Kawi stock 650 exhaust mod instructions
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  1. #1
    PWCToday.com Is My Home Away From Home Laserman's Avatar
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    Kawi stock 650 exhaust mod instructions

    Awhile ago CHAD550 gave me some instructions on how to modify the stock 650 exhaust for more power. I did it, and I agree that it is a nice performance boost. So I thought it was worth posting. Here's his instructions:

    650 exhaust mod
    It is worth it it you dont want to get a aftermarket pipe. I gained 400 rpms and better throttle response.

    1. remove or plug the fitting on bottom of pipe that goes to the bulkhead, also plug hose to bulkhead (on 650 hulls) so water wont get in hull.

    2. If you removed the fitting and welded up the hole than use what you cut off and put fitting on the tail cone of the pipe at the water box. If you plugged the hole you will need a piece of tubing to make this fitting.

    3. Drill and tap the top of the head pipe (theres a nice flat boss) and install a 90 degree water fitting. It should point to the fitting you put in tailcone. Then look up in the head pipe, theres a big hole where water gets injected in to the pipe. Fill that hole with JB weld and let dry then next to it drill a 1/8 hole.

    4. Run a hose from fitting on top of head to fitting on tail cone with a tee in the middle. Off of the tee run a hose to a pisser fitting to dump excess water out of hull.

    p.s. when drilling hole in head pipe go easy its a water jacket dont go all the way through


    Because some people like pictures better than words, here is my version:

    [IMG][/IMG]
    1985 JS 550/750 Stand-up: http://www.pwctoday.com/f72/smileys-...50-114680.html
    1984 JS550 TYPHOON 750 conversion: http://www.pwctoday.com/f72/laserman...ct-186297.html
    1992 Sport Cruiser "Sportscar" Conversion: http://www.pwctoday.com/f72/laserman...-a-173049.html
    Here's a helpfull thread on 550\650 conversions: http://www.pwctoday.com/f72/just-ano...on-133898.html

  2. #2
    Frequent Poster chargerman's Avatar
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    Re: Kawi stock 650 exhaust mod instructions

    Nice post Laserman
    Best Regards Chargerman

    My Machine...1988 X2 bored .50 over.....15.5 Skat Trak ..... Mariner exhaust.....Dual Mikuni's on Westcoast manifolds.....Bad Bones reed blocks with stuffers and 2 stage Boysen reeds.....PJS toploader intake grate.....Rule electric bilge pump...Jet Dynamics concave ride plate .. Whats next?


  3. #3
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    Re: Kawi stock 650 exhaust mod instructions

    Quote Originally Posted by chargerman
    Nice post Laserman
    agreed
    Squarenose superjet with a little get up

    Jetworks bigbore, dual 46mm Blackjacks, MSD TL, 205 compression, B pipe mod w/ ECWI, 12/17 Skat Swirl

  4. #4
    Frequent Poster chargerman's Avatar
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    Re: Kawi stock 650 exhaust mod instructions

    I actually did mine a little bit different, through experimentation looking for the best results........I ran "E" straight to the overboard pisser, I still have "C" connected to the bulkhead....I put a 3/8th's"T" where "A" is..with an 1/8th inch fitting feeding down to "D"....I welded "B" shut also, and re-drilled it to 1/8th. My exhaust stays plenty cool, and it made a noticable difference in overall performance. This winter I'm adding an adjustable needle valve where my water feeds to "D", with a thumbwheel on the handlebars and a speedo cable arrangment running to the needle valve so I can adjust water flow to the stinger....on the fly.......just to see if the water amount into the stinger has a real effect on performance.
    Best Regards Chargerman

    My Machine...1988 X2 bored .50 over.....15.5 Skat Trak ..... Mariner exhaust.....Dual Mikuni's on Westcoast manifolds.....Bad Bones reed blocks with stuffers and 2 stage Boysen reeds.....PJS toploader intake grate.....Rule electric bilge pump...Jet Dynamics concave ride plate .. Whats next?


  5. #5
    PWCToday.com Is My Home Away From Home Laserman's Avatar
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    Re: Kawi stock 650 exhaust mod instructions

    I did this on my 550\650 conversion ski, but if you do this on a 650sx it leaves you with the extra hull line you need for dual cooling!

    First time around I used JB Weld on the stinger nipple, and it fell off. So I recommend have it welded.
    1985 JS 550/750 Stand-up: http://www.pwctoday.com/f72/smileys-...50-114680.html
    1984 JS550 TYPHOON 750 conversion: http://www.pwctoday.com/f72/laserman...ct-186297.html
    1992 Sport Cruiser "Sportscar" Conversion: http://www.pwctoday.com/f72/laserman...-a-173049.html
    Here's a helpfull thread on 550\650 conversions: http://www.pwctoday.com/f72/just-ano...on-133898.html

  6. #6
    I dream skis Tori's Avatar
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    Re: Kawi stock 650 exhaust mod instructions

    About to do this mod, and have a couple questions.
    1. Does it matter what position you put the new nipple on the stinger ? Top, side, bottom ? Since is removing water seems like placement would be critical. Id thing the bottom would remove more the the top ???

