1996 Suzuki DT65. SEIZED!

[Huebillionaire]

Thanks everyone,

I bought a used crank shaft. Just shipped today.

Just in the process of cleaning up all the parts and making a order list.

I cleaned the cylinder head cover, cylinder head, power head, honed the cylinders. Everything is going well.

Without the help of you guys and motivation this engine would be in the scrap metal bin at work!

 

[Faztbullet]

I going call 100% bull crap SEA, as a shop that can do this along with a hardening facility the cost would be near a replacement or used crankshaft. Also the use of different material throws crank balance off...DUH!! And the info was to owner to inform him not to follow your suggestion.

 

[Huebillionaire]

One of these things is not like the other.

My new crankshaft arrived! The new one has oil seals in between the middle bearings. The old one didn't.

 

[mphelle8vld]

I'm guessing you bought an early crank with labyrinth seals. I heard they had problems and they were replaced in 89 with sealed bearings which served both purposes. That said, I had an 85 with those seals that ran great.

 

[Huebillionaire]

I'm guessing you bought an early crank with labyrinth seals. I heard they had problems and they were replaced in 89 with sealed bearings which served both purposes. That said, I had an 85 with those seals that ran great.

Great information. Hopefully doesn't cause any fitment issues

 

[Faztbullet]

May not fit crankcase journals as likely larger and the bearing type uses locating ring in block

 

[Huebillionaire]

Got my parts finally today. New Pistons, Rings, Bearings, Gaskets etc.

Everything fit perfect. Crankshaft installed serviceable, reed valves, carbs. Wife shut me down as its our anniversary today. Cylinder, cylinder heads and drop the motor in tomorrow hopefully. I got the manual. Will have to give it another read tomorrow to make sure i don't lose access by installing too many components before I dropped the powerhead in.

 

[Huebillionaire]

Well everyone. Rebuild DONE!

Compression #1 - 120psi
Compression #2 - 115psi
Compression #3 - 118psi

Strong Spark.

After this pesky storm passes. I'll be taking the boat for a test run.

 

[Huebillionaire]

Works like a charm!

Got to get a drag link for it. For now I just bent some 5/16th tubing and threaded the ends and threw a nut and washer on for the mean time.

 

[Huebillionaire]

Well I took it out today. Had a hard time starting a then would stall under load.

I had my tank mixed at 50:1 and my oil injection was working so I hope its just a issue with too much oil. Going to replace spark plugs as well as they were looking a little rough, drain the gas and replace with straight gas. Then go from there I guess?

 

[99yam40]

I thought you were suppose to run double oil during break in

 

[Huebillionaire]

I thought you were suppose to run double oil during break in

I ran it for 10mins on muffs in the driveway, then shifted it to ensure the linkages were correct.

Then got to the ramp and zippo.

Just ran some tests on it in the driveway. Compression perfect, spark jumping .250 inch. Ran perfect.

BUT.......

Wondering why when I pulled the plugs while it was running.

#1 cylinder pulled, killed engine. Replaced spark plug.

#2 cylinder pulled, kept running, 0 hesitation, 0 change. Replaced spark plug.

#3 cylinder pulled, killed engine.

 

[99yam40]

I ran it for 10mins on muffs in the driveway, then shifted it to ensure the linkages were correct.

Then got to the ramp and zippo.

Just ran some tests on it in the driveway. Compression perfect, spark jumping .250 inch. Ran perfect.

BUT.......

Wondering why when I pulled the plugs while it was running.

#1 cylinder pulled, killed engine. Replaced spark plug.

#2 cylinder pulled, kept running, 0 hesitation, 0 change. Replaced spark plug.

#3 cylinder pulled, killed engine.

I would like to know how you pulled and put the plugs back in while the motor was running

 

[Huebillionaire]

I would like to know how you pulled and put the plugs back in while the motor was running

I meant pulled spark plug cap off the spark plug.

 

[Huebillionaire]

Had the boat out a couple times now. Very hard to get from Idle to Speed. I took the carbs off and cleaned them and still takes 15 or 20 times from idle to trolling to get it to stay running.

At the dock after I was done adjusted the carbs. I disconnected the choke linkage and choked each one separately. #1 carb killed the engine while #2 and #3 didn't changed anything. Checked suction at the reed valves and they were good. I had the boat running at 50km and hour, seems to be running great at medium to high speed.

I must have missed something slow speed jet? I have a brand new fuel pump on it and replaced fuel filter, new gas, new plugs (gapped at .032). Could be a blockage in the line?

 

[Huebillionaire]

Primer was losing firmness. Pumped it while watching lines etc.

Fuel was coming out from around the main nozzle inside the carb throat. That has to be it. After work I will be taking off #2 carburetor and investigate further.

 

[Sea Rider]

Fuel was coming out from around the main nozzle inside the carb throat. That has to be it. After work I will be taking off #2 carburetor and investigate further.

If having carb fuel spills will likely be accounted to any of the following issues :

-Needle's tip is rounded, worn out, not pointy.
-Float's height out of proper adjustment.
-Needle's seat extremy gunked, not letting the needle to close/shut well.
-A combo of all 3 ?
Would recommend to micropolish all 3 carb's needle's seats with toothpaste to a shinny condition....

Happy Boating​

 

[racerone]

Primer bulbs do not stay hard when motor is running.----The primer bulb fills the carburetors and saves the starter motor from doing that.----Or your arms on a manual start motor.-----When motor is running the primer bulb does NOTHING !!

 

[Huebillionaire]

There was a fuel/vacuum leak at the fuel pump hose. Enough it would idle nice but get too much air during throttle.