160 hp mr-1 engine swap (with jet ski engine)

[okula225]

Unfortunately have a seized engine. Lined up an 06 fxho with low hours that runs well. Anyone perform this swap? I have an 06 ar230. Looking for any tips and advice on process.

 

[14SX190]

Hi

One word of advice is take pictures, label connections, keep bolts in zip locks. Careful to keep shims under engine mounts in right place.

Easier if you take exhaust manifold off cylinder head.

You should address intermediate bearing since your there.

Have service manual if you dont.

 

[jocolo21]

yes my bud did it with a 2008 ar210, but with a VX

 

[okula225]

yes my bud did it with a 2008 ar210, but with a VX

Any threads on it?

 

[jocolo21]

he is not a member he change the engine at 850hrs his wasnt the ho so only 110hp

 

[swatski]

Any threads on it?

@itsdgm @Scottintexas @buckbuck @Jgorm @cybuch
These are some of the most knowledgeable members who have done it and/or posted super useful, detailed threads (I'm missing several others - sorry).

--

 

[Brad_Ct]

I swapped an engine from a 02 FX140 into a 06 SX230, the only major difference was that the wiring harness going to the throttle body/air cleaner assy. I believe the skis have some sort of rollover switch that the boats don’t have. I just swapped the whole assembly from the boat to the new engine.

 

[Seadeals]

Is the bad engine port or starboard. I didn’t need to remove the exhaust manifold with the starboard in my case.

 

[itsdgm]

Any threads on it?

I thought that I did a write up on my engine swap. I’ll look for it. In the meantime here’s a step by step engine removal guide for a non ho engine. YOurs would be similar. Hope it helps.

 

[okula225]

I thought that I did a write up on my engine swap. I’ll look for it. In the meantime here’s a step by step engine removal guide for a non ho engine. YOurs would be similar. Hope it helps.

Awesome, that write up is great. Any other threads would be super helpful as well. Much appreciated.

 

[okula225]

Is the bad engine port or starboard. I didn’t need to remove the exhaust manifold with the starboard in my case.

Bad engine is starboard. How did you get by not removing the manifold, wouldn't it be easier to pull it out then swap everything being that I am installing with a new motor?

 

[okula225]

I swapped an engine from a 02 FX140 into a 06 SX230, the only major difference was that the wiring harness going to the throttle body/air cleaner assy. I believe the skis have some sort of rollover switch that the boats don’t have. I just swapped the whole assembly from the boat to the new engine.

ok awesome, going to take pictures of the new and old engine side by side so i can understand what is different if anything at all.

 

[WREKS]

@okula225 I found it easier to pull out with exhausts still connected. I did not remove the ECM, though.

 

[okula225]

@okula225 I found it easier to pull out with exhausts still connected. I did not remove the ECM, though.

So you disconnected the whole wire harness before pulling the motor out then installed the new engine without the wire hanress and plugged it all in when the motor was in place?

 

[buckbuck]

I remember the service manual being very good at the step by step instructions for pulling. I left the exhaust attached and laid the ecm on top. It was not a difficult adventure.

 

[itsdgm]

Awesome, that write up is great. Any other threads would be super helpful as well. Much appreciated.

Heres a thread that @CrankyGypsy put together.

https://jetboaters.net/threads/how-to-removing-an-engine-alone.3863/

theres a few pics on my media too.

https://jetboaters.net/media/users/itsdgm.25/page-8

 

[WREKS]

So you disconnected the whole wire harness before pulling the motor out then installed the new engine without the wire harress and plugged it all in when the motor was in place?

@okula225 The engine weighs near 200 lbs. You need to have a crane set up. I needed to fabricate an aluminum gantry crane to do it. I suggest studying service manual before attempting to remove motor. It is easier if you do not have to contend with the weather. It is quite easy to run into unseen problems, like dropping or losing a bolt, etc. I say this not to discourage but help prepare. Starboard engine removal

 

[14SX190]

#WREKS I like the set up.
Do you have hoist system in work shop.

Always wanted one in my garage when I had skis.
Won't do me any good with boat as it has less lift clearance.

This is what I had to do to get engine in.
Once I had engine broken down I was able to lift it out and on to deck.

To get engine out of ski use an engine hoist. Works great.
Find them used on CL

 

[WREKS]

#WREKS I like the set up.
Do you have hoist system in work shop.

@14SX190 I also work outside. gantry crane

 

[okula225]

@okula225 The engine weighs near 200 lbs. You need to have a crane set up. I needed to fabricate an aluminum gantry crane to do it. I suggest studying service manual before attempting to remove motor. It is easier if you do not have to contend with the weather. It is quite easy to run into unseen problems, like dropping or losing a bolt, etc. I say this not to discourage but help prepare. Starboard engine removal

Do you have a pdf of the service manual?