    2. Also should the new nipple that you add to the stinger be restricted like the one your capping off ?
    YOUR CALIFORNIA WETBIKE DR.
    10 Wetbikes,
    including the Aluminum Wetbike
    1998 Jetbike WX1250r
    1985 JS550
    1994 650sc
    1977 Dynafoil w/ 650sx motor conversion--> http://dynafoil.freeforums.org/tori-...rsion-t11.html

  7. #7
    Resident Guru sah255's Avatar
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    Re: Kawi stock 650 exhaust mod instructions

    Quote Originally Posted by Laserman
    Awhile ago CHAD550 gave me some instructions on how to modify the stock 650 exhaust for more power. I did it, and I agree that it is a nice performance boost. So I thought it was worth posting. Here's his instructions:

    650 exhaust mod
    It is worth it it you dont want to get a aftermarket pipe. I gained 400 rpms and better throttle response.

    1. remove or plug the fitting on bottom of pipe that goes to the bulkhead, also plug hose to bulkhead (on 650 hulls) so water wont get in hull.

    2. If you removed the fitting and welded up the hole than use what you cut off and put fitting on the tail cone of the pipe at the water box. If you plugged the hole you will need a piece of tubing to make this fitting.

    3. Drill and tap the top of the head pipe (theres a nice flat boss) and install a 90 degree water fitting. It should point to the fitting you put in tailcone. Then look up in the head pipe, theres a big hole where water gets injected in to the pipe. Fill that hole with JB weld and let dry then next to it drill a 1/8 hole.

    4. Run a hose from fitting on top of head to fitting on tail cone with a tee in the middle. Off of the tee run a hose to a pisser fitting to dump excess water out of hull.

    p.s. when drilling hole in head pipe go easy its a water jacket dont go all the way through


    Because some people like pictures better than words, here is my version:

    [IMG][/IMG]
    Nice write up. I tried something similar a couple years ago. Had OK results at first but then installed a valve at the stinger to restrict waterflow and that REALLY woke this stock pipe up.
    I'm doing a X2 750 build right now and have been thinking of installing this pipe on it just to see what happens.

    Anyway, here is what I did:
    - Lenghthened the stock chamber by 2" (cut 2" from a donor pipe and welded to another stock one).
    - Pulled out the press fit 1/4" nipple on the stock head pipe and JB welded the hole shut.
    - Drilled and tapped a 3/8" 90 degree fitting through the outer water jacket into the rear of the head pipe.
    - Retained the stock pipe drain.
    - Welded a 3/8" threaded nipple to the stinger.
    - JB welded the water outlet inside the head pipe shut and redrilled it to 1/32? Maybe 1/16. Pretty small. This migh be too small because I burnt up 2 couplers. However, the 1st one was dry rotted and the second was a no hub fitting from Home Depot. This is the point where I stopped testing it and installed a West Coast pipe I already had.

    The new 3/8" rear head pipe outlet was connected to the new stinger via 3/8" hose. A 3/8"x3/8"x3/8" tee was installed before the stinger connection. The 3rd outlet bypassed to the hull mounted pisser.

    Like I mentioend above, the results weren't all that great until I installed the water regulator in between the stinger and pisser. I used a simple 3/8" manual globe valve and played with different settings.

    LENGTHENED TAILCONE


    3/8" STINGER NIPPLE





    MODIFIED HEAD PIPE (The 1/4" nipple was eventually removed)

    Last edited by sah255; 12-17-2007 at 05:13 PM.
    2010 Rickter
    2006 Superjet

  8. #8
    Banned Gorilla's Avatar
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    Re: Kawi stock 650 exhaust mod instructions

    i'm going to do that mod on my fx1 cheater pipe install.

    i put a factory pipe 61x exhaust manifold on, then a stock 91+up kawasaki 650 stock pipe.

    it should run much better with that mod'd setup !!!

    thanks for the wisdom

    gorilla

  9. #9
    I dream skis Tori's Avatar
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    Re: Kawi stock 650 exhaust mod instructions

    Bump for anyone that can answer my question above....
    YOUR CALIFORNIA WETBIKE DR.
    10 Wetbikes,
    including the Aluminum Wetbike
    1998 Jetbike WX1250r
    1985 JS550
    1994 650sc
    1977 Dynafoil w/ 650sx motor conversion--> http://dynafoil.freeforums.org/tori-...rsion-t11.html

  10. #10
    PWCToday.com Is My Home Away From Home Laserman's Avatar
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    Re: Kawi stock 650 exhaust mod instructions

    Quote Originally Posted by Tori
    About to do this mod, and have a couple questions.
    1. Does it matter what position you put the new nipple on the stinger ? Top, side, bottom ? Since is removing water seems like placement would be critical. Id thing the bottom would remove more the the top ???

    2. Also should the new nipple that you add to the stinger be restricted like the one your capping off ?
    1. The water is going from the pipe TO the waterbox throught that stinger nipple. the water is going OUT the nipple. The direction does not matter, but i've found that putting the stinger in so the nipple is UP makes it easier to put the hose on, mkes it clear the gas tank better, and allows you to inspect it easier.

    2. Some people (see the post by sah255) put a valve in there so they can adjust the flow for maximum power. I do not have a restrictor in mine. I keep looking at those automatic flow control valves, but i keep choking on the $40 price. maybe when I have every other part

    Hope this helps.
    Last edited by Laserman; 12-18-2007 at 06:51 AM.
    1985 JS 550/750 Stand-up: http://www.pwctoday.com/f72/smileys-...50-114680.html
    1984 JS550 TYPHOON 750 conversion: http://www.pwctoday.com/f72/laserman...ct-186297.html
    1992 Sport Cruiser "Sportscar" Conversion: http://www.pwctoday.com/f72/laserman...-a-173049.html
    Here's a helpfull thread on 550\650 conversions: http://www.pwctoday.com/f72/just-ano...on-133898.html

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