Weird problem with new 22I

[Seanmcd]

OK, so I have my brand new boat, a 2005 22I, and the first thing I notice is that the engine sounds a little louder than I am used to. Thinking it is just cause it's a new boat, I pay no mind, until it bugs me to the point that I investigate. Long story short......

The front of the engine cover was making constant contact with the front of the engine, specifically the impeller body. It made a loud vibration due to the acoustic properties of the engine cover.

So as I look at it and notice that the rear hinges of the engine cover are twisted and the screws into the floor are bent!!

I removed the screws and installed brand new ones, everything fit fine, no rubbing, until.......

As soon as I put the hydraulic pistons, ie: motor cover support pistons, the engine cover again pushed backwards into the engine and twisted the screws and hinges!!

When I took the pistons back off to put in NEW screws, I tried to compress the pistons and WHOA!!!!, it took like 150lbs per piston to compress them!!


The pistons were forcing the engine cover backwards, into the engine, and twisting the screws. The dealer said that I should put some rubber bumpers on the floor to keep the cover from hitting the engine, but that will not stop the screws from bending.


I have removed the pistons for now, but does anyone have any ideas??? Should a $50k boat have such a poor design, or is it a fluke? Has anyone had such a problem?

Any help would be appreciated, Thanks in advance. Sean

[lee]

I would just leave the shocks off. You will now be able to open your engine box all the way and check your fluids and see the whole thing.

[Seanmcd]

I think that is what I will do, but I guess a part of me says, "It should be fixed and fixed right." I wonder if they make those shocks in lower pressure to fit.....

[lee]

When we have a new 22i come in, we take the shocks and hardware of from the start. Most people do not like the fact that hatch will not open all the way.

[bneub]

Check with your dealer, maybe the wrong shocks got put in at the factory. It should be under warranty.

[Andrew]

Yes there are different lbs shocks however because of that style engine hatch the stiffer schocks must be installed due to the weight difference say of a regular 21i engine hatch. I personnaly agree with Lee about taking the the schocks off the engine box. With the schocks on you can not check the fluids very easy and many dealers due take them off before delivery of the boat. The reason for the shocks was so the hatch would not close and hit someone. On the boats built in the early days 90-98 there were no schocks installed. Please contact the dealer if you would like them exchanged I will send new ones out. This would be covered under warranty if you would like to replace the schocks. Please let me know.

Andrew

[dogbert]

Way to step up, Andrew! You rock!

[Seanmcd]

Thanks very much Andrew, I don't mind not having the shocks there, as long as the engine cover does not damage the hinges when the cover opens all the way.

I will keep the old pistons and if I need them will swap them out for a new set...However,


How can this problem not happen to every other boat with those pistons? It is pretty strange that the designers never had the same problem. Anyway, thanks for everyone's help. Thanks Andrew.

[JASON739]

I think that is the biggest and worst BS solution I have ever seen on this site and Tige should be ashamed to post such an answer.

[dogbert]

Originally posted by JASON739
I think that is the biggest and worst BS solution I have ever seen on this site and Tige should be ashamed to post such an answer.

What? That he offered to replace them? Or that he gave a workaround so the guy could get back out on the water?

[Seanmcd]

I guess I still have the question, is it a design flaw, or did I just get the wrong/faulty pistons??

I would think that if one pistons was faulty, it would be noticebly more difficult to compress than the other, but they were in fact very similiar in the amount of force it took to compress them. I mean, take say 320 lbs and push straight back on a piece of fiberglass with a poor structural shape (half round) and how can you not know that will happen?

I know the answer is to replace the pistons for new ones, and see what the pressure of those are. But still...

[Matt Garcia]

Originally posted by JASON739
I think that is the biggest and worst BS solution I have ever seen on this site and Tige should be ashamed to post such an answer.

What?! An explanation was given by Andrew, what part of that did you miss?