Engine alignment shims

[Dick]

I replaced a 97 GTS motor today. When I pulled it out I found a big stainless washer or shim in the bottom. I figured someone dropped it in there. When I set the new motor in it wouldn't sit normally (rocked around). With the alignment tool it was about 1/4" low, maybe more. I put that big washer on one of the rear mounts and it was a lot better. I've never seen one of those before in a Sea-Doo. It seems close enough to use normal shims now, but!!!!!!!
Has anyone seen one that far out of whack?

[Bill O'Neal2]

Re: Engine alignment shims

I took apart a new 1998 XP and put an alignment tool in it because it had blown a coupler apart in less than 10 hours. The motor was a full inch HIGHER than the alignment tool. Raising a motor to align is easy compared to trying to lower one. With no shims under it, it was higher.

The cure? Remove the pump support plate and re-shim and realign it so the alignment shaft meets the motor correctly. How much shop time did it take? Well, the first one took about 6 hours. We got it down to a couple of hours on a few boats since that first one. I now quote alignments as whatever shop time it takes to get it right.

[Dick]

Re: Engine alignment shims

Maybe the hulls get out of whack. This one didn't appear to be damaged anywhere. What's odd is that one thick shim seems to get it close, within a 16th. I wouldn't think they would let one out like that. Someone had changed the coupler as it was a white motor and had a gray coupler.
I've been to Valcourt a couple times, but I spent my time looking at snowmobile stuff. If I ever get back I think I'll go thru the Sea-Doo line and see how they do things. I guess all that's important is to get it aligned.

[Bill O'Neal2]

Re: Engine alignment shims

Dick,
As in any production line assembly, I'm sure one gets by now and then that just isn't right, like that 1998 XP in my shop back then.

I spent a day in Valcourt watching the assembly line process. All in all, I was impressed with the amount of checks they did during assembly of the SD watercraft.
BTW, it was the same assembly line as the sleds are built on, just a different time of the year (winter for PWC, summer for sleds).

[Dick]

Re: Engine alignment shims

I just never seen one that far out of whack before. Our business is about 80% snowmobiles. We get enough Atv & Sea-Doo to keep us busy in the summer.
I was in Valcourt about 2 mo ago and they are running 3 lines now. Separate Atv, Sea-Doo, & Ski-Doo. They had a huge order from John Deere for Atv's, I think he said 17000. Pretty hard to believe.
This forum is a good spot to hear whats going on, at least for me.
I finished that alignment this morning and it seems OK. It took a lot of shims.

[Bill O'Neal2]

Re: Engine alignment shims

Like I said, the pump support plates are shimmed so that alot of shims are not necessary at the motor if the support plate gets shimed correctly in the first place. I really don't think it is a hull problem at all. Although there will always be some tolerances when using fiberglass to build them.

When the rush is on to produce many fiberglass watercraft hulls in a short period of time, I'm sure they don't leave them curing in the mold as long as would be optimum. Some warpage is bound to happen.