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Rebuilt 787 rfi engine problems

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Chris9333

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Hi, been a long time reader of this forum, but this is the first time I've needed to ask something. I have a 2005 3d with a new 787 rfi engine. (The last one had a leaky inner crank seal last summer, allowing a lot of oil into the cylinder head. It wouldn't start because it was oil locked. I read on here to take the spark plugs out and blow all the oil out by trying to start the engine a few times. This worked for about a week, then blew up.)

I installed the new engine last weekend with some friends who are more mechanically capable than I am, and it started up great. I idled it on the trailer for 10 minutes, with water hooked up, then turned it off and headed to the river today. Once I got here I ran it for 30 minutes never exceeding 20% throttle and I varied the speed every few seconds. Towards the end of the 30 minutes I heard a knock. About 30 seconds later I heard another knock. I then idled back to shore to let it cool down. When I went back to start it 45 minutes later and it really struggled. The starter sounded great, but it wouldn't stay running. Finally it stayed running and I went out riding planning to take it up to 50% throttle. It didn't like that. It really bogged down. So I brought it back in and checked the plugs. They're grey, with not much oil on them. I think that's ok?? After trying to start it again without my body weight on it, it started up ok but doesn't sound right. It died whenever I try to get on it. It clearly doesn't like the additional resistance of having to push more water thru the jet and the exhaust gases having to push more as well. The weird thing is, when I press the button to turn it off, for that second the engine sounds perfect. I've done it 5 times and every time I turn it off it sounds great for a second. Could this be an electrical issue? Or a fuel issue? My batteries a few years old, but I put it on the maintainer on it for a couple of days each month. It's a sealed battery so I can't tell the level of the acid. Any help would be appreciated. Thanks
 
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Gotta do a compression test, I wouldn't do anything else first. I have a feeling you won't like the results.

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150 PSI+ I think the RFI is a little higher. Remove spark plugs and put boots on ground tabs. Hold throttle wide open and spin the engine over until the gauge stops reading, should only be a few seconds.
 
150 PSI+ I think the RFI is a little higher. Remove spark plugs and put boots on ground tabs. Hold throttle wide open and spin the engine over until the gauge stops reading, should only be a few seconds.
Both cylinders are around 120 to 125.
 
342.jpg
just want to make sure the piston don't look like this

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Why did the old engine die? I know the seals leaked but what else, need more info.

The side of the piston exploded, sending the rod out the side of the cylinder head. I assumed it was because the pressure built up from the extra oil in the cylinder head, but now that this crap is happening maybe that wasn't the original problem.
 
Pull one of the raves shine a flashlight through the spark plug hole

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Pull one of the raves shine a flashlight through the spark plug hole

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I can only pull the back rave off as the exhaust pipe is in the way of the front rave. It doesn't look anything like the one in the picture. It looks like a normal piston would look. No scaring, burn marks, or discoloration.
 
Ok maybe compression is still a little low cause break in isn't finished

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Well it is under warranty, did you verify that your oil pump is working and in adjustment?

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The side of the piston exploded, sending the rod out the side of the cylinder head. I assumed it was because the pressure built up from the extra oil in the cylinder head, but now that this crap is happening maybe that wasn't the original problem.

That's why I asked. For the pressure to do that you would have had to empty the oil tank into the engine. Typically with your initial issue you can get a good bit of life out of it. I have a feeling there is an underlying issue. Being an RFI there is more that could cause issues. The knock is what has me worried. But if your injectors are faulty you could be washing down the cylinders. A fuel pressure check would be in order. If the injectors leak down or the pump is faulty things can get sour quick.
 
That's why I asked. For the pressure to do that you would have had to empty the oil tank into the engine. Typically with your initial issue you can get a good bit of life out of it. I have a feeling there is an underlying issue. Being an RFI there is more that could cause issues. The knock is what has me worried. But if your injectors are faulty you could be washing down the cylinders. A fuel pressure check would be in order. If the injectors leak down or the pump is faulty things can get sour quick.

I changed the plugs and went back out. It started up just fine with my weight on it, and got up to plane ok. It does sound like it's misfiring if I try and go any faster than just planing, about 15-20 mph. Sorry I don't have a tach or speedometer. I checked the plugs and they're still grey. I read about testing the fuel pressure in the article you linked, is there any simpler way than ordering parts for a Dodge minivan?

Also, no, I haven't checked the oil pump.
 
Sounds like you need to go through the rfi trouble shooting process check fuel pressure injectors etc

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