SXR 2005 SXR Re-Build Part 1

[pleadingbark]

Recently I picked this up after posting a WTB on FBM. It was local, belonged to a guy who passed of brain cancer and then it sat. It went through a shop to get running again, as it lost spark. They put all new stock CDI/Stator on it, spark came back, but it was back firing through the intake manifold.
Enter me. I was set to buy an 1100 SXR from the person who was selling this, but elected to buy this for a number of reasons:
A: I enjoy being alive
B: Im not super interested in seeing how long it takes me to catch up to a jetski I got hucked off of doing 55-60.
C: I like working on things.



Popped the hood and found this. Factory dry pipe, Novi 48's, R&D 29mm head. Coupled with the Temest 3 ingition (removed, but have still and TL FW) this thing would be an absolute ripper.



Pulled the carbs off, gave them a cleaning inside and drained the fuel and ran new lines. (Kawi green for power and air bubble spotting)

Sick, cleaned a bunch of poop out, figured we're good to go. Wrong. Hit the start button, coughed for a second, got some smoke out of it and then started the intake back fires.

 

[pleadingbark]

Part 2.
I decide, lemme check the flywheel, make sure the woodruff key's still there and everythings happy.

Def a flywheel there, but I happened to notice some dirt right over by the 8 thats on the bottom of the engine cylinders, and noticed tha the top visible nut was wet/oily. Earlier a friend came by, looking at it and noticed the damn pipe had a crack all the way around, so out it comes, which turns into an absolute poop show, due to a lack of any antiseize/grease being used on anything. W/E though, get the pipe out, bring it to a buddies, weld the crack shut and throw a brace on for good measure. I figure at this point, engines just hanging out in the bay, lemme pull it, pressure check it, check reeds, make sure theres not a massive hole in it, etc. This is where it gets spicy.
Start shooting some air into the cyl, spray some soapy water by where I think theres a gasket failure an see this:



Guess the motors coming apart, wasnt on my bingo card today to redo an SXR motor, but here we are I guess.

 

[pleadingbark]

Part 3 of alot of part series (probably). Tear down.
Pop the cyl's off and sure enough, error 404: Gasket not found on the bottom.



Gasket not found on the top:

I did learn in my panic ebay gasket searching that a 750/800 BG is the same and I happened to have one with the sealing ring sitting around that will be going in.
Took some time to observe the piston wash on the cylinders, looked great, which at least lets me believe the jetting/carb settings are close to correct, albeit a bit lean.

 

[pleadingbark]

Wash: Decent.
Piston Side wear: not so decent.

Motor blew like 180 compression, cant catch the pistons with your nail, figure its probably safe to roll with? Ran a quick hone through the cylinder, even though they were fine, just to knock the gunk off the walls. Which brings me to here:

R&D heads are stupid, the old orings immediately tore, and the head is 1211'd onto the engine. The cylinder bolts are all nice and tight now (one was loose-ish by the blown gasket) and loctited to 25 ft/lbs. Going to go try and track down some o-rings tomorrow, reseal the head and re-pressure test this thing and see how it does. Hesitation exists for running the pistons, but if I never saw it, I'd be none the wiser (at least thats what Im going to tell myself). The likely hood is the engines going to come back apart, and get dropped at LPW for a hone/bore/pistons, but I want to confirm the thing isnt back firing anymore and actually works before doing that.

 

[mrfist9]

There goes the neighborhood

 

[JC-SuperJet]

"B: Im not super interested in seeing how long it takes me to catch up to a jetski I got hucked off of doing 55-60."

Uhmm... that SXR 800 set-up will do 58-60 mph once you get it dialed in....

And with that huge Air Leak at the Cylinder Base and the Pipe also leaking, a severe case of Carnage was avoided. Saved the Crank, Block and Pistons by not running.

 

[pleadingbark]

"B: Im not super interested in seeing how long it takes me to catch up to a jetski I got hucked off of doing 55-60."

Uhmm... that SXR 800 set-up will do 58-60 mph once you get it dialed in....

And with that huge Air Leak at the Cylinder Base and the Pipe also leaking, a severe case of Carnage was avoided. Saved the Crank, Block and Pistons by not running.

I figure if it somehow ran, it was going to find it's max rpm real quick.

 

[pleadingbark]

Updates:
Motors in and running. Got the pipe crack fixed, found more leaks that didnt show during a smoke test. The coil didnt have continuity with the plug wires, even though it would spark. Replaced that with another I had that spec'd out correctly. I also replaced the mickey moused in flywheel pick up and found a ground wire in the stator not hooked up, resolved ALL of that, fired off first hit of the starter (After trying to prime it and realizing the fuel was turned off of course). Going to rip it all BACK apart now, drops the cyl's off with LPW for some loving, going to grab a zeel, ordered new OEM O-rings for the head and pipe, to replace everything, and see if that aids in reassembly (Installing the engine with the pipe attached is obnoxious).

 

[pleadingbark]

So motors back out, cylinders are dropped off. Ordered some new SBN 44's for it as well as a stock exhaust. Not trying to have some strung out rec-boat that I have to constantly look over and pay attention to. Wanna gas it and go.

 

[fastgtfairlane]

The gift that keeps giving haha. Awesome ski you got there. At that point id just plan on replacing everything basically fir piece of mind. Paul will get you all setup. Speaking of the carbs, id go with 46s over the 44s just because you can put the 46s on just about any engine combo to 1000ccs. Especially since they are basically the same price

 

[WFO Speedracer]

R&D = reck and destroy , no bueno

 

[pleadingbark]

Current Situation


Engines BACK out. Decided after putting it all together and making sure it ran to drop it off and get a fresh top end done for it. Going to just stick with the dry pipe and 48's, see how it does and decide from there what I want to do. I ordered brand new o-rings for the pipe and head, so that should be GTG and some new SBN44's I may mess with after its back running. 1 step closer to getting it running, riding it, and seeing if I even like the thing.

 

[Qsportperformance]

View attachment 457422
Current Situation
View attachment 457423

Engines BACK out. Decided after putting it all together and making sure it ran to drop it off and get a fresh top end done for it. Going to just stick with the dry pipe and 48's, see how it does and decide from there what I want to do. I ordered brand new o-rings for the pipe and head, so that should be GTG and some new SBN44's I may mess with after its back running. 1 step closer to getting it running, riding it, and seeing if I even like the thing.

poopty situation but nice build! Super hard to find any middle ground when building these things lol. That's why I think you see most skis are either almost fully built or cobbled together and not much in between.


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