Sea Doo Jet Ski Supercharger Failure Aftermath Part 3 of 4: Crankcase Reassembly

In Part 3 of our Sea-Doo jetski supercharger failure aftermath series, we show rebuilding of the crankcase ...in all its glory detail!
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Filmed with a Canon 70D camera in the great Pacific Northwest.
Music: Some of You by Text Me Records / GrandBankss; Swing Theory by Freedom Trail Studio; and Whatdafunk by Audionautix is licensed under a Creative Commons Attribution license (creativecommon...)
Artist: audionautix.com/

[@jeffsmart6348]

I watched all the videos on this motor, and I don't even have a seadoo. if I did I would trust this guy to work on it more then I would a dealership! Awesome stuff man!!

[@3ftDeepChannel]

Thanks!

[@jeffburrus7283]

The four videos in this series were invaluable during my tear down and rebuild (2005 RXT). Thank you so much for doing them and doing them so well.

[@ambiori1]

Best of the best video to rebuild i got it start assembling my engine and this is going to help me 100% thanks for the great work and posting this video to help others

[@3ftDeepChannel]

Great to hear, Amby. Thanks for the kind words and good luck with your project!

[@T-K---]

i dont have jetski but i watch movies because is very intresting !! greatings from Lithuania !

[@3ftDeepChannel]

Greetings, and thanks!

[@karacoban]

Thankyou guys you have helped me so much understanding a Sea Doo Engine.

[@StevenVigus]

Another great video. Makes me want to take on a rebuild!

[@henryperez7472]

Great help guys. Q. When you tourqued the PTO cover you noted 80 ft lb. Seems awful tight for that. I snapped one of the bolts dig it. I could just have a screwed up torque wrench but thought I would ask.

[@3ftDeepChannel]

Inch pounds! lbf.in is "inch pounds", not "foot pounds".

[@henryperez7472]

@@3ftDeepChannel yeah this is what happens when mixing whiskey and rebuilds lol!. figured that out last night right after posting my question. Once again thanks for the feedback and great content.

[@derargentinier8879]

it's a pleasure to see you work ! greetings from argentina !

[@3ftDeepChannel]

Thank you! Greetings from Canada!

[@superhogult]

Great video guys I like the attention to detail with checking the oil clearance and using torque specs. Did you remember to check crankshaft end clearance? Did you have to grind the piston rings at all? From what I have seen the past 13 years most parts are precise enough now fine machine work of parts like rings and bearings are a thing of the past. I still make a point to check these things on any new engines I’m not completely familiar with or when I get a new parts supplier. Looking forward to the rest of the series as I have an 06 gtx 185 waiting for the exact same thing. Here’s hoping I’ll get as lucky as you!

[@3ftDeepChannel]

We did not check the crankshaft end clearance. This was a clean up and reinstall of existing parts the crank faces showed no wear and the thrust bearings showed very little signs of wear if we were installing a crank from a different engine or replacing the thrust bearings due to jet pump bearing failure then it would be prudent to check end clearance. The ring end gaps were within spec even after a light hone to remove glazing on the cylinder walls.

[@superhogult]

3ftDeep cool I thought you had replaced the thrust bearings can’t wait for the next one were the ceramic friction washer exploded too?

[@3ftDeepChannel]

Yes, that was the root of the problem. The supercharger washers also came apart in this machine.

[@d0ggelito]

Whats all the clearences för crank bearings and connectingrods, maybe even the balance shaft? Cant find it in the shop manual(?) Maybe I didnt print that page..., I have green plastigauge. Greetings

[@3ftDeepChannel]

The service manual for the Sea-Doo GTR 215 says 0.07 mm for crankshaft journal radial clearance e service limit. Sorry, I just found your comment now.

[@alex124241]

I came here just for the music. Superb

[@3ftDeepChannel]

Thanks. I wish I could take credit for it.

[@albertrivera9875]

exelent video all i need P.R

[@MikeZ32TT]

Nice

[@LVRACING99]

Awesome video as always !

[@3ftDeepChannel]

Thanks for the kind words! They really helps to keep us motivated.

