Catastrophic stator/magneto failure...please explain...

[shockerfd]

Posted a couple of weeks ago of this issue and just now tapping into it. Stator is fried and in this process, two of the six bolts holding the magneto on snapped off, two came out and one was still threaded in. Omg does it smell from electrical burn and friction!!! Was a little PIA getting off without removing engine but engine may now have to come out to do more work. UGH!

1. Ok, so what would cause this type of failure? Did something seize at one point or did the stator somehow sheer off the two bolts?
2. Two bolts snapped off and should I try and get them out or would the remaining 4 bolts be sufficient? Not sure of the threads with the ones that came out.
3. Manual is on old hard drive and what would need to be replaced if I can't get the bolts out and the others are stripped?

Thanks!!!!

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[Dr Honda]

If I'm reading it correctly...

1) Hot/cold cycles, and vibration made the flywheel bolts come loose. Proper torque, and red thread locker will keep that from happening again.
2) Yes... you must use all the bolts. you may have to drill, and retap the holes.
3) On the 800... you can remove the hub from the crank, and replace the entire thing. (you will need a new stator too)

 

[shockerfd]

I bought a stator thinking it was just that and obviously it was but never thought I would run into this mess. I'm going to need a new magneto as well. Am I correct to assume that I'm going to have to pull the engine to drill these holes out? Tight fit trying to do it while in boat still but possible. What are the bolts that snapped off threaded into?

 

[Dr Honda]

By saying "Magneto" do you mean flywheel? (The round thing with the magnets) Then yes... you will need a new one since I see holes that are warn out.

No... you don't need to remove the engine. Get a flywheel puller, and remove the hub, and replace all of it.

 

[shockerfd]

By saying "Magneto" do you mean flywheel? (The round thing with the magnets) Then yes... you will need a new one since I see holes that are warn out.

No... you don't need to remove the engine. Get a flywheel puller, and remove the hub, and replace all of it.

Thanks for your replies Dr Honda. Yes, I was referring to the flywheel magneto. It got chewed up on the inside as well. When you say "hub" what exactly consists of these parts? Looking at the parts list I'm a little unsure exactly what is needed.

Also, is there a timing adjustment needed after this is replaced?

 

[Dr Honda]

Normally, the flywheel does not come apart. They are normally just keyed onto the crank shaft, and held in place with a large nut. On the 800 engine, you can unbolt the outer part of the flywheel, from the center "hub." I'm assuming it's still on the end of the crankshaft. As far as the part numbers, the flywheel is sold as one part. (that's why you don't see a separate hub)


Yes... the timing can be set. On most of the engines, you adjust the mag plate... but on the 800, the timing is set via the MEPM. You need a BUDS system to adjust it. After you put on a new flywheel, and stator, you will need to check the timing. If it needs adjusted, you will need to take it to a dealer, or buy one of the new home SeaDoo BUDS tools. (but they are expensive)

 

[shockerfd]

Normally, the flywheel does not come apart. They are normally just keyed onto the crank shaft, and held in place with a large nut. On the 800 engine, you can unbolt the outer part of the flywheel, from the center "hub." I'm assuming it's still on the end of the crankshaft. As far as the part numbers, the flywheel is sold as one part. (that's why you don't see a separate hub)


Yes... the timing can be set. On most of the engines, you adjust the mag plate... but on the 800, the timing is set via the MEPM. You need a BUDS system to adjust it. After you put on a new flywheel, and stator, you will need to check the timing. If it needs adjusted, you will need to take it to a dealer, or buy one of the new home SeaDoo BUDS tools. (but they are expensive)

I see what you mean in the parts with it being the "hub flywheel". You're saying the hub will unbolt from the flywheel? Forgive me but I don't see how that happens. Basically I can grab the hub flywheel as one piece and put it back on. It's all coming clear now that the "magneto flywheel" was bolted directly to the "hub flywheel". Expensive piece that is, unless I find used. I'm going to take it off first and see if I can clean up the threaded area the bolts snapped off.

On the timing issue, if everything is put back on as it was removed, does this affect timing? The crank hasn't been turned so I'm assuming nothing has been changed with the timing.

Thanks

 

[Dr Honda]

On the timing issue, if everything is put back on as it was removed, does this affect timing? The crank hasn't been turned so I'm assuming nothing has been changed with the timing.

Yes... it still needs checked. Seadoo may manufacture parts from multiple locations, and there can be differences in the strength of the magnets, or how tight the pick-up could is wound. In turn... you make get a few degrees drift between the old, and new parts. AND... since SeaDoo sets these engines on the ragged edge, you are best to check it, or you chance your engine.

 

[PWCdoc]

For that model and year you do not need the BUDS system to alter the timing. You will however need an MPEM programmer. 2 different tools. I have one and go to Maryland from time to time. If you get it all installed and need the timing adjusted then let me know and I'll see what I can do to help you out.