650/X-2 putting together a 650sx from parts.....help.

[TontoM3]

so I took on the challenge of putting together a ski I have never taken apart, because It was free. If anyone has any sort of direction, or help that would be great. I mostly need to know what size bolts go where. I realize this is going to be a large trial and error process since I haven't done it before. but any tips what so ever will be appreciated. also if you are any where near the ozarks in Missouri, help would be reciprocated with beer and pizza.

I guess I should also state that this ski was running before it was taken apart.

so far I have cleaned everything, new gaskets everywhere and carbs have been rebuilt.
also I have blocked off oil pump and purge cable. (crank case block off)
and have bought:
bilge pump & switch
lanyard faceplate
new impeller
have installed footholds


basically I have done everything but put back in the engine, exhaust, water box, gas tank electrical......you know the important stuff.

I will update with what I get put together and what completely bogs my mind.

 

[Snivilous]

So, what is the first question?

 

[550/440]

It's really a little bit like a jigsaw puzzle when you get them that way. How far apart is it - crank out and cases separated? Post up a couple pics, it will help us help you!

 

[jetx]

Get yourself a manual

 

[nez02]

You usually can find them online for free. it will walk you through every step.

 

[97superjet]

I am just finishing up doing the same thing, I am putting together a 750sxi from just different parts in boxes...its a good challenge because like you I don't have anything to look at to reference and have never owned a 750. Trial and error is #1! haha Before painting I mocked up many parts to see what I had, even after paint during assembly before things are bolted down I was mocking up parts to see how things were going to fit and make sure I had everything. This is where I hit the most snags because I found out I was missing random bolts that I didn't know the size and even though a stock ski should go together easy some things fight you along the way. If you buy any bolts from an actual kawi dealer they are going to be expensive for specific bolts, so my advice would be to see what you have (rough fit as many parts as you can before actual paint or assembly) then watch for people parting 650s either on here or PWCtoday and if your missing something or bolts it would be easy (and cheap) to pick up then...good luck and trust me its fun but frustrating at times! I am almost done with my ski and its really rewarding to see close to the final product after about 6 months of learning the 750!

 

[Vumad]

Shooting from the hip... been years on my 650sx

Motor mounts to hull are 10 or 12mm
Bed plate to motor mounts are 14 or 15mm
Bed plate to motor are 12 or 14mm
Ride plate is 10mm
Pump uses allen heads
Battery box and all clips for straps use phillips screws
ebox uses 10mm bolts
Cover for the pole bracket uses phillips screws.
Pole bracket uses hex bolt or allen bolt?
turn plate uses a large like 17mm nut
Through hull bearing is 10 or 12mm bolt
head is 12mm acorn nuts
cylinder to case is 12mm acorn nuts

Sorry, that's the best I got from the hip. I'm not home and I'm not going to go look into all that just for the heck of it. It would be easier to help if you posted a more specific question.

 

[Joker]

Cylinder to case are 14 otherwise vumad I think you got it all right nice dude

 

[TontoM3]

hey guys, will post pictures as soon as I make it back to my 'shop' I know it will help once you guys can see what I am talking about.

I have all of the bolts organized in size and length. so that should help. and Vumad what you just said is already a HUGE help.

as far as how put together everything is so far:

• Engine - block is complete (crank, rods, pistons, rings, reeds manifolds, and carb) as well as the stator, starter and flywheel. I did pull the fly wheel off and inspect the stator for bad coils and and for any wear on the flywheel and Bendix. they all checked out as far as worn/ missing teeth.

---

• Exhaust - this has the stock exhaust and all couplers seem to be accounted for. I inspected the water box for any drilling mods and there are none. it too is the stock water box. the hoses are not cracked and it seems I have one hose left over/ extra after I laid it all out in the hull.

---

• Gas Tank - still intact, all hoses are cracked or look brittle so those will be replaced. the fuel selector looks to be in working order, but we will find out. do I need an external fuel pump?

• Electronics - this is where I am in the dark. I have the whole e-box set up, but is there a way I can test that the connections are good and the wires still carry current without putting it all on? I am assuming no. lol

• hull/body - the hull was actually pretty clean when I got it, I just added foot holds for the (hopeful) riding one day. the engine compartment has been coated with something similar to very light bed liner. not quite sure but it look fresh! the only piece I had to find was a nose piece and I went cheap and bought some guys home made fiber glassed one. it's not pretty but functional. I added a switch for the bilge on the handle bars, and I am waiting on the bracket to see where that goes. oh also the fire extinguisher tube was removed and someone did a really good fiber glass job to remove the ugly cap in the side, cant even tell it was there.

• pump/nozzle - veins look good, had to get a new impeller, the stock one was in there and it was looking a little used to put it nicely. it has a stock nozzle.

• the drive shaft is fine, and anything else I am missing looks to be in OK shape

like I said earlier I have replaced all gaskets and cleaned all bolts and manifolds as well as exhaust from carbon build up. I will post up pictures tomorrow afternoon, thanks all for replying and hopefully the colective knowledge will help when I hit m inevitable speed bump. also sorry if this is a large repeat of my first post I am just excited about this build and want to get everything down on paper first.

 

[TontoM3]

oh and nez and jetx any idea where you can find service manuals? all I can find are owner manuals.

 

[Austin]

Did you check ebay? That is where I got mine.

By the way If you want any aftermarket parts for your 650 let me know. I have a 650sx with everything aftermarket on it, I am looking to part out. I could make you a pretty good deal if you want multiple things

 

[97superjet]

search www.pwctoday.com thats where I got my 750sx/sxi service manual, people buy them then upload them so with some searching you can save a few bucks..

 

[TJR]

Look here
http://www.x-h2o.com/threads/74013-...wners-Guides-–-Wiring-Diagrams-–-Software-etc

and download
Kawasaki Repair Manual JS, JF, JL, JH, JT 550-1100 1992 to 1998.pdf

 

[Vumad]

You can check the electronics with a meter. The book would tell you how. You cannot check the stator or CDI until you hook it up (I think).

 

[TontoM3]

fell behind this week on work, sorry guys. but thanks for all the help so far, I found a service manual, and as soon as the X lets me upload photos, I will. uploader all ways gets stuck, same with photobucket so it could just be my awesome internet.

I am waiting on my waterbox to get here before I start putting everything back together. sit tight!

 

[Snivilous]

Stock waterbox?

 

[Vumad]

Use a program to reduce the size of the image files before you attempt to upload them.

 

[TontoM3]

Yeah I reduced them to uploadable size. I have satellite internet that sometimes has trouble uploading. Should work this after noon though.

Sent from my MB865 using Tapatalk 2

 

[TontoM3]

Ok so I know I never uploaded photos of this thing, and kinda skipped to the end, but I have finished this thing. surprisingly with only 5 large speed bumps. I got bored and worked through the night yesterday, closed work early came home and finished the thing. and now all I need is to trailer it to the water and see if it floats

 

[TontoM3]

oh also I am doing this again in week with another 650, and I will do it properly this time. still getting used to this whole forum thing. that, and my inteernet sucks, so Ill be using my tapatalk on my phone most of the time.