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Sportster 1800 - Engine stopped while riding

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go_panthers

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First of all, this forum has been a great help to me in my SeaDoo PWC and boating ownership. Thank you for that. I'm looking for some help now with an engine problem.

I have a 99 Sportster 1800 with twin 717s. I cleaned and rebuilt both carbs this spring and had a great time with it so far. Saturday, we were on the lake, running at about 5500RPM, and the right (starboard) engine shut down. I tried to start it and it just clicked. Uh Oh was my first thought. We limped back to the dock on the Port engine. Out of the water, I tried to start it again and it turned over, but made a bad grinding noise. The other engine still cranks right up with no issues.

I travelled on business this week, so I just got back to it this evening. Both cylinders read 140 psi compression, which I think is good. It still has the grinding noise. I can rotate the flywheel counter-clockwise by hand, but hear a click about every 10-20 degrees when I do. It won't rotate clockwise by hand.

Tomorrow, I'm planning to pull the pump and see if that is the problem. I changed the pump oil in both jet pumps this spring, and had the inner seal replaced on both.

Questions: Could it be a bearing or something on the crankshaft? If so, how bad is that?? If I sucked something into the pump, where would the damage usually be seen?? Any other suggestions based on these symptoms??
 
It could be the needle bearings on the crank have failed.. I had this happen on one of my ski's. If you pull the rotary valve cove off you may find ground up parts in there. I would not turn it over again until you take a look. On mine it was the rod bearings.. Good luck...
 
So, I took the engine out of the boat on Saturday, and started looking at it this morning. As I was removing the carb on Saturday, I realized what had happened. One of the bolts that holds the air intake plate to the carb vibrated loose and got sucked into the intake. It got stuck on the rotary valve, killing the engine.

I took the rotary valve cover off this morning, and verified my theory. The rotary valve is chewed up, and I'm sure there are issues with the rotary shaft assembly. I've not got the bottom of the motor apart, so I'm not sure if there are issues with the Crankshaft, or the rest of the engine.

My question is: Should I just buy a new assembled block? Or, should I try to fix this one? I'm mechanically inclined, but am a little intimidated by getting this engine working again on my own.

Any recommendations?
 
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