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  1. #1
    PWCToday Guru SuperDave4x4's Avatar
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    Crankshaft Seal Replacement

    I'm trying to replace the crankshaft seals in my 650, but I searched and it seems that I need fly wheel puller and a coupler removal tool. I talked with Madscientist and he said I could do a few things to get the coupler off with out using a coupler tool and how to keep the crankshaft from spinning.

    Where can I rent a flywheel removal tool or can I get around using one?

    There are 3 crankshaft seals, but I'm only seeing the front and rear being sold? Who has the third one included with the kit? Do I need the third one?

    http://www.watercraftsuperstore.net/.../703SB201.html

    http://www.parkeryamaha.com/jetlyne-...oil-seals.aspx



    If yall have any other tips or tricks to make this go smoothly please let me know!


    The seals are: 92049 (2) and 92049A

    Last edited by SuperDave4x4; 12-19-2009 at 12:25 PM.
    1989 Kawi 440/550 - slightly modded.
    1989 Kawi 650sx
    1988 Kawi X2 - Coffman, Jetlyne, BCW Racing, WestCoast...getting alot of attention before summer....

    http://s347.photobucket.com/albums/p449/SuperDave4x4

    http://www.pwctoday.com/f72/my-100-1...ld-257418.html My slow 650sx build

  2. #2
    resident guru rock_smasher's Avatar
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    Re: Crankshaft Seal Replacement

    Best trick i've found for getting the coupler off, is heat and candle wax. Heat the coupler until its good and hot, then melt wax so it runs down into the threads. let it cool a few minutes, should spin right off. You can stuff some soft rope into the rear cyl to keep the motor from turning, if needed. Righty-titey, lefty loosey, I just used a prybar in the coupler, but had extra coupler just in case.

    A flywheel holding tool is a great thing, can be made pretty easy. (no pics of mine) Y shaped piece of metal with a cpl of bolts to fit into the flywheel slots, works great.

    And when you use a puller for the flywheel, be careful DO NOT run the bolts too far thru the flywheel, or you'll be needing a new stator. Got my puller from harbor freight (1 source for cheap chinese junk) for cheap, and it hasnt broken yet.

    I'd say you need all 3 seals, SBT has them for 16.95 in the gasket section. Some good marine grease, you'll be all set. Maybe a few bandaids, some superglue and some bad words, you're ready to go! good luck
    Those who will beat their swords into plows, will plow for those who do not.

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  3. #3
    PWCToday Guru SuperDave4x4's Avatar
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    Re: Crankshaft Seal Replacement

    Quote Originally Posted by rock_smasher View Post
    Best trick i've found for getting the coupler off, is heat and candle wax. Heat the coupler until its good and hot, then melt wax so it runs down into the threads. let it cool a few minutes, should spin right off. You can stuff some soft rope into the rear cyl to keep the motor from turning, if needed. Righty-titey, lefty loosey, I just used a prybar in the coupler, but had extra coupler just in case.

    A flywheel holding tool is a great thing, can be made pretty easy. (no pics of mine) Y shaped piece of metal with a cpl of bolts to fit into the flywheel slots, works great.

    And when you use a puller for the flywheel, be careful DO NOT run the bolts too far thru the flywheel, or you'll be needing a new stator. Got my puller from harbor freight (1 source for cheap chinese junk) for cheap, and it hasnt broken yet.

    I'd say you need all 3 seals, SBT has them for 16.95 in the gasket section. Some good marine grease, you'll be all set. Maybe a few bandaids, some superglue and some bad words, you're ready to go! good luck

    That's what madscientist said to do for removing the coupler.

    SBT says "end seal kit"?? Does that include middle to? Sorry for my ignorance.
    SBT and WaterCraftSuperstore have the same price for the seal kit, but WCS lists there's as 2 seals only and SBT is "end seal kit".

    As for the puller is this what your talking about?

    http://www.harborfreight.com/cpi/cta...emnumber=40970
    1989 Kawi 440/550 - slightly modded.
    1989 Kawi 650sx
    1988 Kawi X2 - Coffman, Jetlyne, BCW Racing, WestCoast...getting alot of attention before summer....

    http://s347.photobucket.com/albums/p449/SuperDave4x4

    http://www.pwctoday.com/f72/my-100-1...ld-257418.html My slow 650sx build

  4. #4
    Frequent Poster wpmxwb's Avatar
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    Re: Crankshaft Seal Replacement

    if the 650 flywheel is anything like a 550 you will need a puller like this

    http://www.harborfreight.com/cpi/cta...emnumber=37824
    1987 js550 westcoast half pipe, solas 13/18, R&D top loader, op rideplate, quick turnplate w/4* bars and much more to come

    1984 js440 kerker pipe, mariner water box, solas 15*, op scoop & ride plate, oc jet ski intake, aluminum handle pole. still not sure on what to do with it

  5. #5
    PWCToday Guru SuperDave4x4's Avatar
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    Re: Crankshaft Seal Replacement

    Quote Originally Posted by wpmxwb View Post
    if the 650 flywheel is anything like a 550 you will need a puller like this

    http://www.harborfreight.com/cpi/cta...emnumber=37824

    1989 Kawi 440/550 - slightly modded.
    1989 Kawi 650sx
    1988 Kawi X2 - Coffman, Jetlyne, BCW Racing, WestCoast...getting alot of attention before summer....

    http://s347.photobucket.com/albums/p449/SuperDave4x4

    http://www.pwctoday.com/f72/my-100-1...ld-257418.html My slow 650sx build

  6. #6
    PWCToday.com Is My Home Away From Home delagem's Avatar
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    Re: Crankshaft Seal Replacement

    You need 2 each 92049 and 1 of 92049a. None are in the "middle". Put a 90249 and a 90249a on the coupler end of the crank, and a 92049 on the magneto end. I'll let you guess which way to orient the lip seals, I've never been able to make any sense of it.

