Jgorm's 04 ar230 build

[Jgorm]

I rigged up a better micrometer setup and I'm a tooth off for sure.


I made a video too. Maybe it will help someone.

 

[Jgorm]

Pulled the exhaust cam and tensioner and got it in place. The chain fell off the intake cam and i felt like i got spotted by a hungry lion in an open field! I got it back in place. It was a bit tricky to get the exhaust can back in, but i got it. Took about 2hr. I did leak down and had some ring leakage and minimal valve leakage, but it's seemed pretty good for a cold engine (i hope). Time to start buttoning it back up. I made another video with my estimate of proper timing. I probably have 8+ hours sitting on the starboard engine! Probably 200+ engine rotations since i started messing with it.

 

[Jgorm]

I made some progress!

I lost a bolt for the coils so i taped it to remind me.
I spent hours cleaning gasket material.


Even though the water is already mixed with the exhaust, Yamaha still water jackets the exhaust!


I thought this gasket was toast, but it has lots of metal in it.

 

[itsdgm]

Looking good. Nice progress.

 

[Jgorm]

This piece is kicking my ass. Probably 2hrs and no progress. I'm having trouble getting the coupler on and the exhaust lined up with the bosses on the block. I removed the end piece and hope i can get that on after.


It's hard to get behind the elbow place that goes over the hose coupler. I spent 10 minutes looking for the second rubber bushing before i realized that there isn't one. The long bolt goes in the bushing, the next longest goes in the other lower bolt, and the two short ones go in the top. These are difficult to line up!

 

[Jgorm]

I attached the hose clamp to the exhaust manifold side and pivoted the pipe into place. You'll need to remove the rear exhaust piece. It's not hard to install without the metal as the last piece. I couldn't get the starboard upper bow side bolt in all the way. There were thread marks on the exhaust when i removed it, and it's real tight. I got it 3/4 way in and it got real tight so i left it. The other 3 bolts are plenty secure. I dropped a bushing for the air filter box and spent nearly 2hr looking for it! It was between the headers. The compression was 145 to 155 across the board with my new gauge. Hopefully that's not an issue. It idles and revs great! Oil looks clean, no exhaust leaks, no water leaks, no oil leaks, he'll yeah! I got about 20 minutes cumulative of hose time. I'm not sure if I'll take it to the local lake, or straight to the river.

 

[swatski]

Pulled the exhaust cam and tensioner and got it in place. The chain fell off the intake cam and i felt like i got spotted by a hungry lion in an open field! I got it back in place. It was a bit tricky to get the exhaust can back in, but i got it. Took about 2hr. I did leak down and had some ring leakage and minimal valve leakage, but it's seemed pretty good for a cold engine (i hope). Time to start buttoning it back up. I made another video with my estimate of proper timing. I probably have 8+ hours sitting on the starboard engine! Probably 200+ engine rotations since i started messing with it.

Man, I don't completely understand what you doing there - but it is very impressive!!!

--

 

[Jgorm]

I checked the oil 2x more and added about 1/4qt. Still starts and runs nice. I started cleaning up this beat up paint with 3m heavy compound and a wool pad. It was 1030pm, so ill have to check the quality in the day. I removed the Arizona numbers and will add the cf numbers once i get the paint decent. Still have the other side to do, and the polish and wax step.

My mr1 waverunner does this thing where it runs 25mph at wot for the first few minutes, then it kicks in hard and runs 50mph. After that it runs great for the rest of the day. I'm thinking a clogged injector maybe. Still had tons of fun at the Colorado river. I should have the boat there in 2 weeks.



Front done

 

[Jgorm]

I have the maiden voyage tomorrow. I installed this cellphone mount for music and gps. It's on a gopro mount so i can move it to film stuff. Hopefully it works well and the boat works well! I'm going salt water because the local lake cost 100 bucks and had loads of rules, like no swimming unless you are wakeboarding. Wtf? 35mph speed limit, counterclockwise only, and 3 pages of other rules! 1hr+ wait to get in, then the launch is nearly 1mi of waiting to get to the ramp. I almost rode ropeless On my dad's 24 cobalts. 9' board, slight turn. I tore it up! I had probably a minute of slack in the rope, but a new driver on my work team event so i didn't toss the rope. As long as it works it's going to the Colorado next weekend for it's new location.

 

[Jgorm]

Success! The boat works great, there cellphone mount is awesome for music, volume, and gps. You can still use the transom remote too. Now i just need to flush the boat and take it to the river next weekend. I'm stoked to be done with this massive project!

 

[Jgorm]

I freaked out when the boat didn't go over 3mph! I forgot to put the clean out plugs in! We had a blast in the river and I'm stoked to have the boat out there!


Super proud of my kids! My son's first kneeboard at 5yo with my buddy coaching from the wakesurfer.

He learned how to cut too


Shelley (7yo) kneeling on the wakesurf


The boats new home, where i can't work on it every day!


I'm happy for the break. It's been a ton of work! I need to buy a new fuel sender. I did about 40 miles and it didn't leave the full Mark. I've decided i need some fins and a custom bimini out of 8020 t slot. (Took measurements)

 

[Beachbummer]

Nice. Make sure it's not the gauge, mine was stuck. (It came down when I have it a few wacks. You can bench test it before you pull the float... (That's more work, only to find out it works fine...I was not happy)

 

[Scottintexas]

Congratulations! that was quite a journey for you, glad to see your kids are enjoying it to, it makes it worth the effort to see them do new stuff

 

[Jgorm]

Nice. Make sure it's not the gauge, mine was stuck. (It came down when I have it a few wacks. You can bench test it before you pull the float... (That's more work, only to find out it works fine...I was not happy)

I'm pretty sure it's the sender. Getting on plane would cause the gauge to freak out and blink low fuel and bounce all over. Once on plane it would read full. But thanks for the tip!

 

[Beachbummer]

Gauge is easier to change!!! Too bad it's the float.

Amazing build!!!! Congratulations!!

 

[Jgorm]

Hopefully it's not the gauge. Got a sender on order. Mine looks easy to swap.

 

[Scott griffith]

Yea pretty easy to swap make sure you get them put back on right or it will leak around theetal trim ring I bought mine and even sealed with some stuff and mine still leaks when full

 

[Jgorm]

@Scott griffith thanks, i ordered a new gasket too.

 

[Scott griffith]

Good maybe u can get urs to not leak I got tiredof trying so I just don't fill it all the way up anymore

 

[Jgorm]

Have you tried removing, cleaning, then black or gray rtv?