550/650 conversion 93 rear exhaust

air blair · 02-06-2010, 05:16 PM

Hello, I am started on my 550/650 conversion.
I pulled the 550 engine out, took off the coupler to put on the 650 ts engine.
I went to install the 650 and discovered I had to grind the bed plate in a few spots and cut out a hole for the crank drain cause I want to keep it. I sank a ski before
I am waiting on an alum. waterbox and also I need to find a way to mount the throttle cable to the bed plate or something. ANY IDEAS I also was wondering where the best place for a bilge exit is. Bfor I get all the crap in the way.

PrickofMisery · 02-06-2010, 05:38 PM

Are you using a conversion plate? What bed plate are you having to grind on? Use a 650 throttle cable mount for you cable issues.

air blair · 02-07-2010, 10:15 AM

Quote:

Originally Posted by PrickofMisery

Are you using a conversion plate? What bed plate are you having to grind on? Use a 650 throttle cable mount for you cable issues.

yes, I bought a conversion plate http://www.pwctoday.com/f149/im-back...te-258937.html
The plate fit nice and all but I used all the same bolts to mount it back up. I could of used maybe something with a smaller shorter head to bolt to the 650 engine. I had to grind down the plate where the bolts hit on the bed pan. because it was up about a quarter inch and was trying to lift the driveshaft.
I checked the throttle cable from my 650 and it is shorter than the 550 cable so thanks jason. I will switch that out and solve the cable issue, its pretty tight on that side because of the rear exhaust runs right there and one exhaust bracket mounts right where I want to mount the cable mount. I will figure it out and make sure nothing is rubbing on the exhaust. That is the last thing you want is after a few hours it sinks, or bogs right down,
I am enjoying this project, I hope it will be worth it in the end. I took two perfectly running machines and whallah. The engine from the 650 ts was sooooooo clean.

heynagel · 02-09-2010, 10:26 AM

Was the plate mounted to the engine correctly? Is there any possibly that it's on backwards? I only ask because I never had to do any grinding on my 550/650 swap and everything fit quite nicely even with rear exhaust.

mmille_mr2 · 02-09-2010, 11:18 AM

x2

mine was the same way....fit right in

had to grind the exhaust manifold bracket to get the stock pipe to fit in though.

air blair · 02-11-2010, 05:46 PM

I just got my quicksteer and aluminum waterbox today. I tore apart the tandem sport and have it listed on ebay, I kept the start stop switch with lanyard, I may put that on this.
I can start on the installing the box and exhaust, that is def. tight. back to grinding I hear about a 1/4" off the manifold mount.
The pics are hard to take with the engine in, but I snapped what I could.
I need to relocate the bilge exit, I am thinking as high as I can on the exhaust manifold side closest to the tray.

mmille_mr2 · 02-11-2010, 06:03 PM

you will have to grind that part of the exhaust manifold that the stock exhaust bolts onto to get the exhaust in there. Atleast i did.

air blair · 02-22-2010, 12:10 PM

BLRider
Top Dog

Join Date: Apr 2007
Location: SE Michigan
Age: 46
Posts: 1,863

Re: Electrics in a conversion?
Here is how I wired mine and I used Laserman's as a reference. I added a circuit for the bilge inside the box so all electrical connections were protected.
Attached Files

550.650 wiring.pdf (17.2 KB, 20 views)
I found this in an old thread, I think it may help out with the wiring issues, from what I gather they are all a little different. I got spark off of the 650 box but not the 550 box when I hook it up. I will try again and laserman suggests to ground the box off to the engine and battery real good. If I cant figure this electrical out I will either take the 550 cdi out and grind down the mounts and put a 650 cdi in or just take the whole set up to phil. He is a wiz at electrical.

I installed all parts, I swapped out the star/stop on the 550 to a 650ts with lanyard set up, I switched the throttle cable 550sx (too long) with a 650 sx cable. It is a little short but it will work, I may have to set it on top of the gas tank. I will set up my bilge and primer set up after I figure out this electrical set up. I also want to take the pole bolt out and install a my new spring for the long hauls I will put on the ski

BLRider · 02-22-2010, 12:41 PM

My conversion ski had the same throttle location issues. I attached a pic but the bracket is pretty self explanatory.

http://s628.photobucket.com/albums/u...t=DSC01908.jpg

http://s628.photobucket.com/albums/u...t=DSC01903.jpg

This is a pic of my final wiring at the box and it makes engine removal simple.

http://s628.photobucket.com/albums/u...t=IMG_0452.jpg

BLRider · 02-22-2010, 12:55 PM

Here is one of the PJS pipe installed.