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  1. #1
    I'd rather be riding!
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    Ultra 150 Rebuild

    Bought my Ultra 2 years ago. After a few weeks, lost the #1 Cylinder. Rebuilt the top end -- new piston/rings, cylinder and head. Did normal break in and ski ran well for about 5-10 hours, then BAM lost the #1 cylinder again.

    I've been reading old threads about possible causes--oil leak, leaking carbs (partial cause of 1st failure), and air leak in the case. Split the case today and found that the oil hole for the #1 crank was filled with gasket sealer.

    Haven't found any other problems, so I think this may be the cause of the lean/piston killing problem. Hope the experts here can help.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	blocked oil hole.jpg 
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Size:	46.7 KB 
ID:	348604   Click image for larger version. 

Name:	Split Case.jpg 
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ID:	348608   Click image for larger version. 

Name:	Pitted Piston.jpg 
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ID:	348607   Click image for larger version. 

Name:	Piston and Head.jpg 
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Size:	75.0 KB 
ID:	348606   Click image for larger version. 

Name:	Gasket Sealer from oil hole.jpg 
Views:	91 
Size:	51.6 KB 
ID:	348605  


  2. #2
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    That looks like metal debris. Is the crank ok? Thats the first place I would be looking.

  3. #3
    I'd rather be riding!
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    That is gasket sealer. Crank looks ok. Need to check the clearance with feeler gage.

  4. #4
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    So there is no physical damage to the piston? What happened to that cylinder? Looks like it was running plenty rich, so not a lean fuel problem.

  5. #5
    I'd rather be riding!
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    Sorry, misunderstood your post. There is no crank damage that I have found so far. The piston and Head both show signs of damage from detonation--usually caused by overheat/lean condition.

  6. #6
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    That sure looks like damage from metal debris. Was everything cleaned out from the first time you had problems? Detonation damage looks like someone took a sand blaster to it. Im seeing just small bits of damage from what appears to be metal bits

  7. #7
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    I agree with Bryan. Sure LOOKS as though something metal took a ride around in there. Try to post a clearer picture of piston top and edge.

  8. #8
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    Piston sides and cylinder walls too.

  9. #9
    I'd rather be riding!
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    I'll post clearer picture tomorrow. Cylinder walls are smooth with no damage. I think this is the beginning of detonation damage. Noticed the problem quickly and also lost compression so damage was minimal?

  10. #10
    I'd rather be riding!
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    Additional pics of the Piston, Head and Cylinder.Click image for larger version. 

Name:	#1 Cylinder - Other side.jpg 
Views:	86 
Size:	44.2 KB 
ID:	348752Cylinder is clean with no damage.Click image for larger version. 

Name:	#1 Cylinder Head.jpg 
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Size:	114.5 KB 
ID:	348753Head has damage.Click image for larger version. 

Name:	#1 Cylinder.jpg 
Views:	75 
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ID:	348754the other side of the cylinder.Click image for larger version. 

Name:	#1 Piston side.jpg 
Views:	74 
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ID:	348755Some damage on one side of the piston, but minimal. The other side is OK.Click image for larger version. 

Name:	#1 Piston Top.jpg 
Views:	76 
Size:	71.0 KB 
ID:	348756Pits in the top of the piston.

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