2006 Yamaha FX Cruiser HO (second) rebuild - Page 2
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  1. #11
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    Re: 2006 Yamaha FX Cruiser HO (second) rebuild

    Ok, now on to the second repair....

    You can see the corrosion that had formed in the exhaust port. This was the first sign of trouble...
    IMG_5276.JPG

    This is what I had to start with... workbench, tools, bags and boxes of parts (well mostly all the parts as I was to find out later...)
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    You can see that there's no mechanical damage, everything is cosmetic from the corrosive affect of the saltwater on metal:
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    IMG_5632.JPG
    IMG_5734.JPG
    IMG_5735.JPG
    IMG_5736.JPG
    IMG_5737.JPG

  2. #12
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    Re: 2006 Yamaha FX Cruiser HO (second) rebuild

    Removed the valves, then cleaned them and the head.


    IMG_7021.jpeg
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    Valves came up pretty clean, and within spec. I did not lap the valves

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    Last edited by mlebied; 02-16-2019 at 02:34 PM.

  3. #13
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    Re: 2006 Yamaha FX Cruiser HO (second) rebuild

    crankcase sealed, head done, cams, timing chain, and valve clearance all checked.

    IMG_7703.jpeg
    IMG_7697.jpeg

    Exhaust pipes installed and all cables routed correctly. ready to drop in
    IMG_7742.jpeg
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    I also checked the compression and it's showing a little low compared to spec, but I believe that is normal until everything breaks in.

  4. #14
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    Re: 2006 Yamaha FX Cruiser HO (second) rebuild

    A few videos:

    The cylinders cleaned up mostly well except for some staining from the salt water. I ensured they were smooth and honed to achieve the desired cross-hatching




    Lessons learned:

    1. Well of course I now know that towing a Yamaha Waverunner at any speed above VERY SLOW is a really bad idea.
    2. Yamaha should have included a "tow valve" which could cut the supply of cooling water through the cooling water intake pipe.
    3. Learning a new skill is an awesome experience.
    4. Make sure all parts are accounted for before you start the project. Having to go back and forth to the shop 5 times delayed the project.
    5. Procure all your consumables ahead of time (molyb grease, thread lock, etc.)
    6. Make sure you have all required tools before you start the job. Buy or borrow what you don't have.
    7. Always helps to have a brother who has done this before, and is nice enough to sacrifice his time to answer questions whenever you get stuck or need confirmation.
    8. READ THE SERVICE MANUAL and follow its advice.
    9. Be extremely careful and diligent with the timing. Mark a spot with white market where the crankshaft enters the case, ensuring cylinder #1 is Top Dead Center (TDC). You must ensure the crankshaft does not move when you are installing and torquing the cam covers. The chain guides are a little tricky to install, while ensuring the chain stays tight around the gears, and the crankshaft does not turn. Keep all the slack in the chain in the section where the timing chain tensioner will go, ensuring that there is no slack in the timing chain between the two cam gears, and between the cam gears and the crankshaft.
    10.The rings are a pain in the *** to install and then get the piston into the cylinder. The first time I did it, I was playing with the piston and accidentally pushed it too far down the cylinder, causing the oil ring to pop out. Spent about an hour trying to recompress it, to no avail. Had to pull the oil ring, slide the piston up, and replace that ring. Wasn't going to take any chances there. That delayed me several days and set me back another $30 for the ring set.
    11. use a very small amount of gasket maker on the mating surfaces of the crankcase. I used too much the first time and had to re-do. not fun and a waste of time.
    12. Have fun!!!

  5. #15
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    Re: 2006 Yamaha FX Cruiser HO (second) rebuild

    Crank was smooth after pistons were installed.

  6. #16
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    Re: 2006 Yamaha FX Cruiser HO (second) rebuild

    Crankshaft with piston movement


  7. #17
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    Re: 2006 Yamaha FX Cruiser HO (second) rebuild

    Ensure the timing chain is tight after installation

  8. #18
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    Re: 2006 Yamaha FX Cruiser HO (second) rebuild

    A full walk around of the engine after re-assembly, just before dropping it back into the ski


    Lastly, here are two links that discuss how to install the cooling water (tow) intake valve.

    https://jetboaters.net/threads/dont-...g-towed.10842/
    https://jetboaters.net/threads/how-t...ng-system.411/

  9. #19
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    Re: 2006 Yamaha FX Cruiser HO (second) rebuild

    just posted a bunch of pictures and some videos. Hope this is helpful to your project. Feel free to PM if you have specific questions.

  10. #20
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    Re: 2006 Yamaha FX Cruiser HO (second) rebuild

    How did you enjoy all that bearing plus and minus.....blue, red,green, etc...crap!
    http://www.facebook.com/twinlakesjetskirepair

    '89 Kawi 650SX 42.4 GPS
    +3" stock pipe, ported ex. manifold, drilled waterbox, blueprinted pump, Ocean Pro ride plate

    '99 Yama GP1200 65U 61.8 GPS
    ported cylinders, matched cases, milled head, blueprinted pump, long ride plate

    '96 Seadoo HX 717 53.13 GPS
    light porting, massaged cases, lightened flywheel, port matched manifolds, Rossier pipe, stubby pump cone

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