[@LVRACING99]

@@3ftDeepChannel It really gives the energy to rebuild seadoos and do it everything ourselves.

[@John-kp1ql]

Keep up the vids!!!

[@austinbuilds7856]

I can't find any videos on replacing the bearing and bellows. Ours just kind of fell out when we took out the drive shaft.

[@3ftDeepChannel]

Check out one of our engine removal videos for additional details. Depending on the year of your machine, it may be relevant.

[@yeisonx]

It is very entertaining seeing you work. Very neat workplace and editing. I was wondering if you could please give me some advice from you experienced point of view working on these engines, I am buying a brand new seadoo this week and it is gonna be my first seadoo. I am narrowing down to 2 models; the GTR-230 and GTI-SE-155. They both have the same hull and among the biggest differences is the engine the GTR one being the 1500 HO ACE supercharged and the GTI having the 1503 NA (simple and lower maintenance cost from what I have learned) All I wanna have is a toy where I can have some fun and tow floats sometimes. Your expertise and advise is really appreciated. Thanks in advance.

[@3ftDeepChannel]

Thanks for the kind words. Both machines will serve you well for your purposes. The GTR 230 will be considerably more powerful for towing, and will accelerate much higher than the GTI SE 155. It will ultimately be more expensive, however, and will require a bit more work to maintain. Sea-Doo claims that the superchargers on the 300 series don't require maintenance, but I'm not sure about the 230 models. The intercooler also requires annual attention. We have a friend who rides occasionally and we recommended he get a non-supercharged, non-intercooled (155) model, and he's very happy with it. Another consideration for you is the experience level of the riders. If this is the first machine for most of you, I'd say the 155 would be the way to go as it's got plenty of power, but won't get you into trouble as quickly as the 230. Good luck!

[@yeisonx]

@@3ftDeepChannel awesome! Thanks again for your advice. GTI 155 its is :)

[@hybridorbital85]

Did you guys replace the main and connecting rod cap bolts? I thought those were 1-time use. You mentioned you used NEW flywheel bolts, but I didn't see that for the others

[@3ftDeepChannel]

Yes, sorry we didn't really consider this a "how-to" video (it goes quite quickly over most steps), really more of a "what happened" video. We replaced all the stretch bolts. Thanks for your comment.

[@derargentinier8879]

que buen trabajo ! una delicia ver sus videos !

[@3ftDeepChannel]

¡Gracias!

[@TheBoutiqueHotel1]

Great video What happens if the green tolerances tape was out when you put the two halves together and the con rods ?? Many Thansk

[@3ftDeepChannel]

Well, then it's time to start replacing (expensive) parts! Thanks for your comment.

[@raptormaciej]

What margin of tolerance on green tape ?

[@11NickMartinez]

I have 6 big half rings to the main crank and I only see you use 2 and when I try to assemble with all half rings, the bottom half of the engine will not go on and when I instal with 2 I’m afraid the half rings will rotate in the bottom end if I don’t put the other half rings on the opposite side of the case

[@3ftDeepChannel]

I suggest that you get a service manual for your machine, as that will give you the instructions to do a proper job for your engine. Although the Rotax engine design is relatively constant over the years, we wouldn't want you to miss anything specific for your model. Good luck.

[@BarryGeorge]

Great video's really helping in my tear down. Thanks. It looks like you ran a hone through the cylinders before reassembly? Are these cylinder sleeves using some hardened metal combination for wear? Are re-bores very frequently done/required.

[@3ftDeepChannel]

I don't know about the metal of the sleeves, but we took it to a local machine shop to have it cleaned up. I've only ever heard of it being done after some catastrophic failure (almost always a supercharger failure in a Pre-2008 Sea-Doo model). Essentially, if you do regular oil changes and service your supercharger regularly, a 1503 engine should last for a very long time without doing anything to it. Good luck with your project.

[@americaparts13]

i love your videos and would love to take courses or a school to learn and get certified any recomendation?i love this job

[@3ftDeepChannel]

We don’t know of any courses you could take, so keep watching our videos! Good luck.

