650SX/X2 build

[Vumad]

EDIT: Please skip to page 9 , post 166, for updates to this build.

http://x-h2o.com/index.php?threads/650sx-x2-build.25542/page-9




I'm going to start over... The origional thread was http://x-h2o.com/showthread.php?t=23286

Overview:
I could use some help because I'm new to working on engines and I can't afford to pay someone to do the work for me (mostly I want to learn how to do it myself). I just picked up a X2 with an engine in it. I am going to put everything I have back into one nice ski. I'm hoping to get a good powerplant up and running soon, and come back to things involving the hull and etc.

Goals:
I have lots of stuff that I've gotten for next to nothing ebcause I am willing to deal with the junk noone else wanted. I blew my engine so I only have one working engine. I want to get together a reliable engine so I can get onto the water. I'm a stand up guy, so the engine will probably end up in the SX. However, I've never ridden an X2, so the engine will be interchangeable. If I like the X2 (or my friend does who keeps saying he wants to try an X2), we're going to build a 750 X2. That is why nothing is for sale.

Inventory: NOT FOR SALE
I have a huge inventory of parts for this stuff. Here's a current list.
650SX:
-2 good hulls with hoods and poles
-1 stock steering system
-1 quick steer steering system with 0 degree bars
-1 good fuel selector
-1 set of cables (throttle and steering)

X2:
-5 hulls (4 virgins), 4 hoods, mutiple hood latches, 5 standard seats, 1 risen seat, several seat latches
-1 stock steering system
-1 accusteer steering system
-several steering cables
-at least one throttle cable

Interchangeable parts:
-1 650 stock engine, 145 in both cylinders, looks good
-1 complete and good working electrical system from my 650SX
-Complete non-working electrical from new engine (jumped the starter, The starter cylinoid was bad, possibly other bad parts, could just be the switch on the bars)
-Misc electrical components including extra stator and flywheel (so at least 3 flywheels and stators)
-Multiple start/stop switches, at least one confirmed to work
-Jetpro pipe and header
-Westcoast pipe and exhaust manifold
-44mm mikuni carb on stock manifold
-a few other carbs, aftermarket and stock, but the mikuni is the best
-PJS head with pitted domes, would have to be machined to be used
-2 starters
-3 stock bed plates
-2 ocean pro bed plates
-a dozen motor mounts
-several fuel tanks (have oil stuff but will go premix for sure), fuel pick ups
-several stock water boxes, one stainless waterbox (pretty heavy, probably wont use)
-3 billet throttle levers
-1 billet bildge switch bar mount
-1 of the SXIPro super bildge switches
-A good bildge pump
-Multiple bilge outlets and 45* cooling outlets
-Multiple pumps, props (some aftermarket stainless) and drive shafts, at elast 2 sets of good pump bearings
-multiple pump nozzles, at least 3 trim nozzles
-multiple couplers and dampiners
-2 clear titles

I left a LOT of stuff off that list. You get the idea... Build it with what I have. I'm not going to go out and buy pipes and carbs because I have them. I'll go buy fresh bearings and gaskets if they are needed.

 

[Vumad]

I can handle electrical, I can handle hull, I can handle drive line...
I don't know powerplant!

Give me a good engine, with carb, exhaust and all that good stuff, and I can hook up all of the electronics, can probably handle the cooling, all of the parts form the hull and the drive line if you hand me a box of parts.