    I've never had a problem getting a Kawi coupler off, just a touch of heat and I use a long screwdriver across the flats of the coupler.... Of course, I throw the crank in a big bench vise first.

    For a flywheel puller, go to Autozone. buy a steering wheel puller. It's like $9. Then go to NAPA and buy some decent grade 5 or grade 8 metric bolts of the correct size. The bolts with the Autozone puller will strip first time you use it. I've been using one of these for 7 years now.....

    If you really must hold the crank still, the rope trick works. But I've got a better way. I made a block of wood the size of a piston dome. Rounded the corners. Oak. Just unbolt the head, toss this in, bolt the head back on. In the attached pic, you can actually see the block of wood thru the spark plug hole.

    By the way, this was the worst coupler I've ever encountered; this was a Polaris that a clown had filled the motor with water and then left to sit for 5 or so years. Everything was frozen on this motor! Broke a 15" wrench before I resorted to the jack and pipe wrench.

    Amazingly, I rode that thing for 2 years on that same crank! One of the middle bearings finally did disintegrate, by the time I tore it down there were no ball bearings left. All gone!
    Attached Images Attached Images
    Last edited by delagem; 12-19-2009 at 08:31 PM.
    '58 Vincent Amanda Water Scooter, 0rpm, 0mph

    '84 SurfJet 236ss Freestyle, 5950rpm, 24.6 mph

    '91 Jetmate! SX-R 800,GroupK carbs,R&D 26cc head,R&D ProLok F/A, Coffman Rocket Pipe,Impros 13-20,76mm nozzle: 6630rpm and 38.1mph GPS

    '92 SL650/750, dry pipe,extended pump,trim,HotSeat Waterbox: 6320rpm, 50.1 mph

    '00 SLX,Tau Ceti F/A's,NuJet prop: 6670rpm, 63.1 mph

    '03 Octane, Watcon 2318 CDI

    '04 MSX140,Impros stage 2 Powertune 14/23,WetWolf,6deg wedge: 6750rpm, 60.5 mph

  7. #7
    PWCToday Guru SuperDave4x4's Avatar
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    Re: Crankshaft Seal Replacement

    Thanks for the tip!

    I just got the coupler off and now I removed the flywheel cover to take a peek inside. Its got some oil residue and what not, but nothing dripped out.

    I'll have to wait till tomorrow to get the flywheel or steering wheel removal tool. I really want take this thing apart now that I've started.

    EDIT I'm just gonna call the above mention parts carriers and see if they come with all 3. If someone else already knows chim in so I can go ahead and get this suckers in the mail.........
    Last edited by SuperDave4x4; 12-19-2009 at 08:50 PM.
    1989 Kawi 440/550 - slightly modded.
    1989 Kawi 650sx
    1988 Kawi X2 - Coffman, Jetlyne, BCW Racing, WestCoast...getting alot of attention before summer....

    http://s347.photobucket.com/albums/p449/SuperDave4x4

    http://www.pwctoday.com/f72/my-100-1...ld-257418.html My slow 650sx build

  8. #8
    resident guru rock_smasher's Avatar
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    Re: Crankshaft Seal Replacement

    I got mine thru SBT. Delagem is spot on about the grade 8 bolts, too. Dont forget the sharp hits with a large hammer while under tension. Thats the same puller kit I have, the 2nd link.... aside from stripping all those bolts and replacing them.
    Those who will beat their swords into plows, will plow for those who do not.

    Post-No Bills

  9. #9
    PWCToday Guru SuperDave4x4's Avatar
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    Re: Crankshaft Seal Replacement

    Quote Originally Posted by rock_smasher View Post
    I got mine thru SBT. Delagem is spot on about the grade 8 bolts, too. Dont forget the sharp hits with a large hammer while under tension. Thats the same puller kit I have, the 2nd link.... aside from stripping all those bolts and replacing them.

    Right on! I'll get one in the A.M.

    I hope my thread is helpful for others too. I searched a few times and didn't come up with exact info on doing this, just tid bits here and there. I'll follow up tomorrow and let yall know how it goes! Hopefully my crank is in good shape.
    1989 Kawi 440/550 - slightly modded.
    1989 Kawi 650sx
    1988 Kawi X2 - Coffman, Jetlyne, BCW Racing, WestCoast...getting alot of attention before summer....

    http://s347.photobucket.com/albums/p449/SuperDave4x4

    http://www.pwctoday.com/f72/my-100-1...ld-257418.html My slow 650sx build

  10. #10
    Top Dog
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    Re: Crankshaft Seal Replacement

    Pm: SUPERJET-113 or check his thread in the for sale section. He sells full gasket kits including the cranks eals for $50 for the 650 motor.
    JS550/650 conversion- ported (exhaust ports widdened 2mm, raised 1mm, transfers stair stepped, cases ported), Blackjack 46mm, Prok FA, Boysen reeds, stuffers, Westcoast head 30cc domes (175psi), Jetinetics charging flywheel, PJS exhaust manifold, Factory Performance Pipe, Coffmans Waterbox, footholds, Team Waterfly Tubbies.

    650 pump conversion- SXR prop cut to fit 650 pump repitched to a 9/17, TBM pump stuffer, OP nozzles, and OP skegged ride plate.

    JS550/650 conversion- in the works

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