550/650 rebuild build
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  1. #1
    Top Dog Boz Mon's Avatar
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    Jun 2005
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    550/650 rebuild build

    My original green ski that I built several years ago has finally fallen from grace. Been through 3 motors now and for some reason I canít get it to handle good.



    I picked up a decent 560sx hull with pump that I am going to swap my stuff into.


    I started of by cleaning the engine bay and reinforcing the inner nose area with epoxy resin.



    Picked up some rhaas motor mounts


    And I removed the rear sponsons and plugged the holes


    I havenít decided if Iím going to transfer my prowatercraft hull extensions to the sx or not. Anyway, hereís the rest of the setup:

    650 with a mariner head 180psi
    Sbn44 with boyesen reeds and reed stuffers
    Westcoast pipe with diverted manifold
    Mariner water box
    Straight skat 19
    Ocean pro steering nozzle
    Ocean pro quik turn plate
    Ocean pro finned ride plate
    Pjs toploader

    Probably more stuff Iím missing. I really like chasing boat wakes but I want to make this ski really rail on flat water. More to come!



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

  2. #2
    PWCToday.com Is My Home Away From Home BLRider's Avatar
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    Re: 550/650 rebuild build

    S u b s c r I b e d . . .
    Never argue with an idiot, they will drag you down to their level then beat you with experience.

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

    And my prop just showed up today from impros. Skat 15.5 repitched to a straight 19




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

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

    Got my pump in today. Running the ocean pro finned plate, pjs toploader, and the ocean pro steering nozzle.






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

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

    Got back from vacation today and I went to work swapping engine parts. Got my flywheel, bedplate, coupler, and exhaust manifold all mounted to the new motor. I ran into an issue with the reeds. I was going to swap my boyesen reeds to the current reed blocks and use the stuffers that came with the current engine. Apparently the reeds from my engine are already ďstuffedĒ and my boyesens wonít fit on the blocks for the new engine.

    I guess Iím searching for a single black reed block. Unless I should use the reeds that were in the motor with the stuffers and they didnít have the little dampers.



    The second pic here is my reeds that I want to use



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

  6. #6
    Resident Guru still standin's Avatar
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    Re: 550/650 rebuild build

    I built almost an identical ski back in 2012 and ran it for several years. Only differences: I had the OP reduction nozzle with stubby pump cone. Kerker 650 pipe at first and later a 3 piece PJS pipe. Stock reeds. Ran a -2 inch aluminum pole. GPS'd at 47mph on the dot. great for jumping boat wakes. Highly recommend the prowatercraft tubbies if you want to rail turns.

    -2019 SXR - Unlimited Fixed Steer Conversion- 64.8mph
    -86 X2 - Twin carb 750 swap, blaster pipe etc -



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

    Quote Originally Posted by still standin View Post
    I built almost an identical ski back in 2012 and ran it for several years. Only differences: I had the OP reduction nozzle with stubby pump cone. Kerker 650 pipe at first and later a 3 piece PJS pipe. Stock reeds. Ran a -2 inch aluminum pole. GPS'd at 47mph on the dot. great for jumping boat wakes. Highly recommend the prowatercraft tubbies if you want to rail turns.
    Thatís a sweet setup. I would like to find another pipe for this one but itís not in the budget this year.

    I feel like railing turns on a 550 with tubbies is cheating. Plus itís more rewarding.

    On another note, I figured out the reed situation. The reed cages are old school FMF cages with stuffers. I will be running those instead of the stock setup and my friend is 3d printing me some new stuffers.


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

  8. #8
    Top Dog Boz Mon's Avatar
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    Re: 550/650 rebuild build

    Got the motor in and everything wired up over the weekend. Turned over but no spark. Messed with some wires and the e box started smoking. The smoke seemed to be coming from the starter solenoid. I changed that out and now I have no click and no turn over. I jumped the posts and the engine turns over

    Iím taking a break from this ski for a few days




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

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

    I finally messed with this thing some more on Saturday. Found the culprit for no spark:


    Sent the coil out to jet ski solutions this morning in hopes to get it back for the weekend.


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

  10. #10
    Top Dog Boz Mon's Avatar
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    550/650 rebuild build

    Go my new coil back this week. Put it all together tonight after work. I have spark and it started! Iím pumped to splash this thing on Saturday.

    I stripped and painted the westcoast pipe over the weekend and my friend 3D printed me some new reed stuffers.













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    Last edited by Boz Mon; 10-03-2019 at 10:00 PM.
    1994 FX1
    1985 JS550/650 conversion
    2015 Fiat 500 Abarth

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