Super Jet The Square Nosed Time (& $) Vampire. My first Superjet

[BRANDO6X]

Hey there! I'm Jeff and I (like I assume most of you) have been sucked into the awesome world of spending too much time & money on your Superjet (or other standup)

I will start with some story leading up to this time and money vampire I call my SN build... also sorry if my tenses get all messed I have been doing this build for a while now but have only now got around to posting a thread.

I have always been a snowmobile and dirt bike guy...snowcross, enduros, harescrambles... then after my girlfriend and I finished school we moved to Northern MN (from Canada) for a job where we get to work with a lot of awesome people with similar interests to ours. Amongst these people there were two distinct groups, the dirt bike guys... and the standup guys...

I soon had great friends in both groups, but I had been into dirt bikes a long time and had only rode a ski once before so with the shock of not being a student and actually making money I bought a new dirt bike. I told my standup friends I had made my choice and would not buy a ski in the foreseeable future... Soon after this I went out riding with some of the standup group and got to ride some superjets (no mods), 550's and 750's and of course it was way better than I had remembered...and now I want to be in both groups...preferably on a superjet.

At this time I am in need of a vehicle so I surely cannot be spending any more money on a superjet... well while I was at the bank getting a loan to buy a truck I ask if I could get a bit more added on so I could pick up a Superjet... and BOOM superjet mod fever was in it's incubation period...

I planed out my adventure to get a truck and superjet in one trip (it is a long drive to civilization)

The steps I required to catch the Superjet mod fever:

1. Head 5 hours south to Minneapolis to pick up my first truck (small car with a box)

2. Drive a bit longer and meet a guy at a lake to test ride a SN 701 superjet with a B pipe



3. Enjoy the difference that a b pipe makes, pay the man and shove superjet into newly bought truck, head north



4. Ride superjet and at lake with friends, enjoy having the most powerful ski in the group



5. Over load a trailer with skis and head to 2014 Sortie (lake city, MN) and have an awesome time



6. After riding some moded skis at Sortie, realize how badly you need to mod the Sh#t of your superjet

7. Choose box full of exhaust parts at Sortie as a prize for a draw without knowing a thing about it. (Turned out to be a NYNJA exhaust manifold and header pipe with all hardware)

8. MOST IMPORTANT STEP : Underestimate the powerfully awesome feeling of planning your awesome build and ordering too many new parts, then proceed to dig yourself a very deep modification hole that you must buy your way out of to have a running superjet

9. Become friends with @Parsonsjb88 and @plaidward and start builds together and constantly push each other into spending more time and money to be the best of the 3. ( I am the only one who doesnt have 62T cases)

...and there ya go, thats my story... sorry it has not gotten to any actual building yet... I have had a few of these (I'm not a real bad ass... there is ginger ale in there too)




OK! so I started with this 93 SN Superjet Well that is what the registration says, inside the hull someone wrote 92 hull in marker, anyway short list of mods it had when I bought it:
- 61X/61X 701
- B-pipe (I think limited)
- Footholds
- AM flame arrestor
- SS prop (unknown make or pitch)
- D cut ride plate
- Dual bilges that are plumbed to the hood latch area at asymmetrical angles (we called it crazy eyes)
- Dual cooling
- AM bars and grips
- Mega poopy turf job
- Super wet foam (I find out later)
- Hull cracks (likely from flat landing too much at Sortie)

THE BUILD PART (Explained as I was thinking about it at the time)

So this is what I was thinking come winter after riding the ski as I bought it for the summer, "I like this ski and I don't want to go too crazy with hull mods or I wont finish it for summer"

So at I decided to focus on rebuilding and modding the engine with minimal hull work (Just patch up the crack I found, and maybe some turf) so I can actually see how much a difference just the engine mods will make.

Mods I had planned on doing for sure at the start of winter:

- Bore to 82mm (718cc)
- Widen exhaust ports and clean up transfers & boost
- ADA High comp girdled head with 35cc domes
- New plug wires and boots
- Port & match cases
- Port & match Intake & exhaust manifolds
- Port & match Header Pipe
- Get C4 chamber
- Lighten flywheel
- Remove limiter
- Powder coat most engine components
- New flame arrestor
- Rebuild carb
- Patch hull
- Re-turf

That is about all I had planned, So I started with yanking out the motor



This Is when I noticed the crack in the side wall just bellow the black ID sticker (nothing too serious) and also that the pounding this thing received at Sortie tore the engine mount rubber right off the metal casting on the right rear mount



Having never pulled one of these apart before, I made sure to keep close track of all the mounting locations and hose locations etc, not knowing that I will be changing pretty much everything later on...

 

[BRANDO6X]

So now that the engine was out, I pulled it apart to see what is inside, I remember taking waaayy more pictures of the tear down & everything for that matter... but apparently not

You can see the home made flywheel puller that @Parsonsjb88 made late at night in a hurry on the right and you can also see how rich I must have been running... pistons had almost no carbon on them




Everything seemed to be in order except that some of the bearing pins were pushed all the way flat into the case...and someone took a grinder to the cylinder head gasket surface at some point and scratched it all up (no good for o-ring head) Kinda hard to see the scratches in the pictures




I didn't want to deal with the bearing pin situation so I found a cheap set of cases on the X, as for the cylinders I planned on getting the gasket surface fly cut when I get the bore done.

Next Step was to clean up all the parts & bead blast them so they are nice to work with and also so they can be powder coated later.

