posted 08-26-2009 08:02 PM ET (US)        

He had the powerhead shipped back to NY and remounted. I'm not sure if the mechanic initated the break-in mode on his EMM, just assume by the amount of carbon build-up. In less than 20 hrs running at 4K RPM, loss of power. 3/4" hole in #6 piston. For a pile of unfortunate reasons, this happened 2 days after the 1yr warranty was over, even though he only had 20hrs on the rebuild no help from the marine that built it. This is when I got it. I pulled the port head off and there is slight scoring on the wall, nothing another .020" bore wouldn't take care of. I'm thinking of rebuiding this block for kicks, I don't have much to loose as I didn't pay for the engine anyway, it was pretty much thrown in with the boat. The engine is in otherwise clean condition, the water passages are flawless and such. The port head is still in salvagable shape, just have to remove the piston parts from it. I can only guess that the new injector may not have been mapped when it was installed, ran that piston too lean and burned it up. Is this block worth messing with? I noticed that BRP does not list .040" over rings on their site. Is there a .040" option on the market? Any other ideas on root-cause of the failure? I wonder if only the effect of the first failure was fixed but not the cause. Or this failure was not related to the first with the huge spark plug gap.