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  1. #1

    Engine teardown pics and specs

    Tore my engine down as a precautionary measure. It's been a Rotax stage 3 since it was new running 9.5# of boost. Added the Rude1 in 08 @ 130 hours, which brought the boost up to 12#. Motor has 170 hours on it now.
    Compression was around 135# and the leakdown was at 9%.

    The camshaft journals and bores show some wear--still within spec though. I'll need to have those polished.

    Both oil pumps and covers need to be replaced due to wear.

    The block was as clean as could be. Crank and balance shaft look great.

    Cylinder walls still have the crosshatch markings on them--I'll get a light hone done to the cylinders to aid in proper break-in of the new pistons. Going with new pistons as I am just about at the limit of the piston to cylinder wall clearance specs.

    Obviously, I'll replace all crank and balance shaft bearings along with big and small end rod bearings and clips. New cam chain, flywheel bolts, gaskets, etc.

    Head looks pretty good--will be freshening it up though.

    No melting at all on the exhaust end bell!

    In my opinion, based on the condition of my motor, I'd say anyone with a stage 3 or equivalent running less than 12# of boost and using the ski for recreational riding (not beating the sh-t out of it) would want to rebuild their motor at around 200 hours max. If you're running high boost, and/or high rpm (more heat and additional forces) you'll want to rebuild sooner than that. You're looking at around $2500+ in parts and machining services to do the rebuild, assuming you will provide the labor. Add an extra $1000 if you pull the motor and have someone else do the labor.

    Those of you going over 300+ hp with high boost and high rpm's will likely start to lose reliability and will incur some additional expense rebuilding your motors at more frequent intervals.

    Mark
    Attached Files Attached Files


  2. #2
    Moderator beerdart's Avatar
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    Good info thanks..

  3. #3
    EZ Dock of Long Island Shibby1485's Avatar
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    always enjoy your posts Mark! nicely done. things held together pretty nicely for a modded ski.

    you can save a little coin and re-use your pto cover and front cover... machine the surfaces... i know a few shops around doing it, and jawz also has a hook-up on it.

  4. #4
    Lovely

  5. #5
    Water4fire's Avatar
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    Great Info, Thank you!


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  6. #6
    AdrianRXT AdrianRXT's Avatar
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    Smile

    very nice mate

  7. #7
    Great pics! Thanks for the insight!

  8. #8
    Great info! I should be expected a lot of hours on my stock!

    I am not afraid of modding to stage III now since someone has a successful ski at 170 hrs. (thats 4 years of riding for me).

    I am saving his report

  9. #9
    Quote Originally Posted by Shibby1485 View Post
    always enjoy your posts Mark! nicely done. things held together pretty nicely for a modded ski.

    you can save a little coin and re-use your pto cover and front cover... machine the surfaces... i know a few shops around doing it, and jawz also has a hook-up on it.
    I was hoping to avoid machining the pto and front oil scavenger pump housings. Do you think they are bad enough to need machining?

    Thanks

    Mark

  10. #10
    BLACK MAGIC HEADERS hydrojunkie's Avatar
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    damb.you sure do things nice.i like your spec sheet.real cool. that motor too looks clean for that many hours

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