97 Superjet rebuild- Your tips and guidance will be appreciated!

[menatep]

Hi...

Last year I bought a 97 modified Superjet. It ran very good and strong.. much faster than my other 96 stock superjet, but after 3-4 occasions of riding it, it died and wouldn't start over. Rear cylinder plug kept fouling up, there was no spark so i decided to rebuild it.

Whole electrical system was messed up - 2 previous owners played with it too much and it was a total mess so i decided to scrap it. I'm getting a complete rebuilt 62T electrical system from JSS.

While the electrical system was out i decided to take a look at the engine. I was welcomed by sticky milky white residue on the rear exhaust port. How it happened I have no clue, but i suspect whoever installed the head didn't secure the piston ring correctly and it allowed water to infiltrate. Is it safe to say this was the cause for rear cylinder plugs to be fouled?

Do I need to remove the exhaust manifold and clean everything out? If yes, where do i get a replacement gasket? R&D doesn't sell any Superjet exhaust parts on their site anymore.

 

[menatep]

As i was cleaning the pistons, I noticed that front piston had a lot of play in it. I could make it wobble with my finger. Rear piston was not wobbling moving at all so something is not right here. Does it mean the engine needs to be rebuilt? Are the piston rings worn out on front cylinder? If the piston rings are worn out, what should I do? What's the best course of action?

[video=vimeo;11941989]http://www.vimeo.com/11941989[/video]

 

[menatep]

Next, I wanted to be sure what stuff was done to the engine and what kind of parts I had.

It looks like the ski has R&D pipe and R&D exhaust manifold.... but why was the pipe installed so high? It doesn't look like the bracket is manufactured by R&D - looks like someone put it in. The pipe was interfering with the hood and the side of the hull. Is it improper installation or is this not a superjet pipe that was fitted into a superjet?

And exactly what model are those parts? Do I keep those parts or sell them and get something else?

 

[menatep]

What kind of head and what kind of domes does this ski have?
The head said ADA Super Stock 785 CC.... strange because I can't find any 785 CC superjet heads on ADA website.

How can i measure the dome size?

Do i keep this setup or get rid of it and get something else?

 

[menatep]

Next is the intake manifold... again R&D, but not sure which model as it doesn't appear on the website. Any idea what kind of intake manifold it is?

Again, do i keep this or sell this and get something else?

 

[menatep]

So hopefully with your help and advice i'll be able to decide what to do with the whole engine situation.

 

[Powerhouse]

That manifold is an R&D Manifold, with dual 46's on it. This is the right manifold you need for the carbs, and it should work well with a 785.