OK, this ski is likely to be seized in the cylinders rather that the bottom end/crank shaft. All the crud inside the exhaust ports is probably because the intercooler is leaking water into the air intake system. You need to pressure test the intercooler, Then you need to take the head off the engine. When you are taking the timing chain tensioner off, loosen the bolt in the center first.
Thanks for the recommendation and advice! We found that the likely source of the issue was that the gasket in the exhaust manifold blew and thats how water and crud got into the cylinders and seized them up. Fortunately the cylinder head seems good. I have had the cylinders re-sleeved. I need to get a set of valves, and gaskets and then we can start re-assembly.
Checking the intercooler as part of a service usually means removing secondary blow off valve and sticking a camera in to see if there is any water. But as the ski hasn’t been used for a while it will probably appear to be dry. Remove intercooler, it will be easier to test the water passages. I usually block off the water inlet/outlet etc and fill with about 30psi of air. See if it holds pressure.
I have the same ski, intercoolers are expensive to replace. I managed to repair mine, it took a lot of attempts but I got there in the end, and is only temporary until I can find a decent second hand one or bite the bullet and buy new. Also, the cylinder heads are prone to cracking on this model. Water jackets are too close too the combustion chamber. Could be cylinder 3, so check that too.
Good work so far boetie. Enjoyed watching the video. Hopefully you can get it back up and running soon 👍
Is it running now?
OK, this ski is likely to be seized in the cylinders rather that the bottom end/crank shaft. All the crud inside the exhaust ports is probably because the intercooler is leaking water into the air intake system. You need to pressure test the intercooler, Then you need to take the head off the engine. When you are taking the timing chain tensioner off, loosen the bolt in the center first.
Thanks for the recommendation and advice! We found that the likely source of the issue was that the gasket in the exhaust manifold blew and thats how water and crud got into the cylinders and seized them up. Fortunately the cylinder head seems good. I have had the cylinders re-sleeved. I need to get a set of valves, and gaskets and then we can start re-assembly.
Thanks very much for the tip and advice. Any ideas on how I can check the intercooler for leakage?
Checking the intercooler as part of a service usually means removing secondary blow off valve and sticking a camera in to see if there is any water. But as the ski hasn’t been used for a while it will probably appear to be dry. Remove intercooler, it will be easier to test the water passages. I usually block off the water inlet/outlet etc and fill with about 30psi of air. See if it holds pressure.
Thanks so much for the info. Trying to resurrect this project now and definitely think this is worth checking after the engine rebuild
I have the same ski, intercoolers are expensive to replace. I managed to repair mine, it took a lot of attempts but I got there in the end, and is only temporary until I can find a decent second hand one or bite the bullet and buy new.
Also, the cylinder heads are prone to cracking on this model. Water jackets are too close too the combustion chamber. Could be cylinder 3, so check that too.
Hey can you show how the intercooler cool system work ?
What happened?