Blown Suzuki Motor
I pulled the head on the left cylinder and found this. The cylinder liner is OK and the outer casting is OK, but that inner water jacket is hurting.
When I tore it down, I found that 3 of the 6 vanes on the water pump impeller had broken and about 1/4" of the ends were gone on 2 of them. The 3rd was still hanging on - barely. I "think" what happened was that one of those ends plugged a water passage and caused the localized overheating. When I pulled the head, I looked carefully and don't see any pieces inside the water jacket.
Local welding shop says he can weld it up for about $150, then it will cost about ~$200 or $300 to have it machined true.....after I completely dis-assemble the motor and take the bare crankcase into the shop.
I don't have the room to work on a project like that and it'd be one helluva job. I thought about rigging up some kind of jig and adapting a fly cutter to polish the head gasket mating surface myself with the motor assembled as here, but have my doubts about practicality.
Alternatively, 30 years ago I owned a little Saab 99 car that had the 1300cc Triumph engine. Those engines were notorious for getting a "worm" in the head, where a little hole would erode from the water jacket into the combustion chamber. The plume of white smoke in the exhaust was a give-away to the coolant leaking into the combustion chamber. Yup, mine got one.
OK, the shop I was working in at the time had some special high temp epoxy that had to be kept in the freezer. I pulled the head, cleaned up the worm with a Dremel tool and used that epoxy to repair the hole. Remember, this was in the combustion chamber - about as tough a repair as there is.
Amazing - I drove that car for over a year with no problem until one day it ran low on coolant and overheated. That finished the epoxy. Point to make on that is that it "did" work.
I see 2400º epoxy advertised online and it makes me wonder. The cylinder liner is fine and that's where the piston rings ride, so there's no wear factor. I wonder if I could build up that burned section with epoxy and polish it smooth enuf for a head gasket ??
OK, my problem with all this is that $450 - $500 to have it welded and machined isn't insurmountable and the motor would likely be OK for years to come.....but now I can't trust it in my little OCD mind. As is well known, I like to go places and frequently end up way back of beyond. I don't like rowing home or looking for tows.
I'm vacillating - local independent shop has a 25 hp Mercury 2 smoke that he'll sell me for $600. Then again, I really liked the quiet, smooth power of the 4 stroke. Then again, I had endless problems with it. This latest just put a cap on it.
I'm very tempted to just sell it as a parts motor and buy the Mercury. Any thoughts ??
Migawd, I just wanna go play and it's one thing after another. Is there no end to it ??