New to me 650sx needs work

[Antleo]

I picked up a 91 650sx with many extra parts for cheap, I was told it had an air leak. The ski was pretty rough, but it fired right up every time I tried, so I took it out for a little ride and found that they guy had the throttle cable adjusted way to tight. (his "air leak"). He had obviously tried to adjust the carbs in order to get it to dial back (I got maybe 1/4 throttle out of it and the screw caps where chewed up bad)
So I adjusted them back to the stock settings and though I got better response and higher revs it still didn't rev past maybe 3/8 throttle. So after more fiddling with the screws and blowing apart the exhaust(loud bang, scared the hell out of me. Shut it down, and found it blew apart at the boot) I decided I was going to order a rebuild kit among other things. So now I have a carb rebuild kit on the way, a proper throttle lever to replace the bicycle brake lever that didn't give full throttle, a full Gasket set, fuel line and clamps, new plugs and boots (I have 2 coils and 1 the wires are to short to mount it properly but the other doesn't have boots) and will be properly mounting the electronics. Also in the order are a bunch of waterproof bullet connectors to replace the corroded ones that are in this e box.

It also didn't want to suck any water out. Today I found the bailer tube wasn't attached in the hull, and the screen was clogged solid.

Now I question whether this is even the right e box as it doesn't seem to mount anywhere properly. Any ideas on this(see pictures)

I pulled the motor and gas tank today to clean out the hull and it wasn't good. Rust flakes and dust every where. Of course 3 of the 4 motor mounts broke so I'll have to do the fancy repair to all of them. I have wire wheeled the plate and sprayed it with self etching primer, and will be doing black engine enamel tomorrow. I'll finish cleaning the hull tomorrow and go from there.

 

[Antleo]

I apparently don't know how to post as my pictures ended up in the middle of it all..

 

[Midlake Crisis]

Outside of the hull looks good! The eBox goes next to the fire extinguisher tube on the firewall.

 

[Antleo]

Outside of the hull looks good! The eBox goes next to the fire extinguisher tube on the firewall.

Yea thats where I was trying, but no matter how I spun it I couldnt seem to get it to line up. The exterior is in pretty good shape. Needs a bit of cleaning and the gel coat is cracked in some places but overall very good.

 

[Antleo]

I cleaned the hull up today. Not perfect, but a hell of a lot better. Went from this:


To this:

I painted and baked the engine base plate and the tops of the motor mounts:


I also did the motor mount mod/rebuild:

I also installed a crank case block off plate(don't have pictures) and will be cleaning the motor up, the ski should look and run solid
Now I'm just waiting on packages. Everything should get here this week, but I'll be away. So next weekend I'll update with all the new goodies.

P.S I got the hang of this posting thing, all my photos are in the right spot hahah

 

[Antleo]

Well I got home around 8, found all my packages and got to work: so over the week I got to thinking what if it was cavitation? That would make a ton of sense. So I looked at the pump and sure enough, it was "sealed" with black rtv that had broken away and had holes and cracks. Nice.

I pulled the pump cleaned it up and sealed it proper with silicone.

After that I got to work on the motor. I had a hard time pulling the coupler, but it eventually came with a whole lot of heat and a hammer. Then the seal.. That was fun, any tips to properly get them out? Anyways I got it out and was greeted with a mess of what probably used to be grease, but had dried to a yellow waxy consistency. There is also this inner seal

I have 3 seals in my kit and am yet to pull the other side. Does this inner seal come out or is that not the one in the kit? I have to go rent a puller tomorrow to yank off the flywheel and get at the other seal.

After all that I got the primer kit installed and ready to hook up.


I put boots on the other coil pack


And installed the new lanyard kill switch

And have basically gotten set for tomorrow.

Tomorrow I will have the seals in, the carb rebuilt, the motor in the hull.

After that I'll switch to the electrical side. I got new bullet connectors to replace all the older corroded ones.

I have determined that the e box I have is not for this ski, and will be mounting it on the side, closest to the carb.


Also does anyone know what this is for on my intake manifold?

More to come tomorrow. Hopefully will have it in the water Sunday.