Repower 2004 AR210 with MR-1 HO's

[84rzv500r]

did the final measurements and calcs today.... fuel tank will be 58 gross Gallons - 3% foam so figure 56 gal net and 55 usable

 

[84rzv500r]

 

[84rzv500r]

Port engine flywheel, installed cover installed and torqued to spec.... NEW Oil pump installed, tank cleaned and flushed, new o rings and gaskets all round... USPS lost my drain plug banjo fittings so I have some new ones coming from a better source FedEX. Stbd engine oil pump and tank on the plan for tomorrow. Fuel bladder on order from ATL. Built up a new Windows 10 laptop with YDS software and I'll put BUDS/BUDS2 on it as well.. to turn off that DAMN Seadoo D.E.S.S.

 

[84rzv500r]

Well looky looky what magically showed up 3 days after it was marked delivered

 

[84rzv500r]

so not quite enough threads on the bolts once the copper washers are on (see above) and i was tired of waiting for another set to arrive... SO a quick trip to the local hardware store and a few min on the lathe and mill and I made my own outta 316 stainless... with the correct amount of threads...

 

[84rzv500r]

Getting ready to TIG up my exhaust outlets... one to practice on and two for real... I haven't used my Miller Synchrowave 200 TIG since I welded up the homebrew exhaust to stainless cans for my XR-1000... I mostly MIG and Stick weld so it will take a bit of adjusting to get set up for this job...

the trick here is after cleaning and degreasing to cut a few strategically placed holes in that hose clamp and tack the pipes together with just the torch and no/little filler rod then come back and weld it up...

 

[84rzv500r]

quick status update...
ETA on fuel bladder 3 week In January
Two big boxes from boats.net of back ordered yamaha parts showed up today.
Lots of time off for the holidays this year = time to work on Boat

 

[84rzv500r]

picked these up at XXX store yesterday...

 

[84rzv500r]

been hectic with the holidays... Back on the Boat for a week... had a few spare minutes yesterday so I whittled these thermostat housings down 3mm so I got full thread engagement on the fitting... this is for my attempt to move the drain plug on the MR-1 to a place where it is actually useful...

 

[Beachbummer]

Drain plugs? can you elaborate?

 

[84rzv500r]

Drain plugs? can you elaborate?

there are "drain" plugs in the bottom of the engine in the 140, 160, and 110 versions of the MR-1. my Idea was to replace this plug with a banjo fitting and bolt to 1/4" marine fuel line to allow me to get more of oil that remains during an oil change out. running this 1/4 line up to the thermostat housing and using a bulkhead double bung fitting where the grease fitting and hose to the mid bearing was (which i dont use anyway, i put a metric zerk in the housing so i can "feel" the grease going in... some use a metric plug and 80w-90 gear oil) a good solution... i did have to mill 3mm off the flange to get full thread engagement

i should have one all done today and post a pic...

 

[84rzv500r]

zinc chromate on the exhausts... and update on dry sump oil drain... ill use some corrugated abrasion shield and stainless Adel clamps to tidy up the routing...

 

[84rzv500r]

that should give ya the idea.... prolly put a spring clamp on the end plug to facilitate oil changes and slide some split abrasion tube on but... Stick a fork in this one

 

[84rzv500r]

got to recheck the torque on the oil pump & gear reduction snout to make sure i didnt miss anything, starter cables to build, a fuel injection assembly to build for the port engine, mechanical oil gauges line to run, exhaust system to mount and plumb, weld the exhaust transitions, and put the rubber engine mounts on...

 

[84rzv500r]

made good progress... ran outta daylight... prolly be all assembled by tomorrow night... enjoy the pics

 

[84rzv500r]

Pictures or it didn't happen!

the Proof is in the PICs... EASY PEASY

 

[84rzv500r]

mech oil press lines installed.. need some corrugated split tube... the deal is ya cant get at any of this after the exhaust is installed...
starter cables next then Injection intake, and exhaust...

 

[84rzv500r]

working on port injection unit... almost done... waiting on a few little brackets and such to tidy up... prolly get exhaust all ready to go and call it a day...

 

[84rzv500r]

just noticed that the airbox covers not the same color... LOL the red one be faster.... ready to put the exhaust on and tidy up the coolant plumbing... then I can set them in the boat !!!! I expect to signoff on the ATL Bladder tank build for the ski locker this week.... 4.4 qts of oil in each engine as they were just assembly lubed and dyno tested... there was no oil in the sump either as I sealed up the bottom of the long block LOL... polly spin them on the bench to see oil come up the mech pressure line... getting a ton closer...

 

[84rzv500r]

got the engines just about licked... its a little slow and tedious fitting up hoses and wires... next on to the exhaust final assembly and its time to sneak these things into the boat...