Methodical checklist

[Alban1an]

Hello everyone,
As the saying goes, inside a small problem is a bigger problem inside waiting, screaming to get out.
Recently I dropped a washer in the bottom of the crank through the rotary valve, and plan on taking the engine apart and reassembling it with new gasket rebuild kit. This started as an engine mount Replacement.
I had also just rebuilt the carb before attempting to put the engine back. The question is, when I put everything back together in the ski, is there a methodical checklist to go through to rule things out as I am putting things back together, kind of like hardware before software type.
For example, this is what I am thinking:
1. Engine mounts replaced (done)
2. Engine reassembly
3. Leak down test
4. Compression test (by hand crank)
5. Replace spark plugs
5. Oil pump operation test (done)
6. Oil tank reservoir o ring replacement
7. Fuel lines replaced (done)
8. Fuel pressure Relief / check valve test
9. Oil lines replaced
10. Engine installation & proper alignment
11. Cable linkage connections/adjusting
12. Carb rebuilt (done)
13. Jet pump oil replacement (done)
14. Wear ring inspection/replacement
15. Set idle speed on dry
16. Bring on the water and do carb tuning

This is what I am thinking, any feed back if it's good or bad, or if I am missing something important which should be done during early stages befire putting everything back together and then chasing potential problems?

Thanks in advance.

 

[SabotageR1]

Download the service manual and follow the procedures for each item you're working on. The engine assembly part will be your "checklist", the pto part will be your "check list" and so on. It's time consuming but if you go chapter by chapter on what you're working on, it's like a check list.

 

[Alban1an]

Thanks SabotageR1, started taking the engine apart tonight, did not go well at all. 6 out 12 top head bolts sheared off, only 2 out of 8 allen screws for exhaust came off, 5 started to strip, and 1 sheared off. Went around to the magneto, 9 came off, 3 sheared off.
I actually ended up buying 2 new GTI 170SE's for the wife and kids, but I am not giving up yet. I am thinking if I can take the head gasket off, and get access to the inner bolts, I can either try and drill or unscrew the broken ones off, or get 2 new top end cylinder housings with the exhaust manifold.
It's going to be a long fall season, as I work a lot and don't have much time off.

 

[Alban1an]

A little update, rebuilt engine (cost $900), painting magneto, starter, exhaust manifold. Pressure tested both cylinders hold 150 psi.

 

[Alban1an]

Still have to do steps:
2, 3, 6, 8, 15 & 16.

 

[Stevie96xp]

Yep just keep going. I do not envy you guys in the salt lol

 

[SabotageR1]

Still have to do steps:
2, 3, 6, 8, 15 & 16.

Who rebuilt it, you or did you send it out?

 

[Alban1an]

I was going to do it myself, but between drilling out the bolts, or cutting up the top sections (cylinder housings) and buying new ones, I found a local guy (local enough, I am in Jersey) in Delaware. I had read about the guy in PA, and actually called him, he sounded ok and was responsive, however, the red flag for me was that he (the PA) guy wanted me to drop it off, pay upfront in full and then he said about 6-8 weeks. That meant in my opinion that I would have to keep calling him and chase him until it got done, and some comments on here already mentioned that, so I decided against it. The guy in DE had that one already rebuilt, and dropped off the old one, he helped me take off the flywheel and put it on the rebuilt engine, and I was on my way home. The price was the same, I just liked the idea of paying cash and carrying the rebuilt engine with me.

 

[Stevie96xp]

Yeha sounds like you did the right thing to me

 

[Alban1an]

Again, not to discredit him or his work (the guy in PA), I just felt more comfortable paying and getting what I am paying for on the spot. Disclaimer: I told both guys about the broken bolts, and sent them both pics, and both of them were ok with it, and did not have any issues with that, so I wasn't trying to swindle anyone.
Plus, I figured the time he would take ~ 6 - 8 weeks, instead of waiting for the PA guy, I could use that time to paint the rest of the parts, and work on putting it together if I went with the DE guy.

 

[SabotageR1]

I was going to do it myself, but between drilling out the bolts, or cutting up the top sections (cylinder housings) and buying new ones, I found a local guy (local enough, I am in Jersey) in Delaware. I had read about the guy in PA, and actually called him, he sounded ok and was responsive, however, the red flag for me was that he (the PA) guy wanted me to drop it off, pay upfront in full and then he said about 6-8 weeks. That meant in my opinion that I would have to keep calling him and chase him until it got done, and some comments on here already mentioned that, so I decided against it. The guy in DE had that one already rebuilt, and dropped off the old one, he helped me take off the flywheel and put it on the rebuilt engine, and I was on my way home. The price was the same, I just liked the idea of paying cash and carrying the rebuilt engine with me.

You got the DE guy contact info? I need my engine rebuilt as well, and for $900, it pays to just get the swap because me doing it myself will cost over $1000 in parts and service.

 

[Alban1an]

Yes, I am at work now, but I can get it when I get home tomorrow.
PM me and I will respond.

 

[SabotageR1]

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