Repower 2004 AR210 with MR-1 HO's

[84rzv500r]

exhausts done you wouldn't think 8 hose clamps would take an hour and a half...
not the most convenient place in the world to reach but doable...

 

[84rzv500r]

started on the electrical ... my boatwright buddy comin over to detail the hull... cant wait to get the heart transplant finished !!!

 

[HangOutdoors]

@84rzv500r Man, I can hardly wait for the video of the maiden voyage..... Been following your progress and ingenuity the whole journey.

 

[Coult45]

Same!

 

[84rzv500r]

LOL its been what 9 months... Yamaha did all the hard work Im just building the config they should have... Light, simple, 320 horses, shallow draft !!

 

[84rzv500r]

I got 7000 in the boat and trailer 5 years ago, my first boat ever.. ran it nearly daily for over 4 years... I've modified the boat to hang on davits so it never stays in the water and its literally ready to go in 5 min... I'll put less than 15K in the repower and get another 5-10 years out of it... and in 5 years I might rip these MR-1's out and drop 1.8 SVHO's and pumps in... Blond Beach Barbie likes boats with a reasonable freeboard, she likes the water level swim deck, a boat that is slow and quiet but can go anywhere and haul ass.. She says its not a wake board tower its drunk handles...

down here I see lots of new boats turn into old boats in 1-3 years... why spend $50K, 100K or 200K? and building stuff keeps me out of trouble. LOL

 

[HangOutdoors]

TBH, you thread inspired me when I first started reading it. I have been looking around for Yamaha that needs a lot of work/rebuild as well as cheap and I was going to get it and make it a project boat for my brother in law and his kids that I would work on and them give it to them. Unfortunately, I really didn't find anything yet. Of course my skillset is no where close to yours......

 

[84rzv500r]

TBH, you thread inspired me when I first started reading it. I have been looking around for Yamaha that needs a lot of work/rebuild as well as cheap and I was going to get it and make it a project boat for my brother in law and his kids that I would work on and them give it to them. Unfortunately, I really didn't find anything yet. Of course my skillset is no where close to yours......

TR-1's would nearly bolt right in to an LS2000 without all the structural changes I think... and the Jetski rental businesses down here have them all the time... Im still a farm kid 60+ years later... if we wanted stuff as kids we worked hard and bought it or built it if it didn't exist... I have made a career out of that...

 

[84rzv500r]

here are the mods to hang it on davits I made when I first got the boat... I got over the drilln holes fears in my boat pretty quickly.

some 316L plate 3/16" thick and some 3/8 stainless button heads to sandwich the stringer bonded stainless and neoprene washers and a liberal dose of 5200... spread the lifting load over 16 sq inches per side... for the bow its the standard fair... however i did use a boat railing fixture with a backing plate though bolted to handle the the horizontal component of the load generated since the threaded rod is not directly in line...

I also added two more OEM stock cleats per side as 2 wasn't enough, two amidships just aft of the front seats and two on the bow just aft of the bow chocks...

 

[84rzv500r]

Wiring up the engines The rubber grommets for these throttle cables is no longer available from yamaha and I couldn't find aftermarket ones so I made them out of truck tire valve stems They fit perfectly and snap in the hole... I think I got some stainless Z clamps around here someplace for boat seats... quick and dirty hold downs.

 

[84rzv500r]

warmed up today 85 and very few clouds.... one throttle cable down 1 to go.... so tomorrow ill pull the controls out adjust the throttle cables for travel and verify WFO and while im in there ill change the port steering cable and lube the steering cables... 2:30 is beer thirty today.... Damn it nice to have 2 boats.... fuel bladder installation starts tomorrow...

 

[84rzv500r]

I have one whole day in dressing wires and harnesses... still have fuel pumps, Key switches(dash), and 12V power and ground to go... Engine harnesses all done tho... wait for it.... it's a boat load of wires. I did find a problem i was having before the repower... i had a bent pin in the power side of the dash feed connector...

