Trade Great Story for 550 Help

So here's the story: It's a little long if you want to skip to the help part

When I was a kid my dad had this awesome 550 with every aftermarket part available on it. Bored all aluminum engine and shaved head, aftermarket exhaust and waterbox, 440 crank, ported, etc. Thing was the fastest jet ski on the local lake and everyone talked about it, even had it custom painted by a body shop with the family business name on it. It was awesome and I wanted to ride it in the worst way but a couple years before I could get a boat license he decided to sell it which I was unhappy about but eventually forgot all about it.

Flash forward about 10 years and I'm seventeen going to a friends graduation party on their family farm. This farm is about an hours drive from my house in the middle of nowhere. During the party, while everyone's hangin out in a clubhouse made of hay, I decided to go exploring through the barn. I get to the lower, underground level and see an old makeshift plywood trailer sitting in the middle of the room. I walked up to it and sitting inside it was none other than my dads motherf***ing jet ski. Once I cleaned myself up from crapping my pants I went to my friend and made them take me too its owner, her uncle. He told me it had been sitting there for years and he was the third owner since my dad. I told him I'd buy it at any cost but he had that farmer mentality of never letting anything go even if its junk. But eventually after 2 years of back and forth with the guy he agreed to sell it, so I bought it for $375.

I took it home, cleaned the gas tank and lines, rebuilt the carb, jerry rigged the hell out of the starter and after 7+ years of that thing sitting in the bottom of a barn it started right up. I was super excited and rode it every day all summer only having to fix a few minor things

The Help: So the end of the season comes around and I'm out riding when the boat commission stops me. They couldn't see the registration sticker but it was all good. I had shut the ski off and now all of a sudden it wouldn't start, no amount of cranking in the world would even make it fire. So the boat commission towed me back to the launch where I loaded it up and went home. Bought a manual and did every test in the book and couldn't find anything wrong so I figured bad seals, time for a rebuild anyway. So I tore it apart, cleaned and inspected everything and put it back together with all new pistons, rings, seals, etc. Still wouldn't start. I got it to fire a handful of times and actually blew up the waterbox when it loaded with fuel and fired. Now it's been sitting for two years and I'm ashamed to look at it.

To get to the point, I'm looking for a 550 expert in the New England area. I don't want to fiddle with it anymore, I want to take it to someone who's fixed innumerable amounts of these skis and can figure it out and tune it. I live in Northeastern Pennsylvania and am willing to drive it a good ways to the right person. Any help would be much appreciated, Thanks
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Quinc

Buy a Superjet
Location
California
Do you have spark?
-Is the ground hooked up?
- Do you have spark in both cylinders
-is the stop/start switch broken and the stop switch is stuck?

If you pull the plugs are they wet with fuel?
- what happens if you put an oz of fuel down the carb?
What is your compression in each cylinder?

Blowing up the waterbox has me thinking you need to rebuild the carb. @Rdrttoy has the best price on kits.
 
Checked all that, everything seems in order. The water box blew while I was dumping little bits of fuel in the carb. It made me think it was a timing issue but I've tried every bit of timing adjustment and got nothing. Compression was around 120 when it stopped running and is now about 180, that's before it even gets broken in so big difference there


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Rushford_Ripper

Site Supporter
Location
New York
Try cranking with the throttle wide open? I had one with a high compression head, it would flood out and that's how I got mine to start, after that it would be fine with a crack of the throttle.
 
I've tried that, can't get anything to work. Lookin for someone who knows these skis inside and out that I could take it to


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Location
ND
Have you tested the stator? I know a bad stator caused similar problems for me on one of my 550s.
 
Do you have spark?
-Is the ground hooked up?
- Do you have spark in both cylinders
-is the stop/start switch broken and the stop switch is stuck?

If you pull the plugs are they wet with fuel?
- what happens if you put an oz of fuel down the carb?
What is your compression in each cylinder?

Blowing up the waterbox has me thinking you need to rebuild the carb. @Rdrttoy has the best price on kits.

Answer all of these questions with detail. im sure we can get it to start.
 
Location
Wisconsin
My first ski was a 550 and I had a similar issue that you're experiencing. I shut down my ski to take a break in the middle of a lake with others and it would not start back up. The only way we were able to get it to run was off the primer. I think I had a round body mikuni 44 on it at the time.. Eventually I got so pissed at the machine that I just decided to switch the carb with an SBN 44 and it ran finally. Hated that ski, nothing but issues. I probably could have rebuilt the BN44 and ran it, but I opted to just throw a SBN44 on it instead because I read they were easier to tune at the time.
 
So I took it back out today, here's a list of mods that I know of:
RRacing exhaust
Mariner Waterbox
LS (?) exhaust manifold
Oclan Pro aluminum head, milled
Pro ss-al aluminum jug bored 50 over
rev limit delete
lightened flywheel
choke delete with primer added
Early model lower end with circle crankshaft
I believe the carb is 44mm Mikuni

I ran every test in the book and everything passed
Plugs are NGK BR8ES with .31 gap (in spec)
Compression- 150psi each
Ignition coil secondary winding- 5.26k ohm (in spec)
Exciter coil- 143.5 ohm (in spec)
Pulser coil- 17 ohm (in spec)
Carb's been freshly cleaned and rebuilt, and everything's in working order.
The pulser and exciter coils have both been replaced
Stop switch can be easily disconnected and that didnt help
Both plugs have spark but not sure if it's exceptionally good spark, I don't have a proper tester
The stator plate was adjusted all the way to one side when it ran before and I've tried adjusting it every which way in small increments to try to make it fire but nothing works

I don't believe it's a fuel issue because I can't get it to fire even once using the primer or pouring gas in the carb or cylinders.
When I rebuilt it I replaced the crank seals but the manual was pretty ambiguous about which way the rear seal go in so I was never sure if it was right so I disconnected the crankcase hose that runs the fuel pump and put my finger over it. I barely felt any pressure. So I pulled the motor, took the rear cover off that holds the seals and sure enough it was backwards so I popped the seal out, flipped it around and put everything back together. Now I had lots of pressure at the fuel pump hose and was sure it would start but still nothing. The most aggravating part is that it doesn't make any damn sense, something should happen, it should fire at least once in a while. The only possibilities I can see now are either the crank seal got damaged being in the wrong way or by removing it, or somehow the exciter or pulser coil is in backwards which I'm not sure is possible. At this point I'm just looking for someone who really knows these things that might be able to do something.

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This is the front seal, installed properlyIMG_3962.JPG
This is the rear seals, the inner one is installed backwardsIMG_3963.JPG
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This is where the timing was when I got the ski, you can see the marks on top and it's adjusted all the wayIMG_3955.JPG
This is about average timing I believe but still nothingIMG_3952.JPG
 
I'm not very familiar with how Kawi does their electrics but typically...at least on every engine I have ever worked on...the primary winding is the one or two small 14 gauge wires that go into the coil from the opposite side of the high tension leads. There needs to be a primary winding underneath of the secondary to build the needed voltage for the plugs. The primary should measure virtually 0-0.3 ohms max as a rule of thumb. Anything above that and the primary is most likely burnt out.
 
I am also a little concerned with how those two ground wires look. It appears that they have been kinked, you may want to test them for continuity while bending them in different directions. This will test them for broken wires internally if they conduct with no or low resistance and suddenly stop conducting or create resistance spikes. The starter lead looks a little on the "ready to be replaced" side too :D
 
The ground is a good idea, I'll definitely check that out. I'll look into the coil too, here's a pic of a spare e-box I have, not the one in the skiIMG_3943.JPG
 
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