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  1. #11
    PWCToday Regular Fenix169motox's Avatar
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    fuel tank

    now that i've got a fuel tank. time to put some sound deadening foam on it. and this will help protect it inside the hull.
    KIMG3600.jpg

    fits like a glove!
    KIMG3602.jpg

    onto an exhaust while i wait for a good fuel pump assembly

  2. #12
    PWCToday Regular Fenix169motox's Avatar
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    exhaust:

    all right its time to get this exhaust water box taken care of. i didnt want to just straight pipe it, 4stroke exhaust is super hot.
    I cut apart the oem exhaust to see how its baffled and to rob the inlet/outlet fittings from it.
    KIMG3540.jpg
    ^this view is from the discharge side

    time to make a smaller copy!
    inlet: with "blast plate" so the hot fumes are not directly contacting the waterbox tubing
    KIMG3521.jpg
    re use the end caps from the original waterbox. had to cut em down of course
    KIMG3524.jpg
    oe vs mine:
    KIMG3523.jpg
    brought it home to fit up the discharge tube.
    made it like a straw so the exhaust gases will have to go under the water line to exit the waterbox. just like the original but different direction.KIMG3537.jpg

    KIMG3526.jpg
    fits pretty nice lets baffle it and cap off the other side!
    KIMG3539.jpg
    KIMG3540.jpg
    just like oem^

    lets cap this and wrap up this waterbox. didnt bring the right size hole saw so theres a few layers of weld....
    Attached Images Attached Images
    Last edited by Fenix169motox; 01-14-2018 at 04:56 PM.

  3. #13
    PWCToday Regular Fenix169motox's Avatar
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    handlepole

    so i made a pole in summer when i bought this machine, never ended up using it since i never made a chin pad. well i found a use for it.
    KIMG3498.jpg
    worx racing/ riva makes a throttle adapter for the drive by wire sensor. its super pricy. but you gotta do what you gotta do here.
    used a waterproof start/stop switch from Moose racing since seadoo uses the same button to start/stop the engine.
    KIMG3453.jpg
    time to mount the gauge and make a chin pad (the least proud of thing i made so far. but it works....)
    KIMG3619.jpg
    took some abs plastic and started heat forming a chin pad that i can turf. again, not proud of how it turned out.
    KIMG3625.jpg
    glad thats over, time for turf:
    KIMG3633.jpg

    final outcome.
    KIMG3697.jpg
    Last edited by Fenix169motox; 01-14-2018 at 05:10 PM.

  4. #14
    PWCToday Regular Fenix169motox's Avatar
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    Drive shaft adapter

    in the meantime i was trying to get a drive shaft coupler together. took much longer than expected for my shaft to come in so i can hack it apart to make this:
    take a 1998 xp drive shaft since it has the correct splines for the pto and isnt machined for a "wobble" fit.
    turn the outside and cut M18 1.50 threads into it and spin on your oem coupler.
    KIMG3573.jpg

    slips right into the pto housing of the 903
    KIMG3576.jpg
    i had to remove the entire swap in order to slip this piece into the back. so, photo op!
    this is everything thats inside. (minus the electrical center)
    KIMG3577.jpg

  5. #15
    PWCToday Regular Fenix169motox's Avatar
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    Re: SXR 900 ACE build

    now i'm itching to ride this thing! but i live in ohio, its been in the single digits.
    does that stop me from at least starting it? not on your life!
    https://www.youtube.com/watch?v=ZE9tLhOT2Fk

  6. #16
    PWCToday Regular Fenix169motox's Avatar
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    Re: SXR 900 ACE build

    the electrical center is mounted on a piece of carbon fiber i had laying in my garage. mounted it to the left side of the hull under the hood seal area.
    KIMG3607.jpg
    kept the fuse box for safety and used the iBR wire to power a bilge pump.
    since i didnt use a fuel tank with a battery tray i put it where 1100 guys keep em. in the rear, sideways, as far back as physically possible
    KIMG3543.jpg

    for cooling i went open loop.
    dual cooled from the pump (dont have any pictures sorry) one side fed the water pump inlet hose, not modifying the engine/waterpump at all. this lets the original thermostat stay in place, theres a small weep hole in the thermostat so i know water is flowing out of there via the right side 1/2" pisser. plus theres an air bleed off port in the head, this is my standard location 3/8" pisser. plus a 1/2" pisser for the exhaust
    KIMG3418.jpg
    air bleed port:
    KIMG3419.jpg
    left side and exhaust pisser
    KIMG3614.jpg

    white hose goes to the standard location pisser. this is probably the best pic as of 1/14/18 of the setup in there.
    KIMG3613.jpg

  7. #17
    PWCToday Regular Fenix169motox's Avatar
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    Re: SXR 900 ACE build

    i had a makeshift test tank laying behind my shop, so i had to stick in there on the only nice day we've had all winter.
    KIMG3688.jpg
    took this opportunity to get a final weight before i filled the tank the rest of the way.

    KIMG3685.jpg

    filled the test tank with some NICE water....
    KIMG3689.jpg

    and took some videos of it doing its thing.

    https://www.youtube.com/watch?v=zRIH7DrIU0s

    https://www.youtube.com/watch?v=Bte3_x9_NBc

  8. #18
    Top Dog RIDEH2O's Avatar
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    Re: SXR 900 ACE build

    You are making me feel slow, with my build!
    Looks nice, though.

    A few questions...
    1...The rubber seal that seals the driveshaft pto from water on oem setup...I think is supposed to have water against it to keep it cool and keep it from melting?? I might be wrong?
    2...Did you have to extend any electrical wires? like, for the throttle? and the dashboard? who did it?
    3...Do you have a strainer on your water cooling motor input? if not, you better get one!

    I'm jealous, I still have so far to go on mine.
    2017 Jet Jam Racing "Region 2" Sport GP Champion

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  9. #19
    PWCToday Regular Fenix169motox's Avatar
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    Re: SXR 900 ACE build

    You're not being slow dude, I did this for the simplicity. Yours is like from the ground up.
    I'm not certain if the pto needs to be water cooled, the shaft I'm using isn't from a setup like the spark and it's got a plastic piece that's not melted. Time will tell..
    I would have used a single shaft with no rubber damper but the coupler is way easy to make work.

    I did have to extend the "steering harness" by like 24"
    It was nice because I had left over wire from removing the ibr wiring from the harness. I took every inch of harness tape off the original (minus the engine side) and re wrapped it to fit my electrical center easy.
    You might be all right with yours mounted on the front of the engine, my tank wouldn't allow that setup.
    I wasn't worried about a strainer until you just said that. I should look into getting one thanks for the heads up!

  10. #20
    Resident Guru
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    Re: SXR 900 ACE build

    Nice how everything came together . Like the stub shaft idea.

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