Blown Cylinder in a 1995 XP

[itsabowtime2]

Due to poor knowledge on my part my 1995 XP has a bad cylinder. An oil line failed and the end result is a blown engine.

The dealership offered $300 trade in. The engine was rebuilt once already, back in 1999. I do not have a ton of time to rebuild the engine and we planned on selling it anyway to get a 3 seater.

So for the loaded questions:

How long does a rebuild take?
How much $$'s are we talking?
I have rebuilt carbs, calipers and such, but never an engine. It is a project that I would like to do someday.

The VTS was bad as well (typical).

Thoughts?

 

[Dr Honda]

If you are OK will tools, and like eBay... part it out. If it's in good condition otherwise... you could make $600 to $800 from the parts. If the hood, seat, and gauges are faded and cracked... take the $300 trade.

 

[itsabowtime2]

Here is a photo from last spring:

Seat is original. No cracks or rips. I removed the Sea Doo branding once it began rubbing off.
Gaugues work. The black bezel paint is flaking off, but they do work.
Trim motor bench tested good.
Hood has some fade on it, no cracks.

 

[seadooya]

If only a topend, and other cylinder/compression is good (thats if you can do a compression on it), then getta new piston, hone/bore out bad one, and call it good. Maybe 150 buks total for everything.

 

[Minnetonka4me]

Yep that thing is clean. I would go thru the carbs, and replace the fuel lines too if you decide to rebuild.

 

[itsabowtime2]

For $150 it is worth it if for no ther reason to learn more about how these engines work and for the experience of doing it.

Compression on the other cylinder was 130.

I am going to take on this project. I can not do more damage than already has been done.

Any recommendations as to a good manual for this project?

 

[seadooya]

Any recommendations as to a good manual for this project?

If not a prem member, then just ask away.

130psi, i'd leave it alone. Pull the bad cylinder, inspect the "wear" in the sleeve, if good, then getta hone (15 buks), and order same size piston (75 buks). Remove old piston, install new, drop cylinder on, and install head...

For "exact" approach...
remove carbs
exhaust manifold..undo pipe from it
head
4 bolts securing cylinder to case

Once everything ready for install, drop cylinder, "seat" the 4-bolts, then install exhaust manifold, so cylinders line up, then titghten 4-bolts down, finish tightening up the manifold, install head, then pipe, then carbs.

Probably left some minor sequences out, but most part, thats about it.

 

[Dr Honda]

Yep... it's clean. Fix the engine. :cheers:

 

[RFoster130]

Yeah buy a new one and keep this as a project to learn how to work on it yourself. Too nice to give away for 300 bux.

 

[itsabowtime2]

I started on the project.

I am going to replace the fuel and oil lines as well.

Anyone have suggestions as to the best outlet for the parts? I did some looking on SBT as well as a few others. It apprears there are different quality pistons out there etc.

I lost all this week due to corporate audits. I hope to get the cylinder honed this week and be putting her back together in 2 weeks.

Once rebuilt, what are the proper break-in procedures?

Another loaded question. I have been considering getting the cylinders bored out and replacing both pistons. Is this really worth it? I honestly suspect that we will be selling the machine after this season. I do not see us bringing both ski's out with us and the boat unless I pull one of them behind the boat.

I appreciate all the help thus far!

 

[Minnetonka4me]

Fuel lines I get from napa, oil lines from the hardware store b/c they have tygon.

Pro-X pistons are the best aftermarket, but if you are getting rid of it use WSM.

The machinist will tell you if you can get away with just a hone, I would assume you will need it bored. If the other side is perfect I'd leave it, but if its tired, get it matched to the other one. They both have to come off anyways b/c of the base gasket.

You can get the top end done for under $400 bux, then its worth about 1600 with a trailer and cover in my area.

 

[jhjesse]

Where abouts are you in Tennessee? I'm in Chattanooga.
I Can give you a hand or buy it from you.
Would love to see that thing redone either way. :cheers:

 

[itsabowtime2]

:cheers:

Where abouts are you in Tennessee? I'm in Chattanooga.
I Can give you a hand or buy it from you.
Would love to see that thing redone either way. :cheers:

Outside Music City.

I found top end rebuild kits for about $175-$300.

Then I found reman engines for less than $800.

Still going to rebuild.

Thanks for the offer to help. If you were closer I'd take you up on it. :cheers:

 

[itsabowtime2]

Full Bore?

Anyone have any experience with this company? They will bore out the cylinders and use the Pro X pistons for $375.

 

[jhjesse]

Anyone have any experience with this company? They will bore out the cylinders and use the Pro X pistons for $375.

IMO
They are probably one of the best.
Quality is superb.
Customer service is second to none.
Will stand behind their work.
Price is right, as well.