550/650 rebuild build - Page 3
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  1. #21
    Top Dog Boz Mon's Avatar
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    Re: 550/650 rebuild build

    Got my factory pipe shoehorned into the ski today. I had to heat up my gas tank to dent it a bit and I put some aluminum duct tape on the tank to protect it.




    Sent from my iPhone using Tapatalk
    1994 FX1
    1985 JS550/650 conversion
    2015 Fiat 500 Abarth

  2. #22
    Top Dog Boz Mon's Avatar
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    Re: 550/650 rebuild build

    Did a test ride on Sunday and had some issues. Water was not circulating at all. The screw on the bottom of the headpipe wasnít opening until almost a half a turn out.


    Sent from my iPhone using Tapatalk
    1994 FX1
    1985 JS550/650 conversion
    2015 Fiat 500 Abarth

  3. #23
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 550/650 rebuild build

    10/10 switch the duct tape for some turf. id also close the bottom screw and use the top and middle. dont be afraid to open the screw past 1 turn either. ive got the top screw on my 750x2 opened 1.5 turns and the middle half a turn and it still rips on top. bottom and midrange acceleration really came alive after letting more water in.
    Last edited by fastgtfairlane; 03-11-2020 at 02:19 PM.
    91 440; PJS Viper 7000, jetsport exhaust mani, factory full pipe, coffman waterbox,solas 17*, jetco worked 440 pump, ocean pro nozzles. shredmaster ocean rideplate and grate combo, wide tray, footholds, deep strake mod, driveshaft fill,650sx quick turn

    build thread part 1: http://www.pwctoday.com/showthread.php?t=331343
    build thread part 2: http://www.pwctoday.com/showthread.php?t=364872
    build thread part 3: http://www.pwctoday.com/showthread.php?t=396154

  4. #24
    Top Dog Boz Mon's Avatar
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    Re: 550/650 rebuild build

    Iíll look into the tuning more once the weather warms up. What are my options for turfing they tray if I want to get rid of the rubber rails?


    Sent from my iPad using Tapatalk
    1994 FX1
    1985 JS550/650 conversion
    2015 Fiat 500 Abarth

  5. #25
    Top Dog Boz Mon's Avatar
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    Re: 550/650 rebuild build

    I tested again today. Started it on the trailer in the water and it immediately started pissing so I took it for a rip. That factory pipe really makes that ski come alive coming from the west coast pipe! Iím really excited to rail some turns and chase some boats once the weather gets warm.

    I also ordered a turf kit from Blowsion so Iím gonna work on cleaning up the ski some now that I know it rips.


    Sent from my iPad using Tapatalk
    1994 FX1
    1985 JS550/650 conversion
    2015 Fiat 500 Abarth

  6. #26
    Top Dog Boz Mon's Avatar
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    Re: 550/650 rebuild build

    Been working on a plan to turf the ski. Pulled off the rubber mats and the bottom pad and got to cleaning. Today I filled the channels on top of the tray rails with some epoxy resin and cloth. Once that dries I can continue. I cut up the old bottom mat to use on the 6 weird cutouts one the side of the tray.




    Sent from my iPhone using Tapatalk
    1994 FX1
    1985 JS550/650 conversion
    2015 Fiat 500 Abarth

  7. #27
    Top Dog Boz Mon's Avatar
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    Re: 550/650 rebuild build

    This weekend was the first full actual shakedown test of the ski. It was loosing its prime and was very hard to start sometimes, and the issue of course pops up 2 hours away from home. I think the issue was a cracked fuel pickup line. I changed it out today so Iíll test that this weekend.

    I was also having a weak pisser stream so I took the pump apart and Iím pretty sure I had the wrong fitting in there. The removed one on the left



    I picked up some hull braces for the ski. Got those almost all mounted. The rear one on the left side is the only one left because thereís a bilge outlet in the way that isnít used. I cut it so the brace fits around it, but I need some caulk.

    Even with the fuel issues, this thing ripped this weekend for 3 days in a row. Got some good pics of me flying through the air. Once the lake was less busy, I railed some turns and this thing is really fun for that. I built it to be more of a handling ski than a jumping ski but I think itís gonna be pretty gnarly all around.




    Sent from my iPhone using Tapatalk
    1994 FX1
    1985 JS550/650 conversion
    2015 Fiat 500 Abarth

  8. #28
    PWCToday Newbie
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    Re: 550/650 rebuild build

    Those photos are epic!

  9. #29
    Top Dog Boz Mon's Avatar
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    Re: 550/650 rebuild build

    Quote Originally Posted by tacopwr View Post
    Those photos are epic!
    Haha thanks! I have some video too which is much cooler but Iím not sure how to post it


    Sent from my iPhone using Tapatalk
    1994 FX1
    1985 JS550/650 conversion
    2015 Fiat 500 Abarth

  10. #30
    PWCToday Regular
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    Aug 2019
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    NJ
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    31
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    Re: 550/650 rebuild build

    do you have any pics of how you installed the hull braces? I have the nose brace on my 550sx but not the sides. of course iv been a little scared to rebuild the engine, only because I have never done it before and don't wanna destroy a brand new crank so I haven't gotten to ride it yet, been ripping my GPR all summer

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