[@superioraudiosounds4045]

I have a question I have a 2008 RXT215 with a ET 68 140 extreme charger. We had to tear down the entire motor due to paper towels. We are doing full Riva valve train upgrade, Riva valves, CP Carillo pistons, rods all new crank bearings etc. The question I have is wondering how you got the specs for plastic gauge and also why you put assembly lube underneath the crank bearings we can not find this in the shop manual and thinking it maybe something we are not aware of. We just find measurement specs nothing about plastic gauge. Any help would be greatly appreciated. Thanks. What size do we need to look for on the plastic gauge on 08 215 4 tec ? Also do we need to put assembly lube under the bearings ? Thought this was to be dry for grip ?

[@BigBickEnergy]

Awesome videos. Much appreciated. Im rebuilding a 2006 RXP motor that had the same issue. No charger maintenance at 260 hrs. It blew up and sent debris through the engine. Engine is surprisingly in goid shape but doing a full rebuild anyways. My question is…. It looks like you honed the cylinder walls before reassembly. What grit hone and kind of hone did you use. Also how many strokes with the hone did you do?

[@3ftDeepChannel]

Hey, Coyote. We don’t have the skills to properly hone the cylinder, so we always send out the part to a local machine shop. BTW, I’m shocked it lasted 26 hours. Usually they fail between 100 and 150 hours. Thanks for your comment and good luck with your repair.

[@jamenhulegaard5050]

I found a small silver cylinder with a spring loaded hollow cylinder inside that allows about a quarter inch compression. Any idea on what this could be? May have fallen out during tear down. Found it under the flywheel

[@jamenhulegaard5050]

Wish I could send a picture

[@jamenhulegaard5050]

Found another hollow cylinder with an engraved ring on one end roughly the same size... But I think this one goes on the super charger shaft. Not sure though

[@jamenhulegaard5050]

Could it be some kind of retention cylinder for the starter?

[@3ftDeepChannel]

@@jamenhulegaard5050 Send some pictures to [e-mail] and we'll try and help you out.

[@ceregincergei5752]

HI how many millimeters must be a ring gap THANK YOU

[@3ftDeepChannel]

The maximum clearance for our model (and most models) is 0.35 mm.

[@ceregincergei5752]

and minimum?

[@3ftDeepChannel]

No minimum. As long as the impeller can spin, that is fine. Several times we’ve had to grind off the first fractions of a millimetre from the wear ring when it first started up because it was a tight fit. Good luck.

[@tylerfallert8763]

what is the Min-Max clearance values for the plasti gage when you are measuring the piston bushing clearances?

[@3ftDeepChannel]

The crankshaft pin radial clearance service limit is 0.09 mm or 0.0035 in. The crankshaft journal radial clearance service limit is 0.07 mm or 0.0028 in. Good luck.

[@Sportsman037]

The pistons have a arrow marked on each one. What direction are they supposed to point

[@3ftDeepChannel]

They normally point to the exhaust

[@compasstrans]

Where can I get compression tape? Looked everywhere. Thanks.

[@compasstrans]

I think I got it. It's Plastigauge Engine Bearing Clearance Checker On ebay.

[@3ftDeepChannel]

That’s it. Good luck.

[@superioraudiosounds4045]

Can you check bearing clearance without torquing the bolts down all the way ?

[@3ftDeepChannel]

We do, and although it's technically not perfect (as the torque can vary), it seems to work out.

[@longjonsilvers802]

What was the point of tightening the lower piston bolts 90° when they were already torqued to 13 ftlb?

[@3ftDeepChannel]

That’s what the service manual specifies. They’re stretch bolts.

[@longjonsilvers802]

@@3ftDeepChannel got it, thank you

[@MadFat20022002]

Good afternoon Mario! Please tell me, do you always recommend using NEW ones from your experience CONNECTING ROD SCREW, SCREW CRANKCASE and SCREW CYLINDER HEAD?! Thank you very much)

[@3ftDeepChannel]

We always use new screws when we say “new” on our videos. That is because the service manual requires them to be new when replaced. Thanks for your comment.

