Lets get this engine out Pt 3

Posted: March 29, 2011 in Uncategorized

Now we have finally gotten the engine out of the Jet-Ski so it’s time to take it apart and access the damage! The first thing to do is to disassemble the top end of the engine and the first part to remove is the cylinder head. Luckily this ski is a 2 stroke and many of them are so, this will be a very easy task. The cylinder head is held on with 18 x 12mm nuts on top, you always want to systematically break them lose first in a criss cross pattern, once they are all lose, remove them and put them in a labeled bag. The cylinder head is off, and my middle cylinder looks badly scarred, so this will most likely need to be bored out.

Now The cylinders need to be removed to more accurately access all the damage to the top end. There are 8 x 14mm nuts on the base of the engine that need to be removed in the same way that the cylinder head bolts were. Now that they’re off and labeled in a bag, the best way to loosen the cylinders is to tap them at the base with a rubber mallet in several places. Do this only as needed until you can slide the cylinders off and the pistons are exposed. carefully place the cylinders on a shelf so they do not fall, treat the parts with care even if they have to be machined!!

Now that the cylinders are off you can really see the problem: The middle piston seized in it’s cylinder, partially melting it and ruining the cylinder. Unfortunately I am going to have to order a complete top end and have the cylinders over bored. You may be lucky and if you can feel the cylinders and there is not scarring, no scratched, and no damage, then it is possible to get away with a new hone and rings. You cylinders and pistons must be measured by a machinist to properly determine this though. I will be ordering my parts from http://www.shopsbt.com/ They have competitive prices, great service, and everything that you could need!!

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