Repower 2004 AR210 with MR-1 HO's

[84rzv500r]

ok the second one took way less time as all the tools and jigs were already to go... just need top off the bearing housings with some 80w-90 and install... it will take the better part of a day as I want to replace the impeller shaft hoses and the Mid bearings whist I have it all apart...

it will take longer to pick up the tools

 

[84rzv500r]

I ordered new coupling rubbers and a spare mid bearing seal as Im consuming my spares.... last order shows I replaced the stbd mid bearing in 1/2020... port looks to be 2 years older that explains the drip drip drip.. built new short shafts... new O-Rings these are beefy shafts for my little boat 22mm up from 20mm...

 

[84rzv500r]

pressed in the couplers and topped off the bearing housings with 80w-90 Redline synthetic... when my new coupler rubbers get here on Thursday then Thunderbirds are GO! for jet pump installation

 

[84rzv500r]

ok so im gonna try these for $85 each i bought 4 and try stacking them as well for +0, +2, +4 deg up nozzle.. since i can tweak in the mill and have my own studs to bolt the pumps on...

my boat weighs almost 1500 lbs less than a 2006 AR230 HO

there has been feedback that the adjustable jetski nozzles don't have much impact however im gonna see for myself...

ok its a sick addiction but the same addiction pays the bills...

thoughts??

 

[84rzv500r]

all lubed up and no place to go...
and a quick check of impellers....

OEM were 12/20 replacements are clearly 11/20... im gonna run the OEM's strait up at 12/20 to start without the de-pitch on the stbd side
and see what I get as the 12/18's go to 10,500 no issues but I don't get any more speed than i do at 8700-9000 46-47 MPH Steering hard into the good pump and away from the dead pump... so I'll re-pitch the replacement impellers based on the test results from the new pumps...

 

[84rzv500r]

ok there are lots of variables but back of the envelop agrees with my original models... tried a couple boat speed calculators plugged in my GPS 270 HP numbers and weights and I get 164 for the constant im likely lighter than 2500lbs but we'll go with that (100 lbs makes a 1 MPH difference) plugging in 320 HP gives me 58.6 MPH so I think with the impellers just right with the new HO pumps and getting the nozzle trim just right 60 MPH is not out of the question... remember by using actual data from the old engines I remove the prop/pump efficiency at speed conversation.

just for fun 360HP 1.8 SHO yields 63MPH and 500HP 1.8 SVHO is 74 MPH... Id be tickled to have 58-60MPH on tap if needed remember that's gonna be burning 26 Gallons per hour WFO

 

[84rzv500r]

all parts are here for the pump swap (the pump wedges aren't here yet but that's a separate program)

 

[84rzv500r]

up early due to the time change had a couple hours before the endless Zoom meetings start..... idle hands are the devils purview. quick buff and wax... first pass port side get rid of some of the oxidation.... so the boat don't look so ratty... it will take another pass on the red... a test on the white is just one pass... all you guys with shiny new boats give me new boat envy... NOT

 

[84rzv500r]

one side down, and the easier side to go.... oh and the transom and all the white...

 

[84rzv500r]

can you believe it took almost an hour to make a simple 4 wire harness for my stereo remote... And my last 4 pieces of custom Marine Mat shipped today... I wanted to show a little love to the stereo and speakers get the hull and cabin buffed out before I put in the new marine mat... oh and West Marine six10 is scarce as hens teeth is seems and that was holding up my fiberglass console hatch installation got 4 tubes in the last shipment...

things are movin...

 

[Brad_Ct]

I just ordered 4 tubes of Six10 from Amazon, delivery date is the 15th.

 

[84rzv500r]

I just ordered 4 tubes of Six10 from Amazon, delivery date is the 15th.

west marine didn't have any its coming from a distrib on the west coast I think i got mine of Amazon too...

 

[84rzv500r]

Gotta weld this spare nozzle up (for dimension check) and touch up the stator housing with the die grinder for slight clearance issues, thread these stud bolts in the lathe and then I’m ready to install and the entire repower will be compete.. I have 2 degree pump wedges coming and I want to make sure my studs are long enough and threads are long enough to accommodate stacking from 0 to 4 degrees...

OEM pump bolts are 7mm dia with rolled threads... I'm building 8mm 316L studs with cut threads

 

[84rzv500r]

getting closer... worked on fine tuning the jet pump config... checked the fit of the pump nozzle wedges.... found out I ordered carbon steel dies by mistake.. and it would take ME a ton of time to set up the lathe to cut threads so I ordered some 316L/A4 stainless all thread in 8mm x 1.25 from Grainger in Miami be here tomorrow $14/meter needed 2m 8pcs x 250mm good enough for now... checked the high pressure hose for fitment... all between meetings LOL

 

[84rzv500r]

ok no more dilly dallying ... todays the day... 8 bolts each on the jet drives, 8 bolts each on the engines to slide them back, and 3 bolts each on the mid bearings, 4 hose clamps, 2 new hoses and 2 strain reliefs for the hoses and good to go... then I'll have 155mm pumps with22mm shafts 12/20 impellers, intake water screens, and HO pumps... then we can see what 2 good jet pumps will do... oh and the stbd cobra jet fin needs a little tweeking as it looks like I bent the cross bracket running skinny...

oh and before someone says it bad engineering practice to have a bolt in a position where gravity should hold it in on the steering cable clevis.. I know but its easier that way so you dont need to disturb the cobra jet return spring... BTW you know you're getting in skinny water when the fins start bouncing off the bottom and shaking the wheel

 

[84rzv500r]

ya think i was gettin a little cavitation outta this one? 12/18 small hub (non HO/low pressure) and i could still run 46-47 MPH LOL

 

[84rzv500r]

ok so here's the detail... Piece of cake to service.. popped the exhaust hose loose and then slid the engine back to pull the mid bearing... New mid bearing assembly's New coupler shaft and flanges/o-rings... (one thing to note you have to use the shorter 2006 AR230 HO coupler shafts as the jetski shaft is too long) i also set the flange to case depth to match the old ones... they are a light press fit... coolant hose routing up out of the way... pumps bolted right up used the OEM bolts for now... as they worked... (NO pump Wedges yet as I want to see if i can get my 2 stroke speed back first...) all in all easy peasy... cant wait to water test...

Pics or it didnt happen...

 

[84rzv500r]

well it took a bit of time to get the engine mounts aligned... starboard side all done... port side ready to go back together in the morning...
had one good pump

 

[84rzv500r]

done.... port side engine slipped in and out of place with no issues both mid bearing assembly's were shot... one last tweak to the port side bracket that stabilizes the jet unit... the outside hole needed to be clearanced as the castings are much thicker on the later model HO pumps and oh well you know.... sprayed down the pumps and ran the engines on the hose... no bearing noise or alignment issues... gonna drop it in the water and see how it works...

 

[84rzv500r]

ok it was 15-20 mph winds gusty... still a slight cavitation on the starboard side off idle... however port side is instant... I still had the bimini up so i didnt run it past 40-42 at 8400-8500 but it has lots more no bubbles at idle and No leaks... Jumps out of the water... Im happy!!! remember these were all used parts... now to build a set with new parts...