Hand me a box of parts and say build an engine... It'll probably blow up, as proven by my last engine that engested water from the cooling system.

~~~~~~~~

Pics 1-3 are the engine. Pic 4 is my carb. Pic 5 is the westcoast pipe I have.

So here's where I'm at...

I pulled the flywheel cover and got th bendix back in place. Put a starter on and did a compression test. I got 145ish in both cylinders. Engine sounds good, but I had to jump the starter. Flywheel and stator look like they have had some water in there. I haven't worked with these parts before. I'm not sure what to do with this.

My carb is the best carb I have, and it was run with a stock pipe. I think the best route is to put my carb and the stock pipe on the block and get the electronics right. Once everything is in good order, then switch the pipe out and retune the carb.

I bought the kawi shop manual, but I could still use some help for the powerplant.

Thanks...

Hey tom or tim,

Do you know what Chris was using for the start, stop and laynard switches on his build? I really liked those. I might buy a set up like his if it will work on a kawi.

 

[Vumad]

So what do I do next? I need some help with this whole flywheel stator thing. Should I pull the flywheel, clean everything up, test the stator with an OHM meter. I can go buy a flywheel key. Can someone give me a little walkthrough on what I should do? Once I have the stator set up, I should be good with the rest of the electronics.

I can handle getting the carb and exhaust set up. Can I make the gaskets for it from gasket paper or do I need to buy them?

 

[noah45]

You took all the time to doc what you have and what your doing... maybe my reply will get you more responses, who knows?

I put a 750 into a new hull (prototype) based on the 650SX pump. If you search the threads it will give you info on; how to better understand and gear the build towards your objective. I can say, it's a critical part of your rebuild, so take the time to learn how the intake grate/pump/impeller/nozzle work as a system.

 

[WaveDemon]

I can handle electrical, I can handle hull, I can handle drive line...
I don't know powerplant!

Give me a good engine, with carb, exhaust and all that good stuff, and I can hook up all of the electronics, can probably handle the cooling, all of the parts form the hull and the drive line if you hand me a box of parts.

Hand me a box of parts and say build an engine... It'll probably blow up, as proven by my last engine that engested water from the cooling system.

~~~~~~~~

Pics 1-3 are the engine. Pic 4 is my carb. Pic 5 is the westcoast pipe I have.

So here's where I'm at...

I pulled the flywheel cover and got th bendix back in place. Put a starter on and did a compression test. I got 145ish in both cylinders. Engine sounds good, but I had to jump the starter. Flywheel and stator look like they have had some water in there. I haven't worked with these parts before. I'm not sure what to do with this.

My carb is the best carb I have, and it was run with a stock pipe. I think the best route is to put my carb and the stock pipe on the block and get the electronics right. Once everything is in good order, then switch the pipe out and retune the carb.

I bought the kawi shop manual, but I could still use some help for the powerplant.

Thanks...

Hey tom or tim,

Do you know what Chris was using for the start, stop and laynard switches on his build? I really liked those. I might buy a set up like his if it will work on a kawi.

chris is #.0 on here. send him a pm about those switches.

 

[WaveDemon]

I don't know what the ultimate build plan for you should be but starting with your stock motor, a pipe and the mukuni is not a bad place to start. slap it together already!

 

[Vumad]

I don't know what my ultimate plan is either.

I know i can use a 750, but right now I want to just get this stock 650 running. I want anything to ride. I need some advice on how to make sure I have a properly working stator. Is there anyway to test it without removing it?

slap it together already!

I'm afraid to slap it together. I blew my engine by slapping together the exhaust = water ingestion through leaking cooling = BOOM! I'm trying to learn the right way to do things. I had used form a gasket on the head pipe. No good. I was going to use gasket paper this time but I didn't know if that would cause problems too.

I'll PM chris, thanks.

 

[WFO Speedracer]

Do yourself a favor and buy the proper gaskets,if you don't want to buy oem buy hot products or WSM,I can hook you up with WSM gaskets if needs be.

 

[Vumad]

I'll probably get the gaskets from Tom.

Any comments on the stator/flywheel? If I were to take it off, I wouldn't know how to properly tourqe it back down.

I'm going to go pull the intake and exhaust and take a looksy at the inside and start cleaning things up.

 

[Vumad]

I went to the autoparts store and told them I need the tool to remove a flywheel. They looked at me like I was retarded. I guess I am going to have to wait until later to pull the flywheel and set up the stator.

Does anyone think I should tear down the whole engine and check the rings and crank for wear? It looks pretty good. I don't think that would be necessary.

 

[tom21]

clean it up and come by I have the gaskets, bring some beverages and some cash. we can get it running quickly. stop with the stator already, you have spares so lets get it done. free tonite? I may have a few hours to spare. bring your shat.:drive:

 

[WFO Speedracer]

Its called a harmonic balancer puller,all good parts houses have them,should be less than $20.00.On that engine you have to find a bolt or small socket that fits inside the flywheel or inside the crankshaft threads and sticks up for the puller shaft to push against.I would also recommend heating the flywheel hub with a prop and torch,don't get carried away here or you will ruin the crank seal,stator or flywheel.What you do is thread three bolts into the flywheel and through the puller,not too far or you will rape the stator.Put pressure on the center bolt with an impact if you have one,if not use a wrench and a rubber or dead blow mallet.Now heat the hub of the flywheel only with the torch.Take a ball peen hammer and rap the end of the center puller bolt with it,re tighten the puller bolt if necessary.At this point it should come off with a loud pop,if not repeat the above steps till it does.If you do not feel comfortable doing this take it to TOM and get him to do it for you.

