650/X-2 Had to put new engine in my 650SX, not sure about plumbing. Please check my work?

[Scurve]

Wanted to get into stand-up jet ski's. Decided to try the jump in head first approach. Researched as best I could and then bought a ski off craigslist. Figure not worth the stress of trying to find the perfect ski, just start with whatever I find and learn from there. This is what it looked like when I first got it... Noticed the 2 cooling lines coming off the head...

Here's my problem... I had to ditch that engine. It had no compression on one cylinder and I couldn't get the head off due to corrosion (lesson learned. Never buying another engine again without checking compression). Brought to a kawasaki mechanic he couldnt get the thing apart either... (btw if anyones interested in a ocean pro head - corrosion welded to free spinning engine with low compression in one cylinder )

So I found a very very beat up X2 with a good engine and got that in(I know people are probably wondering why I didnt try to save the X2 instead, but it was a basket case. Electrical was fried, severe hull damage). But it's the stock engine with a single cooling line coming off the head. So now I have 2 lines coming off the impeller, 1 line in at the manifold, 1 line off at the head, and 2 pissers?

set up is currently like this (edit: Crap I labeled both lines, "line 2" those are each separate lines coming from the impeller)...


and I'm thinking I'll hook it up like this...


Is there a better way to organize it and utilize the second cooling line?

Thanks!

p.s. Do you need a fuel pump with the 38mm Keihen carb? The carb only has an in and out, no pulse line. Pulse line was blocked off when I got the ski, no fuel pump to be found. I've never run the engine long enough to test how it sucks up fuel X_X

 

[whooiedog]

It will work fine the way its plumbed in the second diagram. If there isnt any remote fuel pump, then yes, you must use the pump on the carb.

 

[Scurve]

Not sure I'm 100% on your answer about the fuel pump/carb. Let me try to re-word it better...

On the ski itself:
No fuel pump; pulse line is blocked off

On the carb:
38mm Keihin. Only 2 ports. 1 for gas in, 1 for what I assume is return line. There's no 3rd pulse line like the 28mm carb. Will the 38mm carb suck gas with just the intake and return line? If so that's awesome... otherwise looks like I have to go hunting for a fuel pump

 

[Moto360]

You got to make sure both lines coming out of the firewall are hooked to the pump. On a OEM 650sx one line out of the firewall is a dump line for the stock pipe. So depending on the second line on the firewall you may over heat the pipe or motor according to your second drawing.

Where you located? I use to live in Onondaga Hill.

 

[Wilke]

You got to make sure both lines coming out of the firewall are hooked to the pump. On a OEM 650sx one line out of the firewall is a dump line for the stock pipe. So depending on the second line on the firewall you may over heat the pipe or motor according to your second drawing.

This. If this is the case you want to run the line from the pump to the exhaust manifold, then from the head to the exhaust head pipe, and then from the head pipe split to the pisser and the pipe stinger.


For the carb, If its a 38mm CDKII it should have a built on fuel pump (i.e. should have three ports - in, return, and pulse) If it doesn't have a pulse hook up something is off (or its a 28mm CDK and needs an external pump), and if the pulse line on the engine is blocked off then something is really off (maybe had been set up with an electric fuel pump?). Can you post a few pictures of the carb setup?

 

[Scurve]

I think I'm gonna need a fuel pump. And looks like the intake line on the manifold is busted. Must have gotten pushed when the pipe went back in?

 

[Scurve]

So I should wire it like this?

 

[Wilke]

Edit... never mind, I re read your original post and option two will work just fine for you. I was thinking the ski was setup single cooled and the new motor was the one pictured, its the other way around, should probably read more closely and not just skim. You should still check to make sure its actually dual cooled and not just hooked to a drainline (i.e. both lines actually hook to fittings on the pump)

The carb you have is a 28mm CDK and it needs an external fuel pump that hooks up to the pulse from the crankcase. If you have the option I would ditch that carb and get a 38mm CDKII with the built in fuel pump, it'll bolt right on your existing manifold (might have to bore out the manifold with a dremel to match the new carb)

In your picture, green is the shipon bilge, blue should be the water inlet from the pump, and red would be the second inlet if its setup for dual cooling (the stock drain line).

 

[Scurve]

Just wanted to say thanks for all the help so far, between that and looking through the forums I'm getting tons of good information!

So I definitely needed a fuel pump for my carb. I got a fuel pump from a TS, and it turned out the engine had a 4 bolt pattern on the side that matches the fuel pump bracket. So the donor X2 must have had a TS engine in it?!

I will let you guys how it goes once I get some water through the lines to see whats pumping.

It may be a while though. I'm currently having to work out with the mechanic what were going to do about the broken intake nozzle. I hired him to swap the engines and try to switch the heads. I found the broken intake nozzle shortly after that. Reviewing pictures I took of when I pulled the engine out of the donor ski that nozzle was definitely intact beforehand < . So I can't wrench on this thing until they decide how much responsibility they want to take for the damage. When he put the pipe back in it must have broke. Do people have to mod the westcoast pipe for clearance so it doesn't smash the intake nozzle?

(anyone wondering why I went to a mechanic after going through all the trouble to re-build one ski and pull an engine out of another... I like to be hands on, but popping off a corrosion welded aftermarket head and trying to put it on another engine was a bit beyond what I felt I could pull off on my first Ski project... so ) that... and I just wanted to actually ride the damn thing at some point instead of blindly wrenching on it for the whole summer.

 

[Wilke]

You don't have to clearance anything to fit the westcoast pipe, but it is quite tight up against that inlet, Like tight eoungh to where you want to put the nut that thightens down the hose clamp on the backside away from the pipe so it doesn't rub. I could see it breaking if the mechanic just jammed the pipe in without noticing how tight it was. If you have pictures showing it wasn't broken beforehand he should definately take ownership of his mistake, and it should be a fairly easy fix for him. He just has to extract the old fitting and screw in a new one - should like 30 mins or less to take the pipe out, remove the manifold, replace the fitting and put it back on.

 

[Scurve]

Update!


Re-did all the lines with clear tubing so I could see what was going on. It did have dual cooling lines! Ran one from intake mani to engine to pissers and other exhaust to pissers.
It's running great so far! Now I need to actually learn how to ride it haha :thinking:

Thanks for everyones input!

PS... what are some good jet-ski friendly lakes in CNY? I'm kind of new to the area and (from Albany) the furthest west I have boated in the past is Raquette Lake. I'm in the Ilion, Little Falls, Herkimer area. It look's the closest lake is Hinckley lake Reservoir?