[@MadFat20022002]

@@3ftDeepChannel TNX!

[@andrewkonetzka5202]

How much time did it take to rebuild the motor and what was the total cost of the parts. I am considering buying a project seadoo. Great video's.

[@3ftDeepChannel]

It’s around a 10 to 12 hour job. Given how expensive most of the personal watercraft parts are (usually because they’re stainless steel), it’s usually not worth it to buy a project personal watercraft. Better to get a good used one that just needs regular maintenance and maybe a little repair. Good luck!

[@stevesanderson8360]

Christ Almighty! I could feel my wallet being sucked towards the image on my computer

[@3ftDeepChannel]

Don't resist! Buy a T-Shirt! ;)

[@grh317]

Great Video. Can I ask whose bearing parts you like to use? Oe. Sbt. Wsm? Im curious of your experience with them. Thanks

[@3ftDeepChannel]

We usually use SBT parts (when not going with OEM parts) and have had good experiences with them.

[@ayhamalhindi5172]

Is the 215 and 255 has the same engine but bigger supercharger

[@3ftDeepChannel]

The 255 has an external (much larger) intercooler. That's the main difference.

[@RanHam]

What year supercharger was this? And how many hours was on the supercharger? I have a 2017 GTR I bought new and the manual claims that you don't need to service the supercharger every 100 hrs like the older ones.

[@3ftDeepChannel]

It was a 2005 RXT. Only those older models had the problems. The dealer is correct that you don’t need to rebuild the new ones like you used to with the old ones. Only the new 300 horsepower machines don’t need any rebuild, though. Thanks for your comment.

[@maxflight777]

3ftDeep quick question... I have a 230wake pro 2019, about 6 hours on it ! Is there anything t outside the manufacturer service schedule ) that I should do to avoid this expense in the future ? I found the videos fascinating from a precision engineering POV , but my wallet was quivering!

[@3ftDeepChannel]

Only the older models had supercharger problems. As long as you do the regular service and rebuild on them every 150 to 200 hours, you should be fine. Good luck!

[@scottspooner6070]

I hope your torque wrench is a highly accurate one or you could get screwed....

[@3ftDeepChannel]

Yes, all torque wrenches need to be good quality and be calibrated regularly as per the manufacturer's instructions. Luckily, we've only had one faulty torque wrench in all our years. Thanks for your comment.

[@reallife5996]

How do I get manual for xrp x 260 2013, trying to rebuild the engine but have no idea about the torque each bolt(

[@3ftDeepChannel]

They're very difficult to get hold of. There are several online sources, but I can't vouch for them. I also can't guarantee that they're virus-free. Here's one example: brpmanuals.com/seadoo-manual.htm. Good luck!

[@scottv9283]

I just came across your videos. I am not sure what happened to my seadoo challenger, but I was out running it and heard a loud whoosh sound. I immediately throttled down to idle and realized I had little to no thrust. Any idea ? Could this be an indication of a supercharger failure?

[@3ftDeepChannel]

More likely there's something in your pump or intake grate. Check that (and the rest of your drivetrain) first. Good luck.

[@haiqiwei2252]

Hi Bro， could you please tell me which brand of the Torque wrench you useing？thank you

[@3ftDeepChannel]

Sure. Our website has a list of recommended torque wrenches: 3ftdeepsports.com/store-tools-wrenches/

[@Crazytouringsle]

Hi. Im building a 2012 rxp 260 i wonder if you have the shop manual for sale thanks

[@3ftDeepChannel]

Hello Marc-Antoine, We don't sell them but there are a few places online where you can download them. We can't vouch for the state of copyright, or the quality of their product, but here is an example download site: servicemanualwarehouse.com/sea-doo/?sort=featured&page=6

[@marcossiqueira9734]

Brazil 2019 tem gente ai

[@elmerscerbo9030]

Do you guys have a number ? Need some advice help on a seadoo2016rxt300 problem. High pitch noise

[@3ftDeepChannel]

We try not to give out too much personal information for reasons you can probably understand. Can you send us a video to our email address? It’s available on our channel.

