SXR1500 freestyle build

[Quinc]

Going to take 2" off the back and rocker the nose. just kidding!

Swapping my zxi1100 guts into one. Engine has all the normal mods, dry pipe, shaved head, cleaned up ports etc. Pump has a Solas concord impeller.



Threads are deeper on the sxr than the zxi so went up a size on the motor mount bolts:



Coupler swapped onto sxr driveshaft:


zxi runs hot so water fitting drilled out a size bigger.


Lots of fittings in the pump area! Had to blow air through each one to see where it went. Thinking the sxr comes with dual cooling from factory?


Every thread gets chased and every bolt gets cleaned as well.


New gas tank came in the mail today!


Need to figure out how I am going to do the fuel pick ups still. Any suggestions?


Hood hooks came today in mail as well and are now installed!


Anyone know which end of the steering cable goes toward the pump?

 

[Quinc]

First major issue is I cant make this bend without kinking the hose (used a hose that had a bend in it as well. Anyone know if they make a 90 degree press in fitting or hopefully I can remove it and tap it for 1/4" npt fitting.



Pole mount and hooks installed!





Anyone have a pole bolt for sale? I think a sxr 800 bolt will also fit. And also need a hood latch and to figure out a throttle cable.

 

[Kohldanielzimmer]

Major attention grabbing title.

If you can’t use a 90 degree push in fitting you could use a very short piece of hose and use SS oetiker clamps to attach a 90.

Very fancy would be some stainless steel tubing with a bender and flaring tool.

 

[Kohldanielzimmer]

Long side of cable collar at pump for Yamaha as I recall. No experience with the 4 stroke kawasakis though.

 

[Sparkplug]

You can put a wire in the tube to hold the bend, drop it in boiling water. Wait a couple minutes. Drop it in ice water. And it should freeze into the bend.

 

[WFO Speedracer]

Going to take 2" off the back and rocker the nose. just kidding!

Swapping my zxi1100 guts into one. Engine has all the normal mods, dry pipe, shaved head, cleaned up ports etc. Pump has a Solas concord impeller.



Threads are deeper on the sxr than the zxi so went up a size on the motor mount bolts:
View attachment 438740


Coupler swapped onto sxr driveshaft:
View attachment 438741

zxi runs hot so water fitting drilled out a size bigger.
View attachment 438739

Lots of fittings in the pump area! Had to blow air through each one to see where it went. Thinking the sxr comes with dual cooling from factory?
View attachment 438743

Every thread gets chased and every bolt gets cleaned as well.
View attachment 438738

New gas tank came in the mail today!
View attachment 438745

Need to figure out how I am going to do the fuel pick ups still. Any suggestions?
View attachment 438744

Hood hooks came today in mail as well and are now installed!
View attachment 438746

Anyone know which end of the steering cable goes toward the pump?
View attachment 438742

On the 3D and other DI conversions you can use a flat aluminum plate and use the stock gasket for a template to drill the holes , then mount bulkhead fittings in the aluminum plate with drop tubes or you can do it like this one on Dans 3D conversion on PWCT.

Dan used a stock seadoo pickup on his and welded an aluminum tube to the plate, those stock seadoo pickups are quite plentiful if the length will work, if they are too long they can also easily be cut off to length, give me a length from the top of the tank to the bottom and I can check the length for you. Yamaha also uses a similar pickup system on the GP -XLT 800-1200's that can be modified to length as well.

 

[JC-SuperJet]

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[Quinc]

Major attention grabbing title.

When I first got into the jetski scene the build threads where all sxr's and superjets being chopped up for freestyle.

Good news the 1/4" npt tap fits perfect and I now have a 1/2" 90 degree fitting. =)

@WFO Speedracer Do you have a recommendations on a small start/stop switch? Leaning toward a Yamaha switch now but if there is something better?

 

[hornedogg79]

Nice! I helping out a friend with one of these sxr1500/1100 builds right now. Just finished building him a motor. He was asking me what all the cooling lines were for. Haha I see what he was talking about now.

 

[bird]

I just wanted to say, this a great idea for a build. Good luck

 

[WFO Speedracer]

When I first got into the jetski scene the build threads where all sxr's and superjets being chopped up for freestyle.

Good news the 1/4" npt tap fits perfect and I now have a 1/2" 90 degree fitting. =)

@WFO Speedracer Do you have a recommendations on a small start/stop switch? Leaning toward a Yamaha switch now but if there is something better?

I am partial to the Kawi style switch that uses a lanyard, they rarely fail

 

[Quinc]

On the 3D and other DI conversions you can use a flat aluminum plate and use the stock gasket for a template to drill the holes , then mount bulkhead fittings in the aluminum plate with drop tubes or you can do it like this one on Dans 3D conversion on PWCT.

