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Jet Ski rebuild (Read 5760 times)
Tyranni
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Jet Ski rebuild
Jan 16th, 2014 at 10:52pm
 
I mentioned I picked up two jet skis at the end of the summer.  One is a 2000 Yamaha GP1200R.It was in pretty bad shape but  I enjoyed it the rest of the season and expected to do a tear down over the winter.  On my last run before calling it too cold to ride, the motor gave out.  I went back and forth if I should rebuild or sell for parts.  I got it dirt cheap and decided if I built it back after tearing it down, it could be a ski to pass around, ride hard, and put away wet.  Here's the rebuild. 
Damage:
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Third cylinder lost oil either due to a failed check valve or a poorly calibrated oil pump, maybe both.

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Every nut and bolt from the ski is set out in boxes and bags in my garage

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Empty hull.  I redid all the fuel and oil lines too so tanks are out.  At this point, worst case, I'm left with an uncomfortable canoe.
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Thrown rod from seized piston. Picked up a quality used crank from a shop
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Don't think that hole is repairable  Cheesy Picked up a good used crankcase from a guy in Ct.
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Damaged cylinder and piston. Luckily this engine is designed with three separate jugs. Picked up a re manufactured cylinder and new prox piston.
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I added an electric bilge pump for insurance.

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And finally, the seat is pretty nasty, so we'll take care of that too.
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Engine rebuilt ready to go back. It has 3 carbs so those got rebuilt too.
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Engine back in. Chokes removed, all new lines installed.
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Buttoned up with a new seat. Purrs like a kitten ready for a lake test. Will need carb fine tuning at the lake
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2003 Mastercraft X2
2001 Yamaha GP1200R
2002 Honda Aquatrax Turbo
 
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nathan
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Going Home !!!!!

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Leander, TX Soon
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Re: Jet Ski rebuild
Reply #1 - Jan 17th, 2014 at 6:49am
 
very nice!!  looks great.  should really tear it up now.
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My Happy place is on a boat at the lake with my kids!!

current boats:
1983 chaparral 235 XLC (restoration)
1977 playcraft p24 pontoon (parents own now I am the mechanic)
1975 skeeter hawk (on hold)
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JC
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Posts: 254
Cedar Park
Re: Jet Ski rebuild
Reply #2 - Jan 19th, 2014 at 12:58pm
 
I never had a lot of faith in those oil pumps. Switched over to pre-mix on all my 2-strokes. Kinda of a pain but I knew I'd never run without lube.

Good job getting it all back together. Those things are a blast in the right conditions!
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« Last Edit: Jan 19th, 2014 at 11:55pm by JC »  

29 Fever w/twin BBC
 
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97FASTech
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Canyon Lake Boater

Posts: 278
Canyon Lake / Houston
Re: Jet Ski rebuild
Reply #3 - Jan 19th, 2014 at 2:17pm
 
Nice being able to tear into the engine and rebuild yourself.

Always enjoyed mine, but got rid of them for the boat.
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Captain YARRR
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Round Rock, TX
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Re: Jet Ski rebuild
Reply #4 - Jan 20th, 2014 at 7:52pm
 
Looks great! You should really get your money's worth out of it now. Today would have been a fantastic day to get out there.
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2005 Sunsation Dominator 32 MCOB - twin 6.3L
2004 Dodge Viper SRT-10: 460 RWHP, 503 RWTQ
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Tyranni
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Re: Jet Ski rebuild
Reply #5 - Jan 21st, 2014 at 8:35am
 
Thanks guys, I hope for a lake test this weekend.  Would have been nice while the weather is warm, but I'm stuck out of town for work.  I have a full body wetsuit and by the looks of it that will be needed this weekend. 
JC, I debated pre-mix or oil injection.  In the end i rebuilt the oil pump and put in see-through tygon oil lines.  Now, when I start it  as I idle out of my no-wake zone I just take a peek to make sure I see the oil pulsing through all three lines.  To me that's less of a pain than pre-mixing.  Even stock I should hit 65mph, we'll see...
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2003 Mastercraft X2
2001 Yamaha GP1200R
2002 Honda Aquatrax Turbo
 
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