650 Wave Jammer Engine Swap and novice Freeride/ Freestyle ski - Page 3
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  1. #21
    PWCToday.com Is My Home Away From Home garrcass's Avatar
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    Quote Originally Posted by 550/440 View Post
    The Jammer was a way fun intro ski - it would be awesome with more power!
    Yes basicly the Hull demensions the part that's in the water..
    ( Girlfrends are cheap X2,s are expensive )

  2. #22
    PWCToday.com Is My Home Away From Home theVetteman3's Avatar
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    Re: 650 Wave Jammer Engine Swap and novice Freeride/ Freestyle ski

    We measured the width against one of eat wake's WB1s and it was pretty darn close. Not sure how well the rest of the ski matches up.

    If time was no object some day it would be nice to take a SJ hull and slice it lengthwise either side of center and widen it, or see what it would take to get a blaster bottom to fit. Just by spending time with the skis the WB1 is a much larger ski overall size wise. It feels huge and is way more stable and easier to board.

    Here are the dimensions I mentioned before:


    WJ 3 view drawing.JPG
    Last edited by theVetteman3; 08-08-2012 at 11:28 PM.
    1985 JS550/800 "Pretty Red": Newmiller 800, Rhaas 750 pump conv. [56.3mph gps]
    2009 1100 SJ:
    Kawi 1100 build in progress
    2009 SJ MINT:
    KP steering adaptor, Worx 228 intake, PWR ride plate [47.3mph gps]
    1987 WJ650:
    6M6, JD Intake Grate, 17/20, Coffmans Sizzler [48.5mph gps]
    1994 XiR: 830cc Superstock, PJS side draft, 13/18 swirl [53.7mph gps]
    1995 SJ MINT:
    Worx 205 intake [42.5mph gps]



  3. #23
    PWCToday.com Is My Home Away From Home theVetteman3's Avatar
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    Re: 650 Wave Jammer Engine Swap and novice Freeride/ Freestyle ski

    This past weekend my brother and I continued the saga of tearing down Nessie. We removed all the major hull components as well as all of the front foam. It is amazing how much space is freed up by not having that dang foam in there. If I so chose I could now fit a water box up front in the nose of the ski, and there is much more room on the left side by the pipe too. This will help with future exhaust routing possibilities with aftermarket pipes.

    Removing the foam should be no real issue because I'm going to run dual 750gph auto bilges. With normal riding due to fooling around I bet we've gotten close to 100-200lbs of water in these skis before. Literally half the interior volume of the ski at least.

    The pump is pretty goofy looking with its shoe which is attached and removes. The pump shoe tube mates against the hull from underneath, and the midshaft pilots on its ID from inside the hull. It really is a slick set up. Basically the runout of the midshaft is always going to be very true to the axis of the pump.

    Yamaha's original siphon bilge system was extremely crappy however. Basically they run a HUGE (~3/4" ID) tube from the high pressure stator section of the pump straight down to the ride plate on the bottom of the ski. It is from this line that the siphon bilge line is connected to. Yamaha must have been forced to do this in order to get around Kawasaki's patents. It has to lose a huge amount of thrust do to having that gigantic hole. So I am going to plug that, since their siphon bilge really didn't work anyway, and just run two massive bilge pumps.

    2012-08-04_08-48-47_450.jpg2012-08-05_08-34-58_101.jpg
    1985 JS550/800 "Pretty Red": Newmiller 800, Rhaas 750 pump conv. [56.3mph gps]
    2009 1100 SJ:
    Kawi 1100 build in progress
    2009 SJ MINT:
    KP steering adaptor, Worx 228 intake, PWR ride plate [47.3mph gps]
    1987 WJ650:
    6M6, JD Intake Grate, 17/20, Coffmans Sizzler [48.5mph gps]
    1994 XiR: 830cc Superstock, PJS side draft, 13/18 swirl [53.7mph gps]
    1995 SJ MINT:
    Worx 205 intake [42.5mph gps]



