and replace. blown head gasket and rumored a popped piston. cheaper to just buy a donor motor and swap. 4cyl and easy as pie, just kind of lazy right now...:rolleyes:
Doc - I admire the can-do attitude. Post a pic of the whole sled with the rebuilt engine installed. - Deerfield
More than likely the rave valve is worn and traveling too far,thats what grabed the rings and caused the piston failure.
That makes some sense as the middle of the valve is chipped. I didn't think the rave valves could travel too far, I will have take a close look at that oneQuote:
Originally Posted by Mikes
Wow Doc, nice work. can you do rebuild pics too? Love to see how-to's like like this.
HA! I was waiting on you to chime in.Quote:
Originally Posted by Mikes
Folks, listen to Mike. He knows his stuff. TRUST ME.
:)
Man, I love this post DOC. I wish I understood more, but I can't help loving learning.
bump for DOC
Last night I went in to the shop manual then poked around the engine and found that the TB throttle body to intake manifold rubber boot clamp was not even secured. I could rotate it around the port on the PTO (power take off) cylinder ( the one fried) . On the MAG cylinder (closest to the magneto) the clamp was not tight as well. I bought the doo 3 years ago so I have to think it was like this all the time and I was lucky to have it last this long. So I think with the air leaking in thru this could definitely caused a lean condition and destruction of this cylinder. Contrary to mike above the rave valve cant travel further into the cylinder as it wears imo as there is a definte stop.
The Doo
http://farm7.static.flickr.com/6193/...c8fc56e4_z.jpgDSC04966 by docdrs, on Flickr
loose clamp between TB and Intake manifold
http://farm7.static.flickr.com/6198/...fa7a223b_z.jpgDSC04974 by docdrs, on Flickr
Jugs back from resizing .020 over
http://farm7.static.flickr.com/6207/...1599b461_z.jpg
DSC04967 by docdrs, on Flickr
Rave valves were ground back at shop for oversizing of cylinders. I think I'm going to take a little more off the middle of the pto cylinder rave as the clearance does not look as much as the rest of the valve.
http://farm7.static.flickr.com/6064/...44d934ff_z.jpg
DSC04970 by docdrs, on Flickr
http://farm7.static.flickr.com/6201/...4acddca2_z.jpg
DSC04973 by docdrs, on Flickr
pick of inside of doo
http://farm7.static.flickr.com/6185/...eec4e213_z.jpg
DSC04976 by docdrs, on Flickr
new rebuild kit
http://farm7.static.flickr.com/6085/...e0e305b1_z.jpg
DSC04977 by docdrs, on Flickr
trial fit of piston, rings wrist pin and bearings
http://farm7.static.flickr.com/6071/...3b2cf92b_z.jpg
DSC04980 by docdrs, on Flickr
gasket off exhaust mani and crankcase removed with razor and then scotch brighted smoothed.
http://farm7.static.flickr.com/6201/...e25414e3_z.jpg
DSC04982 by docdrs, on Flickr
new crankcase gasket
http://farm7.static.flickr.com/6075/...9f4d01fc_z.jpg
DSC04983 by docdrs, on Flickr
which ring goes on top? silver or black
http://farm7.static.flickr.com/6189/...ffd64441_z.jpg
Untitled by docdrs, on Flickr
the silver one goes on top
now how am i going to get the jugs over the pistons while compressing the rings with no room to work????
http://farm7.static.flickr.com/6198/...22e67086_z.jpg
Untitled by docdrs, on Flickr
http://farm7.static.flickr.com/6181/...041cd287_z.jpg
Untitled by docdrs, on Flickr
Would love to know what this would have cost you if you had dropped it off at the shop compared to your monetary and time investment.
so I used 2- 3.5 inch clamps on the pistons to compress the rings and with my bro inlaw we slip the jugs down over the pistons one at a time in about 10 minutes .....Voila..... happy camper......but wait tightened and torqued jug to crankcase.....then placed exhaust mani gasket and tightened exhaust mani to jugs and some of the bolts did not seem right.......one was down right not going in ......so executive decision remove jugs and find out what the issue is.....turns out shop blasted top and holes and shit was left in threads I think.......so back to have them tapped and get me a new bolt that stripped.....thank god it was one I could get totally out of the exhast mani.......a wee bit pissed so I had another beer and called time out.......btw the clamps worked well and I decided to change my oil filter and had to remove the entire exhaust pipe with silver manifold attached , the big black pipe to the orange rubber hose joiner hidden behind jugs, to get to it, it was just the rubber boot and a cooling hose hidden on the underside at the front .......wow what a pita for a filter.......way easier to work on the indmar motors
jugs on Happy camper but wait things went too easy>>>>>>>>
http://farm7.static.flickr.com/6189/...bb0f331c_z.jpgDSC04987 by docdrs, on Flickr
stripped bolt , back to the machine shop..... arrrrgh notice jugs out and back on floor .... wine time :)
http://farm7.static.flickr.com/6200/...239e5815_z.jpg
DSC04989 by docdrs, on Flickr
Thats more like it... lol, kinda the way things go for me, nothing is ever straight forward, or works out the first time.
So , I could not leave it till tuesday , my tap and die set up north....so I bought another at my favorite rental place Canadian tire...... Tapped out all holes on the jugs, there was sand blast crap in the holes. I could not get a bolt to match the one that stripped so I re die'd it and wham , I'm back in business.
first, left mag cylinder in sleeve....note clamp on right one holding rings in place.....now as my trusty assistant holds the jugs steady, I pull the right one up into the cylinder until I feel the clamp slide down the piston and the piston slide up into the last cylinder. Remove the 2- 3.5 in hose clamps and seat the jugs down onto the crankcase and gasket
http://farm7.static.flickr.com/6190/...b9571aec_z.jpg
DSC04992 by docdrs, on Flickr
note clamp
http://farm7.static.flickr.com/6206/...40bd379d_z.jpg
DSC04991 by docdrs, on Flickr
Jugs back in place and rest assembled. All bolts torqued in pattern and to specs. I also replaced my fuel filter ( tough to get those oem clamps off, replaced with hose clamps) and did a pressure test as it went from 80 psi to 120 psi ...a possble culprit for lean condition.
http://farm7.static.flickr.com/6209/...e2dceb45_z.jpg
DSC04993 by docdrs, on Flickr
also did a compression test 125 on both cylinders, pretty good considering nothing is worked in yet
http://farm7.static.flickr.com/6196/...2aee62ea_z.jpg
DSC04995 by docdrs, on Flickr
And lastly of course it started raining , so a quick pull out of the garage and she fired up right away :)
Update. Ran my seadoo for about 2 hours this weekend. Smooth and 60 mph top end. I then pulled both plugs to find them both tan in colour , the way they should be. Rebuild appears to be a success. :)
http://farm7.static.flickr.com/6191/...0a73e5f1_z.jpg
DSC04999 by docdrs, on Flickr
Congrats and thanks for sharing this. Way cool thread and well documented as usual.
Nice Job! Glad to hear everything worked out. What do you think total cost in parts and machining was?
Cost Piston Rings gasket set. 230. Delivered off ebayMachine Jugs/cylinders. 140. Bored and honed to .020 overSatisfaction of DIY. Priceless. And about 5hours + beerSo total for rebuild. 370Note I repace oil filter. 15 and fuel filter 90. Yep 90. So add 105 as I believe these have not been changed in 265 hours but that is the life of them.