Dan used a stock seadoo pickup on his and welded an aluminum tube to the plate, those stock seadoo pickups are quite plentiful if the length will work, if they are too long they can also easily be cut off to length, give me a length from the top of the tank to the bottom and I can check the length for you. Yamaha also uses a similar pickup system on the GP -XLT 800-1200's that can be modified to length as well.

10.25"

 

[Quinc]

Nice! I helping out a friend with one of these sxr1500/1100 builds right now. Just finished building him a motor. He was asking me what all the cooling lines were for. Haha I see what he was talking about now.

That engine looks like you are going to have a 70mph ski.

 

[Quinc]

Any guesses on what thread pitch the steering cable is.. 6mm x .9 pitch! First time seeing that pitch. Going to drill and tap the ball joint to fit. But all I have is taps for 1 and .75 pitch..

Pump is installed! thru-hull bearing and driveshaft are installed. And wow did kawa get it right when it comes to the pump. Simple and easy. Got the engine set in and it did not come near as close as I was hoping for. So have some riv-nuts coming in in the mail.

 

[smokeysevin]

Big fan of the kawasaki 4 stroke driveline setup. Its super simple to install and align and it just works even at 400+ hp.

On the pump, what made you use the zxi setup vs the stx style 148mm or stock sxr pump? The cooling outlets on the newer pumps are a better design imo.

Sean

 

[Quinc]

Big fan of the kawasaki 4 stroke driveline setup. Its super simple to install and align and it just works even at 400+ hp.

On the pump, what made you use the zxi setup vs the stx style 148mm or stock sxr pump? The cooling outlets on the newer pumps are a better design imo.

Sean

4stroke is great right up until you have to pull it out and rebuild it. ZXI pump is also 148 and bolted right up. Plus I already had it. I agree the new pump setups look much improved and better for keeping sand out.

4

 

[WFO Speedracer]

I didn't have a Seadoo pickup to measure but then it occurred to me I didn't need one I have a tank, so the distance from the tank bottom to the top of the neck is 10 1/4", I also had a Yamaha early model 800-1200 pickup out, it measures 14 1/2" but on either you can easily cut it off to whatever length you want it .

The cool thing about the Yamaha pickup is the tubes at the top are at 90 degrees if you are tight on space or need the 90 degree bends to make for a cleaner installation.

 

[WFO Speedracer]

I also saw this interesting looking pickup on Facebook today he did not say what ski it was off of, he said Yamaha but it looks like a Kawi SXR 800 pickup to me, that being said something like this wouldn't be a bad choice either. The Facebook link is below.

That second pickup is off of an STS or a Sea couch, you can drill and tap those for fittings or for a stainless steel brake line and make them whatever length you want, I have also pressed old steering cable pieces into them before with great success.

The third one is off of a ZXI 750-1100 and it also has the petcock integral to the pickup, you have a lot of options.

The second two pics are off of Ebay listings but hit me up before you go buying anything , I may have what you need laying around here already.

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[Quinc]

Good to know! I need to figure out how to get the zxi pick up out and see if its usable. Also considering the ADA fuel pickup.

 

[WFO Speedracer]

Good to know! I need to figure out how to get the zxi pick up out and see if its usable. Also considering the ADA fuel pickup.
View attachment 438825

Going to take 2" off the back and rocker the nose. just kidding!

Swapping my zxi1100 guts into one. Engine has all the normal mods, dry pipe, shaved head, cleaned up ports etc. Pump has a Solas concord impeller.



Threads are deeper on the sxr than the zxi so went up a size on the motor mount bolts:
View attachment 438740


Coupler swapped onto sxr driveshaft:
View attachment 438741

zxi runs hot so water fitting drilled out a size bigger.
View attachment 438739

Lots of fittings in the pump area! Had to blow air through each one to see where it went. Thinking the sxr comes with dual cooling from factory?
View attachment 438743

Every thread gets chased and every bolt gets cleaned as well.
View attachment 438738

New gas tank came in the mail today!
View attachment 438745

Need to figure out how I am going to do the fuel pick ups still. Any suggestions?
View attachment 438744

Hood hooks came today in mail as well and are now installed!
View attachment 438746

Anyone know which end of the steering cable goes toward the pump?
View attachment 438742

What's the size of the hole in the tank, outside to outside on opposing bolts and maybe add a little wiggle room at least 1/4 to 1/2 inch. There are a bunch of Aluminum disc on Ebay fairly cheap, 1/8 " thickness should do nicely.