I shall continue with this past tense present tense mash up of a build thread far far in the future from the point that I was just writing about, which would/will be about 15 hours from now

 

[BRANDO6X]

Ok so I found some more pictures of the tear down. My pistons were real clean, thinking I was running rich.. or maybe a bit too much water ingestion?




I finally got to see the insane port mismatch of the 701



I also noticed that the sacrificial anode was not in place, and half of it was just bellow the mount... but where did the rest go?


I found the screw jammed into the cooling passage coming from the manifold, took a bit of fishing to get it dislodged




Do people often find these anodes busted off? Does every body run them? even in fresh water?

 

[BRANDO6X]

After a crazy amount of time taping up all the important surfaces, I bead blasted most of my engine components and cleaned up surface defects with a grinder

The Nynja head pipe I picked up at Sortie cleaned up pretty well,



Cases were for sure the worst thing to blast... the stock paint was very difficult to remove, and they were too big to fit well in the cabinet. Getting inside the crank area and cylinder water jackets was also challenging, I had to be very careful to not damage the bearing and sealing surfaces









After I had the main engine parts blasted and cleaned up, I had to mock them up to try to get an idea for colors, earlier I started an engine paint thread to get some ideas --> http://www.x-h2o.com/index.php?threads/701-engine-pics.160249/



At this point I still had no idea on colors... nor was I ready to send anything out for painting. I wanted to finish most if not all of the porting I had planned on doing before the painting as I knew I would just mess it all up

 

[Mud-Nut]

Woooo build thread!!!! Subscribed.

Amongst these people there were two distinct groups, the dirt bike guys... and the standup guys...

I miss that group... I guess a good portion of them are gone now, but I'm glad to see stand-ups live on!!

"I like this ski and I don't want to go too crazy with hull mods or I wont finish it for summer"

Good call. I made that mistake.

 

[plaidward]

Good call. I made that mistake.

He didn't follow his own advice, lol, it's all cut up haha. Though it is going back together now.

 

[BRANDO6X]

He didn't follow his own advice, lol, it's all cut up haha. Though it is going back together now.

....correct... I had some major "scope creep"

 

[Mud-Nut]

....correct... I had some major "scope creep"

It happens to all of us.... Post pics!

 

[BRANDO6X]

... I know.. I am slackin hard.. I have a bunch of updates I have to make. I hope this week I can get it caught up to where I am now

 

[BRANDO6X]

OK... I need to catch this thread up to where I am now. Now where was I... I think i was just starting to port.

I started with the intake and exhaust manifolds. I matched the manifolds to the gaskets and widened where I could. I will just post a bunch a pics with some captions.




They both had casting defects and/or ridges that I had to grind away.



I found and broke out a dirty internal flash defect that would have likely caused some cooling problems had it gone unnoticed






I took out as much as I thought safe... I was worried about getting into a jacket. With a small amount of welding I think that there is more to gain with my intake manifold.. maybe next time.










I matched the intake manifold to the gasket, then bolted on the Reed mounting bracket and made a nice transition.

 

[BRANDO6X]

More pics











I wanted to do something about that stupid notch at the split.. but just wanted to get done

 

[BRANDO6X]

Next I moved to the cases.

I couldn't find too many pictures of ported 61x cases so I just did what I felt would work.

Started with digging out some channels for the transfers,











Then marked what I needed to clear for the gasket matching,











The last three pics are pretty much where I ended up for the case porting, I was kinda just rushing to say I am done with the cases. There is a large amount of material I could still remove but I did not want to increase the case volume any more then I already had. I also did not want to change the length of the boost port, but I did widen it to match the cylinder at the top, and widened it more so at the bottom.

If anybody is wondering I did not need to epoxy anything for this porting, the 61x cases seem to have ample thickness for the amount of porting I did. If I was going to need to epoxy anywhere I think the thinnest spot would have to be by the stator area.

Hope it works I am making so many changes at once... I will not know what did what.

 

[BRANDO6X]

Cylinder porting up next... I didn't do too much on the transfers or boost. I didn't even match them all the way to the sleeves, I was worried about controlling the roof angles and staying even. I have never done any porting before so I figured I wouldn't dive in too deep. I spent most of my time widening the exhaust ports using a template @plaidward was using.













Since this last picture I have adjusted and polished the ports, I will post some pictures later.

 

[plaidward]

@yamanube's template

 

[yamanube]

Rad, keep us updated on how it runs.

 

[BRANDO6X]

...I hope it will be rad, and I will keep this updated... after I catch it up... hah it is taking me long enough to do that. It is not looking too good for this summer, running out if time. I want to have it done for sortie sooo bad

 

[yamanube]

Either way, it's worth it to come out for the weekend of the Sortie.

 

[BRANDO6X]

This is very true, I will be there for sure. Just the ski situation that sucks... I started this project way too late knowing sortie would be a hard deadline... So my girlfriend and I bought a X2 just to have something fun to ride... then just a bit ago it crapped out... still have not had time to investigate. Either way ski or no ski we will be there

 

[BRANDO6X]

Ok back to build stuff...

Some pics of carb disassembly and choke removal.

 

[BRANDO6X]

I pulled out the Bendix insert from the cases because it was cracked, I tapped the inside then pulled it out with a bolt





Then went to walmart and bought a bunch of baking soda, to soda blast everything with sensitive surfaces. I used this method to clean the carb interior/exterior, bearing surfaces on the cases, starter and cylinder surfaces. I also cleaned the threads on much of my hardware.