 

[84rzv500r]

not much progress on the repower today, did get some back ordered trinkets from Yamaha... finished that perkins 154 sherwood h5 raw water pump for my buddys 42' sail boat... Had a ball bearing race had no inner race left that I couldn't get a blind puller to hold on so I called on Mr Miller and his Iron fist... and the welding shrunk the race and heated up the bronze tapped right out...



Weekends repower task list:

• finish tagging electrical connections make a list of connectors needed to integrate boat and engine harnesses
• pull faria euro tachs and install AR230 HO tachs
• Lay out port/stbd CEL, Temp, out warning light harness with Back feed for instrument lamps to engine bay for Mech oil gauges
• Pull Lead acid batteries and install LiFePO4's tidy up 12V wiring/install 12V and ground bus bars..
• tidy up solar panel chargers
• hook up throttle cables to levers check for WFO and adjust for sync, dress off cable routing with adele clamps
• install M6 helicoil in in the starboard throttle body
• dress off oil pressure lines and hook up gauges
• install and switches for bilge fan and LED engine bay lighting.
• prep ski locker and install bulkhead pass throughs for port/stbd fuel and return lines, fuel sender wiring.
• layout and install fuel system components and install bladder tank

 

[84rzv500r]

break for lunch... quick update... all going well... cleaning up things a bit.... all the old 12V wiring is gone... time to put in the new LiFePO4 batteries, positive, and negative buss bars... bus bars should tidy up the wiring a ton... Made space for my tool box again...

 

[84rzv500r]

more pics...

 

[84rzv500r]

Im making all new battery cables... these Buss bars gonna clean up the wiring then the Brother PTouch labelers gonna have its work cut out for it..

 

[84rzv500r]

some detail on the power, fuel, and safety systems... What was in the boat was clearly substandard and I ripped all that out and rewired all the 12V cables. I usually coat all the connections after their done with waterproof grease or a corrosion inhibitor like CRC 656 even if they have rubber boots.. the thought was to use a buss bar so I can have boots over all the connections. I'm using Made in the USA #4 SAE J1127 105C rated cable and adding high temp abrasion resistance. I also have a couple of halon systems leftover from my corvette racing days so I was thinking of putting a dual trigger halon (really FM-200 these days) system in as well... auto-thermal and fire pull. I'll do a quick volume calc on the engine to see if any of the tanks I have are big enough though I think there are all aluminum rather than stainless though. The fuel tank is partitioned off with a separate set of continuous 1 1/2" vents for the ski locker and fire blocked with GB duct seal, much better than the OEM setup. I carry 2 marine fire extinguishers, one in each the dry storage compartments in the helm, with conspicuous external reflective labels for fire extinguisher inside as well.. On the fuel side im using made in USA SAE J-1527 type A1-15 ISO 7840 and NMMA/CE type marine grade high pressure fuel lines with oetiker stainless ear clamps, fuel shutoff ball valves are in the ski locker accessible from the helm, Im using walboro continuous duty fuel pumps with secondary relays rated for the correct ampacity with marine breakers fed from the bus bar after the battery cut off switch. I don't have a stator interrupter switch, killing the ignition and battery cut off should be good enough. Also in conjunction with the OEM Rule Auto bilge pump... I have a big pump on a float switch with a on off auto switch powered off a separate 20A feed from the buss bar to my Aux power panel that also handles the radar and LED Spots and flood lighting..

PS I did read the USCG electrical regulations in 33 C.F.R. Part 183 apply only to boats with inboard or stern drive I/O gasoline engines.

 

[84rzv500r]

much cleaner... wire up the battery switch and the starter relays tomorrow and then on to the fuel system...

 

[84rzv500r]

so i needed something to occupy the choke cable holes in the dash.... so a Fireboy FM-200 automatic/manual system on it's way... 100cuft system has 10% extra...

 

[84rzv500r]

did I mention there were a boat load for wires.. just a few more terminations and some strain relief and the boat will have 12V power again...