Seadoo Utopia 185 Rebuild 200 Optimax

[abnwayne]

So I just picked up a new to me utopia. Seller told me he lost compression on 2 cylinders one with 0 and another had 20 psi. The seller described everything to me that sounds like a lean seize. upon checking the case for holes we settled on a price and i bought it. most of my experience being with the rotax powered engines this will be a bit different for me as its the 200 optimax engine upon initial teardown it definitely looks like a lean seize


The picture is a bit blurry but number 4 melted the piston and number 6 had stuck a ring

So as of right now i dropped the block off at the machine shop and have dug around looking for what caused the lean condition on this boat and i find this...



that is the injector four number 4 i disassembled the rails and proceeded to clean them out i will end up sending my injectors out to be flowed and cleaned the price of these injectors are crazy!!!!!

i proceeded to do a bit more digging and disassembled my air compressor but did not find anything damaged or broken inside it the piston looked good in it with no visible scoring on the walls and tearing into the bottom end showed no visible signs of bearing damage. if anyone wants to chime in here it would be beneficial on where this metal came from id be much appreciative becuase im looking and cant find anything as of yet.

i forgot and spaced to take pictures of the compressor but i do have one of the piston in it and it looks fine

 

[abnwayne]

Took the compressor down today for some reassurance hoping I missed something but again I'm finding no issues if anyone has any ideas im all ears

 

[abnwayne]

so i ordered the new compressor anyways as a precaution does anyone have any personal recommendations for a business to clean and flow the 6 air and 6 fuel injectors?

 

[abnwayne]

Some progress has been made just got all my pistons knocked in and got the block back from the machine shop went with a .020 over bore ring gap is about .020 so its a little higher but nothing im too concerned about. This weekend I plan to have more done gard to do much between two jobs

 

[abnwayne]

Got a bit more done today quick question for anyone following this thread how many check valves are on the optimax 200 and which are they want to check them all while on the bench

 

[abnwayne]

This is where I called it quits last nigh

 

[abnwayne]

not much to update all that is left is waiting on one fuel injector that tested bad during flow testing but i did get majority of the engine back together and ready for drop in all i have left is cooling lines

 

[abnwayne]

Well i got the engine in sorry no pictures as of yet the top of the oil reservoir is leaking by the cap so i ordered a new reservoir its the engine mounted one. she fired right up though sounds great. currently my fuel gauge reads empty so i will have to look into that but she starts and idles i will be launching her in a couple weeks and update when i finish my first water test.


also had a few bent mounting studs which made putting in the engine a nightmare it was soo rear end heavy i needed a load leveler to put it in so for those of you pulling your own engines i highly recommend it!

Also i used noico sound insulation from amazon to redoo the engine cover as all the foam was deteriorated. i have nothing to compare it too but it seems to work well and went on rather easy

 

[abnwayne]

So i was able to take her out yesterday for the first time unfortunately i had a leak in my air line causing sputtering past 3k rpms due to a cut hose a bad hose clamp will replace and update on performance after but the engine moved the boat and the kids were atleast happy

 

[abnwayne]

Finally got her out and running right shes alot quicker than the single 787 challenger I had

 

[spearson]

Nice Job! I think overall the 200hp merc has proven a little more reliable than the other variants. You should get some good years out of it after your rebuild.