Repower 2004 AR210 with MR-1 HO's

[84rzv500r]

4 boxes and harnesses to make 2 plus spares... one done and one almost done...
I'll dress off the harness in the boat... There will be some mucking about to disable the security, light the Boat Tachs, and connect the ignition switch harness. thankfully thats all been worked out by others before me...

 

[84rzv500r]

 

[84rzv500r]

 

[84rzv500r]

engine assembly started... the first one gonna take a couple days... its like a jigsaw puzzle... and for reference the wave runner service manual is way better quality than the 2006 AR230 HO supplement... i have the stator on, and the gearbox stuck on with no o-ring as I am waiting for a oil pump drive gear... i have 4 of then and only 1 serviceable and i need 2...

 

[84rzv500r]

starboard engine Injection/airbox, done, oil tank cleaned and flushed, oil pressure Tee fitting gonna work fine... waiting on parts now for final assembly, making sure all the hoses fit, just need to clean up the bottom part of the header... gonna start on the port engine this week. Im glad i did it this way ... its a little more work however I'm now pretty familiar with how these things go together...

 

[84rzv500r]

some more pics from this weekends work... Prepping the exhaust...

 

[84rzv500r]

 

[84rzv500r]

Had to improvise some of these aluminum washers... I could have made them on the lathe but I found these suspension bushings for my old golf cart, a quick snip with my handi cut and I saved $60 and didn't have to wait for unobtainium from Shizuoka....

 

[84rzv500r]

started putting together the port engine today... I had so steal some parts from my Milkshake motor but all the parts I needed were clean and serviceable. I also looked over the oil pump situation... Im guessing that the VX pumps would work however I'm not gonna take a chance this far in... two new 6B6 oil pumps and gaskets on order from Yamaha

...

 

[84rzv500r]

squirted a little zinc chromate on some of the parts after cleaning with a stainless wire brush

 

[84rzv500r]

ready for oil pumps.... did I mention that there are a boat load of bolts in these motors and they all have different torque specs.... and there are more hose clamps that bolts i think

 

[84rzv500r]

ok Just solved the MR-1 oil drain challenge... for less than $30 a side !!

3068-08-125 | Metric Banjo Bolt M8X1.25 $3.80 each
3069HB-04-08 | 1/4" Hose Barb x M8 Metric Banjo (Low PSI) $6.35 each
Stainless Steel Bulkhead 1/4” Hose ID Barb Fitting Fuel Water Boat Air Splicer $16 each
dexierp Protection Force Round Cap for 1/4" 6.5mm OD (Pack of 50) Pipe Post Tube End Cover 1/4-20 UNC 1/4-28 UNF Screw Thread Protectors Elastic Rubber $10

I have a big roll of 1/4" USCG approved 1/4 fuel line

and i already ditched the grease fitting in the thermostat housing so ill pop the bulkhead connector in that hole....
I'll just use my Milwaukee M18 transfer pump necked down to 1/4" to suck the sump dry at oil change....

easy peasy

 

[Russell]

Pictures or it didn't happen!

 

[84rzv500r]

Pictures or it didn't happen!

parts on order today... will post as soon as its complete and installed... trying to get this project wrapped up by Xmas and this has to go on before the new engines go in the boat..

 

[84rzv500r]

Parts starting to trickle in... ill prolly open these bolts up a bit in lathe and mill to flow a bit better.. or not...
you get the idea a banjo fitting to go with the rifle and cross drilled bolt and some 1/4 inch line... and suck the last quart and a half out....

 

[84rzv500r]

6B6 oil pumps and new gaskets shipped today... be back in business soon...

 

[ThatJeepGuy]

Great work! I can’t be the one of the only members that checks this thread daily for updates…?

 

[84rzv500r]

LOL yeah well the REAL job was busy the last few weeks and my oil pumps wont show up till this Tuesday however I may have some updates today in the MR1/VX1 oil drain challenge...

 

[Julian]

starboard engine Injection/airbox, done, oil tank cleaned and flushed, oil pressure Tee fitting gonna work fine... waiting on parts now for final assembly, making sure all the hoses fit, just need to clean up the bottom part of the header... gonna start on the port engine this week. Im glad i did it this way ... its a little more work however I'm now pretty familiar with how these things go together...


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That engine looks so much bigger out of the boat!!!

 

[Julian]

Great work! I can’t be the one of the only members that checks this thread daily for updates…?

Gonna have to have drones up and filming for the first runs!!!! Live stream? LOL