Routing cooling lines
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  1. #1
    PWCToday Newbie
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    Routing cooling lines

    Hi... i am in need of of some suggestions of how fo run my cooling lines on my x2. It is an able performance motor that was just rebuild with a new factory pipe and a port matched West coast manifold with dual cooling nipples .


    On my head I have 2 nipples on the coupler side and 3 on the flywheel side.

    Manifold two cooling nipples tee'd to 1 line.

    Where should I run the cooling line from pump? And where should I run the extra fitting? 20181023_183746.jpg20181023_183854.jpg
    Last edited by tko; 10-23-2018 at 08:29 PM.

  2. #2
    PWCToday Newbie CALJET's Avatar
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    Re: Routing cooling lines

    This may help you
    x2 exhaust.jpg
    x2 exhaust.jpg

  3. #3
    PWCToday Newbie
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    Re: Routing cooling lines

    Thanks

    That's how I have the manifold currently routed.

    Should I run the 3 extra fittings on the head each to it's own pisser. Right now I have 1 going to the head pipe and 1 for the flush kit.

    I'm not sure if I should be running the extra fitting on the head to somewhere on the exhaust or manifold or just connect the 2 fittings together (with a tee'd flush fitting) and run 1 or 2 pissers from the head.

    Seem to be so many options.

    Thanks for your help

  4. #4
    PWCToday.com Is My Home Away From Home wmazz's Avatar
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    Re: Routing cooling lines

    You only need 2 brass fittings. 1 on the front, and 1 on the rear.

    I prefer a single 1/2" cooling line, compared to dual cooling. Especially when
    people don't add a 2nd ss 3/8" tube.

    If you don't mind me asking, how is that engine setup? Port timing, carburation,
    impeller, nozzle.

    I would hate to see that nice set-up seize, if it isn't set-up properly.



    Bill M.
    Last edited by wmazz; 10-23-2018 at 10:06 PM.
    Horsepower == Speed, RPM != Speed



  5. #5
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    Re: Routing cooling lines

    20181009_192611.jpg20181009_192620.jpg20181009_192044.jpg

    The motor is a stroker, cases trenched and ported, cylinder is ported and before the rebuild it had 220psi of compression.

    Carbs are dual 46 boswell mikuni' s

    Vilder lightened flywheel

    Purple vilder c.d.i

    Stock 750 stator and coil

    I am going to be working on the pump next. I was planning on running a sxr 13/18 cur for a 650 pump. And still has a 650 nozzle but I have a 1"pump spacer I'm planning on installing.

    Any recommendations would be apre iated?

  6. #6
    PWCToday.com Is My Home Away From Home wmazz's Avatar
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    Re: Routing cooling lines

    We need to review the cylinders history first.

    Why did the engine need to be rebuilt? Was it previously seized.

    You seem to be assembling this combo for the first time, or was
    this a reliable engine in one of your other ski's?

    When was the last time this cylinder was running?
    ===============================================

    I asked, because I would prefer to hear that you had a good break-in with
    no problems.

    I recommend that you estimate where peak HP will occur, and with a tachometer
    you will know if your set-up is good, or that you need some work to prevent a
    problem. You need to know what the exhaust duration is, the tuned length of the
    pipe (is it an FPP 650 limited pipe?) to determine peak HP rpm.
    ================================================== ======

    I am curious about what I saw in the pictures.

    Do the arrows on the piston point to the ring end gap locations? If so, you will need
    to remove the ring locating pins (either a small end mill, or grind and file) and install
    new pins half way between the transfer ports.

    If the arrows are pointing at the ring end gaps, the ring will wear out the top and
    bottom edge of each boost port. It will look like someone went crazy chamfering the
    ports.

    The exhaust tract diameter (flange diameter). Some engine builders like to cut them
    out to 45mm and larger. This will cause problems with most aftermarket exhaust manifolds
    by compromising the distance between the water jacket and the exhaust tract. It is
    possible for water to leak into the exhaust, effect the tuned length, and cause an
    engine failure.

    If the exhaust tracts are large diameter, you may want to add a water injection system
    to help regain the acceleration that you will loose with large head pipe diameters.

    Because the cylinder is aftermarket, you may want to pressure test the cooling system
    before you go any further. An automotive percentage leak tester would do the job. You
    will need to pressurize the water jackets to 110psi to 120psi.

    Keep in mind, the jet pump will supply ~50psi of flowing water pressure (not static pressure).
    Line pressure from an air compressor is necessary to test for leaks that might only occur
    when the engine is warm.



    Bill M.

    If the engine rpm in the water is 500 rpm less than peak hp rpm, then engine will be
    at risk of seizing.

    Quote Originally Posted by tko View Post
    before the rebuild it had 220psi of compression.
    Do you know what the new geometric compression ratio is?
    Last edited by wmazz; 10-24-2018 at 05:16 PM.
    Horsepower == Speed, RPM != Speed



  7. #7
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    Re: Routing cooling lines

    Thanks for the write up. A lot of good info.

    This motor and carb combo was running 2 years or so ago in a ssxi sit down. It was rebuilt due to a rusty crank bearing. So crankworks rebuilt the crankshaft. Then the cylinder was bored to 81mm and the pistons are drilled due to the bridged exhaust port. The arrows would point to where the ring gaps are. I'm not sure if the pins are still there, I got the motor back with the cylinder on and the exhaust manifold bolted.

    I do know the cylinder exhaust exit ports are rather large. I don't know the measurements but the guy who bored the manifold and gasket said it was close to the water jacket.

    Yes it is a 650 factory pipe.

    I don't know the current compression ratio.

    I will order a tach and the water injection sounds like a good idea.
    Last edited by tko; 10-24-2018 at 08:08 PM.

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