2000 Challenger w/M2 jet drive PROBLEM!!!

[Dr Honda]

Well... fortunately, the cylinder sleeves can be exchanged on these blocks. So... even if it's damaged badly... it can be removed, and a new one installed.

Post up some pics of the damage, and lets asset it.

As far as the boat checking out when you bought it... it could have been just fine. But... sometimes 2-strokes just let go. The cast pistons can crack... it could have run lean... or bolts can break.

Or... if the dealer could have just lied to you, if they were the one selling it.

 

[cjohnson]

I can not find anything in the service manual about replacing cylinder sleeves..I looked through the whole powerhead section... Am I missing it somewhere? Pictures are coming soon

 

[cjohnson]

Well... fortunately, the cylinder sleeves can be exchanged on these blocks. So... even if it's damaged badly... it can be removed, and a new one installed.

Post up some pics of the damage, and lets asset it.

Its not pretty...

 

[cjohnson]

. here is another shot of the head

 

[cjohnson]

I am by no means knowledgable, but to me, the cylinder wall doesnt look that bad. If I do need to replace the sleeve, can you inform me of where in the service manual it is and where to order it?

 

[Dr Honda]

The head is fine. The rough edges just need smoothed out. Easy.

The manual doesn't talk about changing the sleeve, because it's not something (most) end-users, or even shops can do. The sleeve is installed via an interference fit. SO... there are 2 ways to get it out.

1) Heat the block to about 450 Deg F... then hit the cyl with a cool towel... and pull it quick. (basically shrink it fast, and pull)

2) cut it out. (That needs to be done with boring equipment)

The other issue is... the new liner isn't finished machined. So... even if you put in the new liner... you would have to send it out to be machined to fit the piston.

Personally... if that was my engine... I would inspect everything... but honestly... I would machine that one cyl for the next size piston, and put it back together.


FYI... that piston melted down either because of a lean run, or lack of oil.


Do you have the entire engine out... or did you just pull the heads?


Here's a 2.5L Merc sleeve... (I should be doing the install on my on engine next week)

 

[cjohnson]

The heads are just pulled... the next size up that i have found is .015 correct? Having one cylinder a different size won't hurt anything? Also is the cylender wall that bad? It looks to be like the damage was done to the piston and the head

 

[Dr Honda]

I can't tell how bad the cyl is from here. But... 0.015" isn't that much material to be removed, and I'm sure the damage is deep enough that a replacement stock sized piston would be too small once the melted aluminum is removed.

No... one cyl that is oversized won't hurt anything. Actually... it says it's acceptable in the Merc manual.

 

[cjohnson]

So I need to find a machine shop... How much does it typically cost to bore out a cylinder?

 

[Dr Honda]

To do a typical bore/hone is $35 to $50. But... since these blocks have blind cyl's... not all shops will do them. You need a shop that specializes in boat outboard/2-stroke engines.

This is partly why I'm investing in the tooling. There is one shop that is semi-local to me... but they have gotten a bad rep, and the BBB gives them an "F". SO... there was no way I was sending my engine block to them. Besides... I have an $80k mill sitting at my shop. I'm sure I can handle making a hole. (lol) Don't get me wrong... I do regular cyl's now (mostly motorcycles) but holding the v-6 and the blind holes poses some issues, that I have to make special tooling for.

 

[cjohnson]

What exactly are blind holes?

 

[Dr Honda]

What exactly are blind holes?

They don't go all the way though. Most engines have cyl's that open into the crank case, so the hone, and/or boring bar can cut though, and out the other side. These cyl's have a bottom, so the people doing the work have to be careful not to mess up the block.

It's not a big deal... but you need an outboard engine shop... not just a typical engine shop.

 

[cjohnson]

Okay, so I found a place that will put in a new sleeve for around $260 which I think is pretty good. They will also lightly hone the other cylinders to remove the glaze and clean them up. So hopefuly I will be back on the water sooner than I thought!

 

[Dr Honda]

Great !! Give us the name of the shop so other people will know.

Just an FYI... the place I got my Rebuild kit from is Tri State Marine in IL. But they guy sells kits via ebay under the name of... FasterThanMachOne. He ships quick, and answers questions. Also... today, I found an issue with one of the bearings he sent me... and one phone call later... and he is getting me a new one. So... his customer service seems OK.