[@anurawijewickrama5062]

Please help me assembly canotong road 1st tourqued 3lbf &90degrees it's ok??

[@3ftDeepChannel]

???

[@AdminMedooH]

hi did u change the rod bolts and lower case bolts ?

[@3ftDeepChannel]

We replaced all the stretch bolts (as per the Service Manual). I believe there are 26 or so total.

[@compasstrans]

Do I need to use new bolts for connecting rods? 6:04

[@3ftDeepChannel]

Absolutely.

[@raptormaciej]

Hi does the cylinders been honed ?

[@3ftDeepChannel]

No, in this case it was unnecessary (check out Part 2 of the video series). So far we’ve found that the debris after a supercharger failure normally doesn’t affect the cylinder walls.

[@samooyseadoo]

What the cleansers number and tourq number?

[@3ftDeepChannel]

Most of our other engine teardown videos show the engine bolt torques. Try this one out for what you need: kzbin.info/www/bejne/j6jEl4iHqKaSiNE . We don’t know what you mean by “cleansers number”. Please elaborate.

[@fjduwjaksjeicjwkskkz3173]

Anybody knows where i can get the bolts used in 11:30 cant find any of them and need help fast.

[@3ftDeepChannel]

You should be able to get them from your local Sea-Doo dealer. Good luck.

[@fjduwjaksjeicjwkskkz3173]

@@3ftDeepChannel Thank you, great video btw!

[@julioblanco]

how much would a rebuild job like this would cost?

[@3ftDeepChannel]

Depending on how much damage there is, and how many parts need to be replaced, anticipate anywhere between $1000 and $3000 US. I think we spent about $2000 US on this job.

[@julioblanco]

@@3ftDeepChannel Does this includes labor and parts? Thanks.

[@3ftDeepChannel]

No, You would have to add thousands of dollars onto that price to include labor.

[@scottsmarine2817]

does 5910 go on outer perimeter only?

[@3ftDeepChannel]

5910?

[@serafimmaroulis]

@@3ftDeepChannel that's an old thread but I have the same question. I believe he means the loctite 5910 sealant for the lower block (crankcase). Do you apply it to the perimeter of the mating surface only or on all of the mating surface?

[@compasstrans]

Is 0.03 bearing clearance good or not? Thank you.

[@3ftDeepChannel]

What machine do you have? Year and model.

[@compasstrans]

@@3ftDeepChannel 2014 GTX 260 IS

[@3ftDeepChannel]

The service manual for the Sea-Doo GTR 215 says 0.07 mm for crankshaft journal radial clearance service limit.

[@compasstrans]

@@3ftDeepChannel So, it's not ok?

[@3ftDeepChannel]

Sorry, but I can only find the limit. I would think that 0.03 is OK and we would proceed with that. Good luck.

[@otrfitness4878]

Where did yall learn this?

[@3ftDeepChannel]

Tinkering, reading service manuals, forums and watching videos.

[@otrfitness4878]

@@3ftDeepChannel copy that...im just getting started on the same journey in the same way. No school.

[@maxflight777]

Was the crank reground?

[@3ftDeepChannel]

No, fortunately it wasn't necessary.

[@ayhamalhindi5172]

What do you mean with reground

[@davobansheee]

Are seadoo cylinders plated?

[@3ftDeepChannel]

The cylinders in the 1630 engine are plasma coated. The 1503 cylinders are steel sleeves.

[@davobansheee]

@@3ftDeepChannel can the 1630 be honed?

[@3ftDeepChannel]

Given that the plasma coating is quite thin, I don’t think so. You should chat with a machine shop to see what they suggest. Good luck.

[@jerrychase4177]

After seeing how these 2 brands of engines were built I will not buy either.

[@3ftDeepChannel]

Remember, this machine is 14 years old. They corrected the problem some time ago.

[@jerrychase4177]

@@3ftDeepChannel Great idea, showing us how the latest engines are built will help consumers make the best buying decision. Makes no sense buying a high performance marine engine that will not last when operated at high RPMs.