This thread will hopefully dispel some of the rumors surrounding the legitimacy of putting Kawi 900/1100 triple in a 550 hull. It should also result in an interesting experiment and quite a ski, even it it ends up at the bottom of the lake.
The 900 being used will be replaced with an 1100 as soon as a decent deal pops up on one. 1100s are very expensive in NorCal, plus the exterior dimensions of the 900 engine are very similar to an 1100 so it should be nearly a direct swap when the time comes. The 900 also starts with a lot of better fitting parts - Regular sized coupler, smaller exhaust, smaller manifold, etc. 100hp stock is exciting, plus the sound of a triple is like nothing else...
First - Questions! (Please ask any questions that might be missing)
1) How much does this massive engine weigh?
2) Will it fit in a 550 hull?
3) How will the engine placement workout within the hull?
4) What do you do with the exhaust?
5) Electronics Placement?
6) Is there any room for a tank? Electronics? Battery?
7) WILL IT EVEN FLOAT?!?
I don’t have all the answers yet, but we’re here to find out! The point of this thread is not just to build the ski, but to build it with performance and cleanliness in mind - while keeping it as factory looking and as 550 as possible.
RHAAS pump kit is on order, tubbies are standing by, massive box of fiberglass supplies from US Composites on the shelf, tons of ideas floating around in my head. Let’s do this!...
As long as this thing is faster than Waverunner Eagle’s build I’ll be happy hahaha
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Towards the end of the summer I found a nice deal on a 1990 550sx with a bunch of aftermarket parts. Gutted the hull to use the parts for another ski.
I think this thing sat in the water for months. The sea scum was seemingly epoxied to it.
Time to strip the Hull. Hull inserts for the tray pads were spinning - time for the saw…
Decided to do a little sanding. The hull will get fresh paint once all glasswork/mods are done. Rear sponsons removed to reduce any possible rear flotation.
Recently picked up a 1996 900 zxi on a trailer for $400, not bad for CA. Only a broken plastic fender on the trailer and broken trim cable on the ski.
Triple is out! Pop an advil for the backache…
Question #1 - Answered! Engine weights 128lbs with only the exhaust removed. It will be reduced a little bit since we are not using the ZXI bed plate which weighs 12lbs. Exhaust weighs 18lbs. Heavy for sure.
After a quick wipe down…
Holy smokes ,there’s a lot of electronics in this couch…
The triple savvy guys will know this - The Kawi triples actually have 10 tapped motor mount holes in the cases. Six holes mount to the ZXI bed plate, the other four are unused and are the exact bolt pattern of any 650/750/800 engine - quite convenient! SXR1100 conversions take advantage of this.
So, if a triple will bolt to an SXR bed plate, then a triple will bolt to a 550/650 conversion plate - which bolts to a 550 bed plate, right? Yes! Well, with quick mods.
Also, I’m using RHAAS 550 to 650/750 conversion plates because they allow you to position the engine about ¾” further back than a standard conversion plate. All this weight needs to be as far back as it can get.
Mods are simple, the middle two ZXI Mounts need to be clearanced 5mm.
During surgery…
All cleaned up. Mounts are right about flush with the reinforcing rib on the cases…
To install the bed plate, one engine mount bolt needs to be shortened or it will contact a reinforcing rib. It still fully engages all threads in the conversion plate.
Bed plate installed (Will be painted before final install)
The 900 being used will be replaced with an 1100 as soon as a decent deal pops up on one. 1100s are very expensive in NorCal, plus the exterior dimensions of the 900 engine are very similar to an 1100 so it should be nearly a direct swap when the time comes. The 900 also starts with a lot of better fitting parts - Regular sized coupler, smaller exhaust, smaller manifold, etc. 100hp stock is exciting, plus the sound of a triple is like nothing else...
First - Questions! (Please ask any questions that might be missing)
1) How much does this massive engine weigh?
2) Will it fit in a 550 hull?
3) How will the engine placement workout within the hull?
4) What do you do with the exhaust?
5) Electronics Placement?
6) Is there any room for a tank? Electronics? Battery?
7) WILL IT EVEN FLOAT?!?
I don’t have all the answers yet, but we’re here to find out! The point of this thread is not just to build the ski, but to build it with performance and cleanliness in mind - while keeping it as factory looking and as 550 as possible.
RHAAS pump kit is on order, tubbies are standing by, massive box of fiberglass supplies from US Composites on the shelf, tons of ideas floating around in my head. Let’s do this!...
As long as this thing is faster than Waverunner Eagle’s build I’ll be happy hahaha
----------------------------------------------------------------------------------------------------------------------
Towards the end of the summer I found a nice deal on a 1990 550sx with a bunch of aftermarket parts. Gutted the hull to use the parts for another ski.
I think this thing sat in the water for months. The sea scum was seemingly epoxied to it.
Time to strip the Hull. Hull inserts for the tray pads were spinning - time for the saw…
Decided to do a little sanding. The hull will get fresh paint once all glasswork/mods are done. Rear sponsons removed to reduce any possible rear flotation.
Recently picked up a 1996 900 zxi on a trailer for $400, not bad for CA. Only a broken plastic fender on the trailer and broken trim cable on the ski.
Triple is out! Pop an advil for the backache…
Question #1 - Answered! Engine weights 128lbs with only the exhaust removed. It will be reduced a little bit since we are not using the ZXI bed plate which weighs 12lbs. Exhaust weighs 18lbs. Heavy for sure.
After a quick wipe down…
Holy smokes ,there’s a lot of electronics in this couch…
The triple savvy guys will know this - The Kawi triples actually have 10 tapped motor mount holes in the cases. Six holes mount to the ZXI bed plate, the other four are unused and are the exact bolt pattern of any 650/750/800 engine - quite convenient! SXR1100 conversions take advantage of this.
So, if a triple will bolt to an SXR bed plate, then a triple will bolt to a 550/650 conversion plate - which bolts to a 550 bed plate, right? Yes! Well, with quick mods.
Also, I’m using RHAAS 550 to 650/750 conversion plates because they allow you to position the engine about ¾” further back than a standard conversion plate. All this weight needs to be as far back as it can get.
Mods are simple, the middle two ZXI Mounts need to be clearanced 5mm.
During surgery…
All cleaned up. Mounts are right about flush with the reinforcing rib on the cases…
To install the bed plate, one engine mount bolt needs to be shortened or it will contact a reinforcing rib. It still fully engages all threads in the conversion plate.
Bed plate installed (Will be painted before final install)
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