  4. #24
    PWCToday.com Is My Home Away From Home theVetteman3's Avatar
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    Re: 650 Wave Jammer Engine Swap and novice Freeride/ Freestyle ski

    Wow does this website blow... more pics to come later apparently.
    1985 JS550/800 "Pretty Red": Newmiller 800, Rhaas 750 pump conv. [56.3mph gps]
    2009 1100 SJ:
    Kawi 1100 build in progress
    2009 SJ MINT:
    KP steering adaptor, Worx 228 intake, PWR ride plate [47.3mph gps]
    1987 WJ650:
    6M6, JD Intake Grate, 17/20, Coffmans Sizzler [48.5mph gps]
    1994 XiR: 830cc Superstock, PJS side draft, 13/18 swirl [53.7mph gps]
    1995 SJ MINT:
    Worx 205 intake [42.5mph gps]



  5. #25
    PWCToday.com Is My Home Away From Home garrcass's Avatar
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    That 3/4 hole of thrust straight down is a trip so odd... they should have at least angled it
    ( Girlfrends are cheap X2,s are expensive )

  6. #26
    PWCToday.com Is My Home Away From Home theVetteman3's Avatar
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    Re: 650 Wave Jammer Engine Swap and novice Freeride/ Freestyle ski

    Here are the other pics, you can see the massive tube. This piece of nose foam is only about 1/3 the total amount in the nose of this ski. There was two side pieces connected to this chunk, as well as side pieces in the hull. We filled up half of a garbage can with it.


    jammer pump.JPGjammer nose de-foamed.JPGjammer nose foam.JPG
    1985 JS550/800 "Pretty Red": Newmiller 800, Rhaas 750 pump conv. [56.3mph gps]
    2009 1100 SJ:
    Kawi 1100 build in progress
    2009 SJ MINT:
    KP steering adaptor, Worx 228 intake, PWR ride plate [47.3mph gps]
    1987 WJ650:
    6M6, JD Intake Grate, 17/20, Coffmans Sizzler [48.5mph gps]
    1994 XiR: 830cc Superstock, PJS side draft, 13/18 swirl [53.7mph gps]
    1995 SJ MINT:
    Worx 205 intake [42.5mph gps]



  7. #27
    PWCToday.com Is My Home Away From Home theVetteman3's Avatar
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    Re: 650 Wave Jammer Engine Swap and novice Freeride/ Freestyle ski

    Ok I received my box of parts so I can really start getting things done!

    Old impeller was removed using the tool and LOTS of heat from a propane torch.

    Siphon venturi on the bottom of the ride plate was filled with metal epoxy putty and sanded flush.

    New impeller fitted, wear ring clearance checked, and impeller installed.

    Siphon bilge hole tapped for a 3/8" NPT plug. I ordered a stainless steel plug with a hex insert from McMaster. The tap fit right in! I am going to seal in the plug, and then from the inside put some epoxy putty in and sand it smooth so the ID of the pump is smooth.

    On the engine side, I cleaned up the intake side and reassembled everything with new gaskets. I put on the exhaust manifold with new gaskets, and installed the primer bilge fitting. I also took the opportunity to paint the superjet 650 head.


    2012-08-10_18-57-39_941.jpg2012-08-10_18-59-06_136.jpg2012-08-10_18-59-44_842.jpg2012-08-11_14-08-21_24.jpg2012-08-11_14-18-09_146.jpg
    Last edited by theVetteman3; 08-12-2012 at 01:33 PM.
    1985 JS550/800 "Pretty Red": Newmiller 800, Rhaas 750 pump conv. [56.3mph gps]
    2009 1100 SJ:
    Kawi 1100 build in progress
    2009 SJ MINT:
    KP steering adaptor, Worx 228 intake, PWR ride plate [47.3mph gps]
    1987 WJ650:
    6M6, JD Intake Grate, 17/20, Coffmans Sizzler [48.5mph gps]
    1994 XiR: 830cc Superstock, PJS side draft, 13/18 swirl [53.7mph gps]
    1995 SJ MINT:
    Worx 205 intake [42.5mph gps]



  8. #28
    PWCToday.com Is My Home Away From Home theVetteman3's Avatar
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    Re: 650 Wave Jammer Engine Swap and novice Freeride/ Freestyle ski

    Which reminds me, I've posted a couple of comparison pics of the normal/ superjet 650 head with the LX head. It has larger domes to lower compression.

