Finally got the recoil rebuilt and the rest of the peripherals on.
I had to make myself a flywheel holder for removing the nut. Was nice to finally get the welder out. Haven't used it since before Halloween! With some help from my friend leverage and the pulley-remover set, that flywheel flew off there like its been ont here since 1991. Don't underestimate the power of the taper! lol Stator, flywheel interior, and crank seal were IMMACULATE. I left them all as-is and re-assembled. I need to find the little plastic insert piece that goes in the hole on the case above the flywheel, as the face of the flywheel had a little corrosion on it.
Tore down the recoil and cleaned up the housing with bead blast, soak in carb cleaner (old paint was REALLY on there), more bead blast, wire wheel, #000 steel wool, and then 4-coats of heat-cured clear. Re-assembled including a pull-rope replacement. The starter rope replacement was a BREEZE. I used a #8 74" rope from Helix Racing Products. They were liquidating them on evilBay a while back and I bought 3-4 of them for like $4 each. Perfect length, and right strength. The whole recoil rebuild was extremely easy and intuitive. Only special tool you'll need is a pair of snap-ring spreaders.
Got the oil pump swapped. The pump on my Skidoo setup worked great and is in better shape than the Seadoo one. Same exact pumps EXCEPT for the plastic drive gear. The Skidoo gear is .010" bigger in diameter (2.25" Skidoo vs 2.15" Sseadoo) and the Skidoo one will not fit in the single-carb SeaDoo housing. I also had to steal the throttle arm linkage off the Skidoo setup for actuating the oil pump. Gave it a shot of bead blast and its clean and beautiful like the new carb. Stole the oil pump cable elbow from the old pump, too. Just need to find my e-clip stash and get a new clip on it (hence the note to myself in the
Engine photo).
I ditched the flat-head screwdriver head bolts that held the Skidoo intake plate on, and replaced with hex-bolts.
Then I assembled the SeaDoo spark-arrestor and intake housing. But...I want to get the 'other' SeaDoo intake box for attaching an air filter too. Not too much dust out on the water to require a filter. But in a buggy, air filtration is a MUST-HAVE.
Compression and leakdown test are all that remain and of course all of the tanks, electrical, etc when it gets fit to the buggy. Intake plate, rod bearings, and rings are lubed, so I want simply give the rope a slow pull every few days to keep everything alive and well until I get the Engine mounted in the buggy.