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94 Sea Doo XP Rebuilding Engine

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  • 94 Sea Doo XP Rebuilding Engine

    Hi. I am rebuilding an engine on a 94 XP 650. I had the cylinders bored to match the new pistons. However, the old pistons had broken off into small pieces in some areas. I am concerned that fragments could be inside the engine.

    What is the best way to flush these potential fragments out of the system before I reassembled the top end?

    Just want to make sure this thing runs good as I plan to keep it.

    Thanks,
    Joshua Cole
    In this life if you are in search of happiness it will surely elude you, if you focus on the needs of others, family, and God happiness will find you.

  • #2
    Re: 94 Sea Doo XP Rebuilding Engine

    Better took out the crankshaft to check it out & the RV parts all you need to check,mine was same case last 3 month.Check the oil seal of crankshaft too.
    :emoticonb

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    • #3
      Re: 94 Sea Doo XP Rebuilding Engine

      the only way to inspect and be 100% sure is to pull the engine apart compleatly
      PRIDE IN SERVICE<br /> <img src="http://www.sbtontheweb.com/images/forposts/4609/1.jpg" alt=" - " />

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      • #4
        Re: 94 Sea Doo XP Rebuilding Engine

        Thank-you to all. Stripped it down and all is well now. Reassembled and it looks good.

        The head has some pits in it from the previous pistons coming apart. Do I take it to a machine shop and have it machined? Buy new one? Sand down rough areas?

        Thanks,
        Joshua Cole
        In this life if you are in search of happiness it will surely elude you, if you focus on the needs of others, family, and God happiness will find you.

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        • #5
          Re: 94 Sea Doo XP Rebuilding Engine

          take it to a machine shop and have them clean it up or buy another one

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          • #6
            Re: 94 Sea Doo XP Rebuilding Engine

            if not bad then sand it down.. so any little craters are not protruding..
            taking it to get machined will and may alter compression..
            a little rough and then fine sanding should be ok.... as long as its not excessive..
            the dome does not need to be smooth to run good.. all it does is contain the combustable gases

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            • #7
              Re: 94 Sea Doo XP Rebuilding Engine

              The head has what I feel are a couple of deep pits. I hand sanded it down slightly but those areas are still inset. I have purchased another one via eBay that is in good shape. I will take some detailed pictures of mine and sell it on eBay.

              Joshua Cole
              In this life if you are in search of happiness it will surely elude you, if you focus on the needs of others, family, and God happiness will find you.

              Comment


              • #8
                Re: 94 Sea Doo XP Rebuilding Engine

                Hi. I pulled this thread from the archives as following the top end rebuild I had an issue. Riding the ski, yes wide open after only a tank of gas, I jumped a wave. When I came down the ski died. It later started and ran fine although we did not ride it anymore. I brought it home to check out. I then decided I would pull the head to paint the outside. Upon doing so I noticed the following impact on the front piston.

                Issue: Piston is severally pitted as you can see in pics. The rear is fine. What caused this to take place? In order to fix do I need a new head? Amazingly the cylinder walls are fine. Can I just get another piston to .5 match and replace only the front or do I have to have both cylinders bored/matched to the new pistons?

                Please input.

                Joshua Cole
                Attached Files
                In this life if you are in search of happiness it will surely elude you, if you focus on the needs of others, family, and God happiness will find you.

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                • #9
                  Re: 94 Sea Doo XP Rebuilding Engine

                  if you need a head email me at flamed94xp@yahoo.com i have two a brand new stock head and a westcoast head with two sets of domes.

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                  • #10
                    Re: 94 Sea Doo XP Rebuilding Engine

                    Inputs? See pictures above.

                    Josh
                    In this life if you are in search of happiness it will surely elude you, if you focus on the needs of others, family, and God happiness will find you.

                    Comment


                    • #11
                      Re: 94 Sea Doo XP Rebuilding Engine

                      This motor ran severly lean or is detonating extremely, or both.

                      Are the filters in the carbs clogged up?
                      Is the intake manifold cracked?
                      Is the head a stock head ?
                      What mods does the motor have?
                      Are the crankshaft seals shot?
                      Bill O'Neal <br>
                      WCM
                      <a href="http://www.watercraftmagic.com"

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                      • #12
                        Re: 94 Sea Doo XP Rebuilding Engine

                        See my integrated responses below....

                        Bill Wrote: This motor ran severly lean or is detonating extremely, or both.

                        Q-Are the filters in the carbs clogged up? A-No, double checked.
                        Q-Is the intake manifold cracked? A-No, double checked.
                        Q-Is the head a stock head ? A-Yes, although had some pitting and was hand smoothed.
                        Q-What mods does the motor have? A-Oil Pump Block Off.
                        Q-Are the crankshaft seals shot? A-How do I check?

                        I did notice the cover to the breather was not on all the way in rear. I also note I did ride wide open full throttle on 1st tank of gas w/40:1 mixture. I am upping mixture to 32:1. I also note the oil bath was almost empty.

                        Josh
                        In this life if you are in search of happiness it will surely elude you, if you focus on the needs of others, family, and God happiness will find you.

                        Comment


                        • #13
                          Re: 94 Sea Doo XP Rebuilding Engine

                          A case pressure test will tell if the crankashaft seals are shot and sucking air into the motor.

                          Something is amiss or it would not be eating pistons, especially as severly as yours are being destroyed.
                          Bill O'Neal <br>
                          WCM
                          <a href="http://www.watercraftmagic.com"

                          Comment


                          • #14
                            Re: 94 Sea Doo XP Rebuilding Engine

                            Is case pressure testing the same as compression testing?

                            I had within 2 lbs of each cylinder when measuring. I think it was right around 140-142 in each cylinder.

                            I have totally dis-assembled this thing. Double checked everything. Added to the pre-mix to where I should be around 28:1. All seals look good, are lubed with oil for tighter seal. I also looked to see if I could note any leaks of water, etc...having run down the side with nothing.

                            Could my having ran it wide open with a 40:1 mixture killed it? I did run it wide open for about 3-5 minutes on several occasions during the initial 30 minute ride.

                            Josh
                            In this life if you are in search of happiness it will surely elude you, if you focus on the needs of others, family, and God happiness will find you.

                            Comment


                            • #15
                              Re: 94 Sea Doo XP Rebuilding Engine

                              No it is not the same as a compression test.

                              Did you ever check the fuel valve ?

                              How old were the pistons that broke? Was it recently rebuilt?
                              Bill O'Neal <br>
                              WCM
                              <a href="http://www.watercraftmagic.com"

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