650 SJ budget build and defoam

[jetski9010]

My friend picked up a 1990 650 SJ thats is bone stock in overall in good shape. He has never rode a stand up before but I wanted to make sure he is not going to out grow the ski in a month and be stuck with it the rest of the summer so I am doing some mods to it to at least last him his first year I hope.

Malone footholds
Defoam with no foam
home porting on the 650 motor/cases
shaving stock head
aftermarket pipe
Hooker prop

 

[jetski9010]

more pics

 

[jetski9010]

some pics of pulling the wet foam out

 

[jetski9010]

finished defoaming tonight. Going to get some drains from the hardware store tomorrow then start fiberglassing the tray back together.

 

[jetski9010]

pics

 

[nightrider05]

Great progress! Your buddy is lucky to have a friend like you!

 

[jetski9010]

I couldnt find anyone local that had the plugs I was looking for. Everyone packed up their boat supplies for the winter I guess. I ordered some online that should be here in a few days I hope.

 

[jetski9010]

got the motor out today.

 

[SXIPro]

Looking good. Seal that puppy up good at every pipe/fitting/hose, etc. and bond line of course. Also a good time to throw in a bilge pump or two now that you yanked the motor.

 

[jetski9010]

Looking good. Seal that puppy up good at every pipe/fitting/hose, etc. and bond line of course. Also a good time to throw in a bilge pump or two now that you yanked the motor.

Yea going to put a 2nd layer of 5200 on everything before I seal up the back to make sure its all good. I was going to put a bilge in there that way I can also run dual cooling but I am trying to figure out if its worth it to spend his money on a bildge setup or put the money into other mods first.

 

[jetski9010]

started pulling the motor apart. Cylinders look good. piston wash on the front cylinder looked a little weak but over all the engine looks like its in good shape. Got the flywheel and head ready to send out to be shaved down.

 

[jetski9010]

more motor pics

 

[jetski9010]

just got the pro tec pipe in today.

 

[jetski9010]

Pics before porting. Also starting filling the cases with epoxy.

 

[jetski9010]

tray glassed back together and footholds installed. Also installed the drain plugs.

 

[jetski9010]

pics of the porting in progress. I got the one exhaust port done I still need to polish it. Going to do the other exhaust port then match the transfers then going to move on to the cases.

 

[jap7t8]

pics of the porting in progress. I got the one exhaust port done I still need to polish it. Going to do the other exhaust port then match the transfers then going to move on to the cases.

Dumb question...is "porting" simply making the ports larger or what?

 

[jetski9010]

Dumb question...is "porting" simply making the ports larger or what?

In a way yes but there is a lot more to it then that. I real port job will factor in everything about the motor like what time which port opens and for how long and how much air gets in and were that air is directed. Doing all of that is a black art skill that very few are good and doing. What I am doing here is just called "home porting". If you want to learn more about it check this out. http://www.x-h2o.com/threads/1540&highlight=home+porting

 

[jetski9010]

Did some work on the pump today. Setup for dual cooling and installed hooker prop.

 

[jetski9010]

ported the cases tonight