1995 Yamaha Superjet Resto-Mod

[Big Kahuna]

I use to have that same multi color HOT sticker on the back windshield of my S10 Blazer!!!!!!!!!

 

[brapperdoodle]

I forgot to post this but I started building my engine a week or so ago. First I removed my old starter bushings from the case and stator cover with an M12 tap and a slide hammer with vise grip attachment. I originally tried to use a blind bearing puller but it wasn’t deep enough to reach the back of the bushing you get a proper tug on it.
Then I installed the new OEM bushing so I could begin assembly. I used a proper sized bearing driver to insure no damage to the bushing or cases.
I am a big fan of OEM parts and Japanese engineering in general, so here is a few of my OEM hardware parts. New Head bolts, exhaust bolts, intake and ride plate bolts etc.


I began assembly and decided to go with Yamabond 4 Marine for sealing the cases. I did also use a drop of Loctite 620 a bearing retainer compound, on the case bearing mating surface to insure no fretting or any bearing movement. Unfortunately my old engine had an SBT crank so that’s what I put back into it. A remanufactured SBT crank. Kinda pains me to put anything stamped “Made In China” inside of my engine, or anywhere for that matter. I also followed the OEM Service Manual recommendation to apply Loctite 572 to the case, cylinder and head bolts when assembling. This is a low strength thread sealant and it is used to keep the treads free of moisture and corrosion free. Smells good too... I used regular Blue thread lock on the other bolts specified by the manual.

All went well so I flipped the engine over and moved forward to install the pistons. The pistons were shipped to me in the cylinder with the rings installed. I trust Harry’s work but I decided I needed to see with my own eyes that everything was proper and not just assume it was ready for assembly. I wiped the cylinder walls thoroughly with premix until the were clean. Then I moved forward to check the ring end gap before installing the cylinders. Everything checked out fine

 

[brapperdoodle]

I continued on last night building the engine. Everything went nicely. I have a new OEM starter and starter bendix. I just want to keep it in the box and stare at it haha.

I went ahead and pressure tested my engine and found that I am leaking about 1psi in 5 minutes, starting at 9psi. I sprayed the engine with wd40 and quickly exposed the intake gasket leak. Everything is thoroughly cleaned and using new OEM gaskets. I’ll need to take them off and use a sealant, probably a thin layer of Yamabond....


P.S. I have a new friend that watches me while I work.

 

[mikidymac]

I had the same issue in my 61X intake. Use 1211 on the gaskets not the Yamabond.

Also when running a pipe it is a really good idea to run a girdled head to prevent cylinder cracks.

 

[Big Kahuna]

Please tell me you plan to paint the cylinder and cases?

 

[brapperdoodle]

I had the same issue in my 61X intake. Use 1211 on the gaskets not the Yamabond.

Also when running a pipe it is a really good idea to run a girdled head to prevent cylinder cracks.

That is true, I read quite a bit about the issue and decided that this set up will work best for my application. It’s kind of a catch 22 cause an o-ring will never seal as well as a metal head gasket over time. My engine isn’t really that powerful so I think this will be fine.

 

[brapperdoodle]

Please tell me you plan to paint the cylinder and cases?

Pretty hideous isn’t it? I don’t know what to do. Should I just tape up the ports and spray the main parts? I guess I should have blasted the parts before I sent them to Klemm but for some reason I thought they would come back cleaner... Originally I was trying to have this ski finished before the 2020 Daytona freeride so I was rushing a little.

 

[mikidymac]

Just do like Yamaha did. Mask off the carb opening and the exhaust ports and spray paint everything else.

 

[smoofers]

Just do like Yamaha did. Mask off the carb opening and the exhaust ports and spray paint everything else.

Try not to paint the rear crank seal lips

 

[brapperdoodle]

Just do like Yamaha did. Mask off the carb opening and the exhaust ports and spray paint everything else.

I forgot to mention also, this is the 760 hammer kit from Group K so I cannot run a girdled head kit according to Harry. The head is actually a modified 62T cylinder head

 

[mikidymac]

I forgot to mention also, this is the 760 hammer kit from Group K so I cannot run a girdled head kit according to Harry. The head is actually a modified 62T cylinder head

And you said the engine isn't really that powerful. You are a liar sir.

I would call Harry as he specifically states that, "Failing to use this half girdle greatly increases the risk of fracturing the cylinder casting around the inlet side base bolts." I know he started making them when Pro-Tec quit.

 

[Rushford_Ripper]

I think it depends on the strength of Yamabond, I use 4 and he’s worked fine.

 

[mikidymac]

I think it depends on the strength of Yamabond, I use 4 and he’s worked fine.

On bare surfaces and the cases absolutely on the Yamabond. His was leaking on the intake gaskets and 1211 is better for that.

 

[brapperdoodle]

And you said the engine isn't really that powerful. You are a liar sir.

I would call Harry as he specifically states that, "Failing to use this half girdle greatly increases the risk of fracturing the cylinder casting around the inlet side base bolts." I know he started making them when Pro-Tec quit.

Wait, what? Did I misread something... I have 2 girdled head kits sitting in a box here...

 

[mikidymac]

So........ are you running both girdled heads at the same time or the Group K 62T??????

 

[te4250]

3 motors geared together like a pulling tractor

 

[brapperdoodle]

So........ are you running both girdled heads at the same time or the Group K 62T??????

Hahahahah. My brother also has a 1995 Superjet. I bought these girdle kits for both of us long before I started building this motor. When I spoke with Harry during the engine work, he told me that his kit required a 62T cylinder head and I didn’t have one. He sold me a cylinder head and modified it. He really made it seem like that was the best option. I spoke with him multiple times and just explained I wanted the best reliability to power ratio. He sold me on the 760 hammer kit and sold me that cylinder head. I originally wanted to keep the 701 but he said the 760 is just as reliable so I went with that.

 

[mikidymac]

I would believe Harry on everything he says. He has been my go to machine shop for over 25 years now and never once had an issue. I would call him and ask about the half girdle though. Would be a shame to go to all this work and crack a cylinder.

 

[brapperdoodle]

I would believe Harry on everything he says. He has been my go to machine shop for over 25 years now and never once had an issue. I would call him and ask about the half girdle though. Would be a shame to go to all this work and crack a cylinder.

Just spoke with Harry, he recommend not to use my girdle head kit. He did however sell me a fully stainless half girdle kit and it should ship out today or tomorrow. Good looking out bud!

 

[mikidymac]

I would agree to not use the aftermarket head and instead use the 62T that Harry supplied.
Glad you went with the half girdle, cheap insurance in my opinion.