    The LX head is the upper and left head in the pics. It's a 2 piece design.

    Switching to the normal 650 head is one important component of boosting the power of the 650 from 42hp up to more normal 50ish levels. One more component I'll do at some point is a 650/ 701 CDI with an adjustable rev limiter.

    2012-07-29_14-02-07_559.jpg2012-07-29_14-02-16_811.jpg2012-07-29_14-03-38_27.jpg
    Last edited by theVetteman3; 08-12-2012 at 01:44 PM.
    1985 JS550/800 "Pretty Red": Newmiller 800, Rhaas 750 pump conv. [56.3mph gps]
    2009 1100 SJ:
    Kawi 1100 build in progress
    2009 SJ MINT:
    KP steering adaptor, Worx 228 intake, PWR ride plate [47.3mph gps]
    1987 WJ650:
    6M6, JD Intake Grate, 17/20, Coffmans Sizzler [48.5mph gps]
    1994 XiR: 830cc Superstock, PJS side draft, 13/18 swirl [53.7mph gps]
    1995 SJ MINT:
    Worx 205 intake [42.5mph gps]



  9. #29
    PWCToday.com Is My Home Away From Home garrcass's Avatar
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    Re: 650 Wave Jammer Engine Swap and novice Freeride/ Freestyle ski

    did you get a pipe can you fit a lazerman mod 650 kawi pipe in it ?
    ( Girlfrends are cheap X2,s are expensive )

  10. #30
    PWCToday.com Is My Home Away From Home theVetteman3's Avatar
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    Re: 650 Wave Jammer Engine Swap and novice Freeride/ Freestyle ski

    I have seen the Kawi 650 pipe thing done before but I haven't heard of any real benefits first hand. Do you know of a thread where someone sings the praises of it? I actually have a mint pipe from my 650sx, I'd need the head pipe and the Yami manifold. I would like to consider it because switching to the Kawi pipe will easily shave 10 lbs from the ski. That stock pipe is HEAVY!

    Got the engine all buttoned up. The paint is 350 deg wrinkle black. Looks fantastic and is so easy to do. I'm going to compare the durability of it to a similar wrinkle powder coated head I have on my 550/750. The p/c head looks perfect and never seems to get dirty, its amazing!

    Btw.. I know the carb is on backwards. I'm doing some experimenting with mocking things up.

    EDIT: oh and please excuse the 3 crappy looking bolts that secure the pipe to the pipe mount. I need to clean those up. The others I removed the paint and rust on them and they now look quite fresh and shiny.

    2012-08-12_13-09-48_889.jpg2012-08-12_13-10-26_173.jpg2012-08-12_15-20-46_289.jpg2012-08-12_15-21-01_568.jpg
    Last edited by theVetteman3; 08-12-2012 at 10:50 PM.
    1985 JS550/800 "Pretty Red": Newmiller 800, Rhaas 750 pump conv. [56.3mph gps]
    2009 1100 SJ:
    Kawi 1100 build in progress
    2009 SJ MINT:
    KP steering adaptor, Worx 228 intake, PWR ride plate [47.3mph gps]
    1987 WJ650:
    6M6, JD Intake Grate, 17/20, Coffmans Sizzler [48.5mph gps]
    1994 XiR: 830cc Superstock, PJS side draft, 13/18 swirl [53.7mph gps]
    1995 SJ MINT:
    Worx 205 intake [42.5mph gps]



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