1994 Sea Rayder Outboard Engine Swap

[codes28]

Hi all.

I bought a 1994 Sea Rayder last year and it rode great until cylinder 3 piston blew up and gouged the cylinder. The quote I got to have the cylinders bored and a new piston kit is more than the boat's worth so I'm looking to do an engine swap.

I found a couple Force 90 outboards for sale and I'm wondering if the Force 90 outboard will work in the Sea Rayder? I've read that the blocks are the same but the splines are different, so I'm wondering if I can put my sport jet crankshaft in the outboard block?

I've added some photos of my block/crank and the outboards for sale.

Any advise is greatly appreciated. Thanks!

 

[Cobra Jet Steering LLC]

You may want to check with www.sbt.com the 90hp , 3 cylinder was a converted force outboard engine and I know the intake manifold was different but I do not know if the splines in the end of the crank were different.

 

[codes28]

Thanks Cobra! I bought the outboards; the splines match and the manifold bolt pattern seems to match. Waiting on gaskets right now before I put it together, will let you know how it works. I did have to buy the exhaust stuffer (F722479-2), as the block on the outboard has a hole for the exhaust through the bottom. I'm thinking it might just work!

 

[TaintFarmer]

Hello Codes,

Any updates?

Personally, I was considering the possibility of a total powerhead/pump swap with a Japanese brand like Yamaha or Kawasaki, anything but these domestic POS systems with the reliability of a Ford Pinto.

 

[codes28]

Planning on putting it together this weekend. Had to order a second set of gaskets because the first ones came bent. I'm also swapping the electronics because my Sport Jet has the red stator.

Would any other jet system fit? I feel like they're pretty specific, otherwise I'd consider it.

 

[TaintFarmer]

I wish I knew!
That’s a question for the original Force engineers/techs who built these engines/jet pumps. I would absolutely ask them to help me rip this God awful 90hp out and drop in a 240 EFI 6 cyl., lol.

All I can think of is that old show, “Home Improvement with the protagonist, Tim, shouting, “MORE POWER!”

One major tip I will give you if you don’t already know is to keep using your original trigger made for your specific engine but NOT the voltage regulator/rectifier. Credit for this tip 100% goes to @Cobra Jet Steering LLC ! I found his post from 2018 where he advised using an updated, high quality, 20 amp regulator/rectifier. He warned a user about the electrolytic capacitors in the old regulators that were responsible for frying the “brain” (I think he’s referring to the switch box) almost every time an owner would shut off the motor. This originally confused me since my engine didn’t have a switch box since someone had previously done the CDM conversion.

I ordered and installed a CDI Electronics product, specifically #194-5279. I had previously tried a cheap Amazon “highly reviewed” regulator that died while just cranking the motor! Big mistake.

Now @Cobra Jet Steering LLC recommends a jet ski regulator but I wasn’t able to find where he specifies which one or where to get it so I just went with the second best option after OEM.

I was in a situation where I had replaced my dead stator with the latest and greatest Red stator and then made the mistake of changing my trigger too which led to a no spark nightmare. This was due to thinking the superceded part numbers would give me the best option, not so. The later triggers weren’t designed for the older engines so the timing was way off.

The trigger insight is credit to another user, @kend301 from the iboats forum;
Post in thread 'Chronomania Sport Jet 90'
Chronomania Sport Jet 90

 

[codes28]

Thanks for all the info Taint! I swapped all the electronics this weekend, I took everything (stator, trigger, regulator, limiter, coils, temp switch, starter, and the harness) off the Sport jet and put in on the outboard motor, didn't upgrade anything so I'm hoping it works.

I will note that the flywheel off the outboard didn't fit the Sport Jet trigger (I wanted to use the outboard one as the Sport Jet flywheel magnets came loose). So now I have to re-glue the magnets. I read that there's no particular position as long as they're evenly spaced out, would you know anything about this?

Reading the manual my outboard must be older and Sport Jet newer, as there's two wiring diagrams, "late models with bullet connectors" and "early models with ring connectors". My Sport Jet has bullets and the outboard has rings on terminals, which is why I swapped everything.

 

[codes28]

Got her running in the boat today! Just tested it on the trailer. Going to take it out this weekend to make sure everything's square. Will update you guys and let you know what I had to tweak to get her going.