 

[aranka]

soak the bendix in atf for at least 24 hours preferably 48 so it stays nice and loose.

 

[Vumad]

What is ATF?

I'm going to bring it to Tom. I'm going to clean it up 1st and paint it with rustolium (lets take a vote on what color! I'm thinking blue and silver :bigok. It's not so much that I don't want to pay Tom, as much as I want to do everything myself. I'm going to do like 95% of the work and then have Tom inspect everything when I'm done.

BTW, Here's the pics of the flywheel out of my other (blown up) engine. That's why i want to change them out.

 

[WFO Speedracer]

Automatic transmission fluid.

 

[shawn_NJ]

Test the stator resistance, it might be fine and you can just run the motor. Its a kawi 650, you could probably run it on everclear and tcw3. They dont die easily......lol I would test the stator and then slap it in the ski.

Colors change by year and model:

Charging coil: (brown wires on sx, I believe)
Yellow to yellow: 1.5-2.3Ω
Yellow to black(ground): 0.7-1.3Ω

Exciter coil:
Purple to Black(ground): 250-380Ω

 

[Vumad]

Trying to prep the engine for paint using a hand powered wire brush got old pretty fast. I abondond the project for now. I don't want to go buy any more wire brush attachments for the drill, so I'm stuck waiting on my dad to get home from vacation (today!) so I can make him find my shiet he hid.

So I started prepping the ski to be useable. I didn't spend much time cleaning off the grime since that's not a concern right now. I pulled everything off, then replaced a few broken things. It's great to have parts in inventory!! I don't have any good throttle or trim cables. Not worried about trim right now but will need a throttle cable.

Check out that risen seat. That bad boy is COMFY!!!

 

[Vumad]

I did some more work today. A lot of what I spend my time doing is pulling, preping and cleaning parts. You know my accusteer is sexie. My Ocean Pro bed plate is sexie too. I set up my bars and swaped out a few more broken parts. Going to use the throttle cable from the SX. I started taking the electronics off my ski to get them moved over. I want to go with a set up like Chris was doing on his superjet project instead of the stock laynard... Chris, where did you get your stuff? uppy_dog_eyes: I'm going to be rolling with stock for now.

My dad found where he hid my brushes, so I got started on cleaning up the engine and the pipe. The pipe is nasty! but she has potential.

My camera sucks. Sometimes the color doesn't work.

1 - updated ski
2&3 - pipe b4 and after
4&5 - Motor b4 and after
Lots more to do!

 

[Vumad]

Can someone tell me which intake manifold I should plan on using? I'll be running a stock engine with a 44mm Mikuni Carb and a westcoast pipe. Reads are not stock if that matters.

The plain silver one has only number written on it. It is the intake off my old engine that my 44 mikuni was on. This one seams like it might be bored bigger but that may just be an illusion.

The one with the blue conversion on it had a keihin on it. The conversion would be removed to put the Mikuni on it. It says "Extreme Thrust" on it.

They both look the same to me, except the huge spikes obviously. Otherwise, they appear to be the same inside and out.

Also got some more prepage on the engine. Right now I'm leaning towards painting the head and pipe gloss silver, and the block and manifolds gloss black. Or the head and manifolds blue, with silver exhaust and black block? Maybe all silver, but then it'd show more grime. meh... not important.

 

[Vumad]

Grandma, "When did you get a new engine?"
Me, "I didn't get a new engine, this is the same engine"
Grandma, "Oh, wow, I thought you bought a new one"

:wiggle:

The block is preped to be painted. I am tired and I didn't want to rush the 1st coat of paint. Tomorrow the block should be gloss black. :headbang: I hope the paint lasts. I spent a lot of time on it. The only way you could do a better job is to sand blast it.

Also a picture of my arsonal of wire brushes. They are all old from home depot. I did need one smaller brush (like the one on the drill) so I bought it from lowes. What a POS. Don't buy wire brushes from lowes. I broke it in 10 mins. They took it back and acted like they were doing me a favor accepting back their POS brush. I went up to home depot and got their brush, and the home depot brush got the job done.

I still need to know where Chris bought his electronics.
I still need to know which intake manifold I should use so I can prep it.
Thanks.