1998 Sportster 1800 Engine removal

[kartracer76]

Hello everyone!

I have a 1998 Sea-Doo Sportster 1800 and I seem to be in a bit of a pickle!!!
Part of the cylinder wall broke off in the right side engine and the chunks of metal jammed everything... I'm trying to remove the engine from the boat as its the only way I can repair it but I don't know how to remove the drive shaft.

Any tips?

Cheers,
Kartracer76

 

[Jared]

You are in luck. I just got done removing my engine a few days ago and I have the exact same boat. The drive shaft took my me a while to figure out.
1. Take the pump off.
2. Remove the fasteners from the PTO/driveshaft boot
3. You should see a carbon ring with a metal piece in front of it. Push the metal piece toward the back of the boat. Now you should see a small groove with a clip in it. You have to push the clip out. I used two screwdrivers for this.
4. Have someone twist and pull the shaft:rofl: while you hold on to the metal peice in front of the carbon ring.
Good luck

 

[kartracer76]

Thank you very much for the help.

I'll tackle it tomorrow and I'll let you know how it goes.

Cheers :cheers:
Kartracer76

 

[kartracer76]

Jared,

I got my engine out... finnaly. Thanks for the help. Turns out that I will need two new cylinders, a set of main berrings, new con-rods, two pistons... and maybe a crank :banghead:

Thats the last time I use cheep gas!!!!

Cheers:cheers:
Kartracer76

 

[Jared]

Man that sucks. I had lost the wrist pin bearings on my front cylinder and they pretty much went everywhere. I ended up getting a rebuilt from SBT and just got it back in the boat yesterday. Got a friend coming to align the engine tomorrow. Do you plan on doing the rebuild yourself? The one year warranty engine cost me around $750 plus the extra parts I needed.

 

[kartracer76]

I'm rebuilding the engine myself as I build racing engines, I have the skills required. But I cannot split the crank and re-align it myself as I do not have the proper tools to do so. Last year I replaced the pistons in both engines and that saved me around $2000 from what the local marina quoted me at.

Hope it goes well for you,
Kartracer76

 

[pincusa]

Take a second look at the reman'd engines. I had no where near your damage and planned to reuse the crank and rods, but after adding up all the parts it came very close to the cost of the reman. Factor in time and other things, and it wasn't worth rebuilding. I have to think that with your damage and parts bill, you'll be well over the cost of the reman.

I'm not doubting that you can do it, just saying to look at it from a $$$ perspective