New to me squarenose

[lcgordon]

Hey guys just picked up a mostly stock 92 650 superjet. I rode a bunch in high school and college but have not rode at all since moving away about 8 years ago. I actually still have a 91 back home. Pretty pumped on this ski I’m pretty sure it’s a good deal for my area. It came with a decent trailer all for 1500 bucks. I rode the ski on the way home the other night and it ran great and was a lot of fun.

Couple problems somebody put long bolts in that hold the exhaust mount to the head which caused the exhaust to rattle and brake the bolts and mess up the holes bad. I ordered a used head, new oem gasket and oem bolts for 90 bucks so I will change that out.

Also which is a bigger problem the intake grate broke 3 of the bolts off. One in the front is good and one is broke off in the ski. I tried everything I could but could not get it to budge. I got most of it drilled out to the insert. I’m going to try to get the rest out up to the insert and epoxy another insert in there. On the back one is broke off in the pump shoe and enough is sticking out I think I can slit it with a dremel and get it out hopefully. The other side broke out some of the plastic so I think I’m gonna epoxy a nut in there. My goal is to run a stock intake grate so it has less force than a top loader. Maybe over the winter I would replace the pump shoe so I could have 3 good bolts and 1 insert in the front.

Anyways here are some pics

 

[bored&stroked]

stock head, oem intake grate. I don't like this build thread lol

 

[kevbo]

You have a good starting point. I know this is foreign to the jetski crowd but first, fix everything that is broken! From there you can upgrade everything incrementally, that is if you want to stick with the hobby.

 

[WFO Speedracer]

Yep everyone does not have 30 G's laying around to put in a freestyle ski and if they did they couldn't ride it to its potential , I know I fit in that catagory.

 

[lcgordon]

Yeah my thought is as some point find a 701. That would be the best bang for my buck right now. Just trying to get it out on the water right now. Who knows how much I will stick with it. I’m a big moto and mtb guy so time is and money are a bit limited.

My plan is get the exhaust to not fall off. Fix the intake grate if I can. If I can’t then I will have to wait until winter to do a new pump shoe and figure out the front hole issue.

I would like to put on some new bars,grips and throttle.

Also I bought back in the day some yellow sano old school yellow turf that I may put on this ski. Would yellow look okay? I think it matches some of the stickers.

The thing runs just like my 650 sn back home from what I remember. Man the oem turf is slick though.

 

[lcgordon]

I am going to have to replace the pump shoe. It is not worth fixing. It is all cracked and one insert has a stuck bolt and the other is gone.

I did manage to get the front bolt out of the intake grate. But the insert is ruined. I will need to epoxy a new one in there. Would 5200 work good for epoxy?

 

[kevbo]

5200 is more of a sealant. You need to remove the bad inserts and fill that area with a thickened epoxy. Then tap and install new threaded inserts, glue them in by adding a little epoxy on the threads. The pump shoe will be more tedious since the old one is harder to remove and the new one will need to be aligned to the pump if you want the stock seal to work. The mid shaft needs to be removed and cleaned/inspected, it probably needs a bearing and seal. Clean the through hull driveshaft cavity and make sure the splines are perfectly clean and greased before assembly.

 

[lcgordon]

5200 is more of a sealant. You need to remove the bad inserts and fill that area with a thickened epoxy. Then tap and install new threaded inserts, glue them in by adding a little epoxy on the threads. The pump shoe will be more tedious since the old one is harder to remove and the new one will need to be aligned to the pump if you want the stock seal to work. The mid shaft needs to be removed and cleaned/inspected, it probably needs a bearing and seal. Clean the through hull driveshaft cavity and make sure the splines are perfectly clean and greased before assembly.

Thanks for the write up. I think the only way to get the insert out is to go in through the tray. It is way up in there so I’m just going to epoxy an insert up against it. It’s only 1 hole.

Yeah the pump shoe is some more work. I don’t fully understand the lining I up the the pump. Don’t you just get the old one out clean up the sealant then reseal? Guess I need to watch more videos and do more read ups. Not fully sure what the mid shaft cleaning and all that has to do with it. Or is it just because you have to pull the pump out that you might as well do all that?

What is a good epoxy to use?

 

[WFO Speedracer]

Basically you lightly bolt the pump on, with the midshaft off you look to see how centered the driveshaft is coming through the hole, shim it till you get it centered properly then install the midshaft, the midshaft should slide right onto the driveshaft , if it doesn't then you do not have it lined up correctly

 

[lcgordon]

Cool I got ya. Is this before you put sealant on the pump shoe or after but before it dries?

I will do more research on it I really only figured out last night I need to do it.

Thanks for the info guys

 

[WFO Speedracer]

I would dry fit the shoe and pump then see where you are at on alignment

 

[lcgordon]

I would dry fit the shoe and pump then see where you are at on alignment

Thanks good idea. The shoe bolts to the hull so I would not think you would get much movement. But you may need to re shim the pump if the shoe is not built exactly the same as stock

 

[kevbo]

The midshaft seals leak and the bearing will rust. Plus dirt always gets on the splines when the pump is removed. Ever wonder why so many riders have midshaft problems?

 

[lcgordon]

I will take a look at it all when I do it this winter

 

[mikidymac]

As much as everyone talks crap about the 650 they are still stupid fun. I bought a stock one for my son and yes it’s slow but it’s still a blast to just go out and have fun on.

 

[lcgordon]

They are super fun. Way better than a 650sx. Atleast in my opinion.

 

[lcgordon]

How much of this do I need to get off. Already hit it with a wire wheel to get turf I could not scrap off. I think the glue would stick to it after a bit of clean up.

 

[kevbo]

They are super fun. Way better than a 650sx. Atleast in my opinion.

I just rode a square nose and a 650sx last weekend. The Superjet is a lot easier to ride. The Kawasaki got better with ride time, it requires you to lean first then turn the bars.

 

[lcgordon]

I just rode a square nose and a 650sx last weekend. The Superjet is a lot easier to ride. The Kawasaki got better with ride time, it requires you to lean first then turn the bars.

Yeah my first ski was a 650sx and my second ski was a 650 superjet. I liked the superjet a lot better.

 

[lcgordon]

I have started the process. When I get back I. Town I will glass it up. I am really leaning toward defoaming this winter but who knows we will see.