Oil filled cases on 2003 800 GTX Fi

[Spaaz]

Hi, I am new to Seadoo but I use to build 256 Rotax motorcycle motorcycle road race engines so have 2T engine experience. I bought a Seadoo 2003 800 GTX Fi with a problem of cases filling with oil. It had sat for 2 years. Have now stripped the engine and inspected. Because I have no manual nor experience of these engines, sorry. The balancer shaft end drive seems to be lubricated by the oil/fuel charge ? and the center worm rotary valve drive seems to be lubricated by oil, not sure whether this is a closed oil cavity or uses the 2T oil ? The engine has had a recent crank and the inner seals were not silicon sealed and was showing signs of spinning in the cases, which would explain how the cases have filed with oil. so I am hoping with the seals sealed to the cases the crank cases will not fill up again. because I did not remove the engine I am unsure of pipe routing. Can somebody tell me if the RV gear drive cavity is sealed or does it use the 2T oil ? hopefully it will be a simple fix ? Any advice gratefully received, Thank you. SP

 

[GGuillot]

You can download a service manual here...SeaDoo Manuals - FREE PDF Download! yes, the rotary valve cavity is sealed and is feed oil directly. Likely someone didn't torque the cases properly or didn't use the proper sealant on the case halves which caused the leak problem.

 

[mikidymac]

The seals don’t use sealant on the cases.

It is either going to be bad inner crank seals requiring a reman crank or the rotary shaft seal. Typically it’s the crank seals that cause this.

 

[Spaaz]

Hi thanks for your help, i shall inspect the manual and be a little wiser. I shall report back on my progress. Thanks again or your help. SP

 

[etemplet]

I bought a bottle of automatic transmission fluid conditioner that helps the transmission seals. I've been contemplating putting a small amount in the oil line going to the Rotary Gear. I use premix so it won't her anything if it gets back to the oil tank.

 

[DanSquires]

The later RFI skis will spin the inner crank seals. It's.. a thing.
Side note, when I rebuild I always lay sealant in the seal groves.

 

[mikidymac]

The later RFI skis will spin the inner crank seals. It's.. a thing.
Side note, when I rebuild I always lay sealant in the seal groves.

Good to know, sounds like the tolerances got sloppy at Seadoo on those.

 

[Spaaz]

Thanks Dan, I thought this too, the web of the seal has 1.5mm side clearance to the slot in the cases, So I think that they changed the spec of the seal from a thicker web. When I put racing 2T's together with original Yamabond No.3(not available now) so I use Threebond 1103 slightly thinned with isopropanol, painted on both faces. With the problem seal I think I shall use some fuel resistant RTV.
When I took the engine apart the M10 and M8 case bolts had been Loctited with thread lock ? I got the manual and it says use Loctite 518, which I beleive is the gasket eliminator, so I guess the last person who put the cases together got it wrong, I think they specify the gasket sealant to stop any corrosion problems, especially from the open ended studs.
Luckily I have a Vixen engine washing machine so the cases look like new. The salt water corrosion has got to the rotary valve cover, one of the fixing bolts has corroded and broke the casing bolt eyelet. I chose to vapour blast the cover, after blocking off the oil jet.
The anti corrosion coating under the paint is quite tough to get off the alloy. I shall TIG the repair tomorrow. Any idea what is the anti corrosion coating is ? I think it will be needed to coated with something, not sure what makes paint stick to alloy ?
I am very naive about watercraft, please excuse my ignorance. I am an ex Motorcycle racer that has never experienced salt water corrosion before. Nick Turner . Ashburton, Devon, England

 

[mikidymac]

You should be using Threebone 1184 on the cases although some use 1211 too. I wouldn't use 1103 or any RTV on the cases or seals.

 

[Spaaz]

Sorry I was wrong, brain injury, those Manx stone walls really hurt.
Not 1103, but 1104, similar to early Yamabond grey.
1104 is no longer available in the western world, because it contained lead, but in the Far East they don't mind selling it to the brain injured ?
I have been using this for 40 years and I don't suppose I am going to change now.
I used this at GP's in the 80's, on Rotax's, never had a case leak yet ?

 

[mikidymac]

That is correct I used 1104 until they changed it for us to 1184. You are using the correct stuff.