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  1. #11
    PWCToday Regular ZacFlyer's Avatar
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    Aug 2016
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    Alabama
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    Re: JS440 / 550 Swap Ski Refresh

    Quote Originally Posted by Mokarran View Post
    Rebuilding the first pwc I have ever owned, it is fun to read builds like yours while mine is in progress too. Funny how mine starded with fuel tank issues and now it is completely pulled apart. Glad I am not the only one. Keep us posted. Question, how did the hand cleaner do on the non polished area's inside the engine bay? Would like to get mine cleaned up before reassembly.
    Thank you so much! It is funny how our minds... err hands tend to wander when there is only one or two things that need fixing.

    As far as the engine bay cleaning I used mechanics hand Goop from Lowe's. I varied my cleaning tools between paper towels and a pack of micro-fibers. My general method is to throw some gloves on and lather the Goop on the surface, or nastiness that you want to clean. As you rub it in the solution will do its work and loosen the oil, dirt, and grime. Come back with your choice of cloth or rag and wipe away the Goop and dirt leaving you with a clean surface! I use it to clean darn near everything. Paint, fiberglass, engine, wires etc.
    ‘80 SurfJet 9ft White Build Here: http://www.pwctoday.com/showthread.php?t=492092&p=4550438#post4550438
    ‘82 JS440 / 550 Swap Build Here:
    http://www.pwctoday.com/showthread.php?t=491239&p=4543624#post4543624
    '92 750sx Barn Find Build Here:
    http://www.pwctoday.com/showthread.php?t=493981&p=4561610#post4561610
    '95 Yamaha Wave Raider 700
    '97 Yamaha SuperJet Build Here: http://www.pwctoday.com/showthread.php?t=494510&p=4564967#post4564967
    '16 Yamaha VXR


  2. #12
    PWCToday.com Is My Home Away From Home WFO Speedracer's Avatar
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    Aug 2006
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    Al-ugh-bam-ugh
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    27,384

    Re: JS440 / 550 Swap Ski Refresh

    Quote Originally Posted by ZacFlyer View Post
    Awesome. I am going to see if my guy at the airport can do it this weekend, if not I will be in touch. Thank you sir!
    I hope he can my plans have had to be moved up , I will be up there on Friday this time.
    Y'all know me, still the same O.G. but I been low-key
    hated on by most these &^$$@s with no cheese, no deals and no G's, no wheels and no keys, no boats, no snowmobiles, and no skis, mad at me cause I can finally afford to provide my family with groceries

    WWSRD , What would Speed Racer do ?

  3. #13
    PWCToday Regular ZacFlyer's Avatar
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    Aug 2016
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    Alabama
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    Re: JS440 / 550 Swap Ski Refresh

    The bearings are done!

    As I left off in the last post I was returning home for the weekend to have the bearings pressed. Unfortunately, that did not happen. Then it occurred to me that my Uncle is rather handy when it comes to big boy tools. I am very thankful for his expertise and knowledge of metal works. I knew that I was leaving it in good hands...

    IMG_1448.jpg

    Here is a shot of the before. Mass destruction


    IMG_1814.JPG

    The cleaning process with no bearings.

    IMG_1813.JPG

    IMG_1812.JPG

    The final product. When I received the word this morning that the shaft had been completed I was overjoyed! Many months have passed with worry and fear for this one item to get done. I am extremely thankful to my Uncle and the contribution that he has played in this build.


    On the next episode: Re-assembly
    Last edited by ZacFlyer; 03-05-2020 at 04:31 PM.
    ‘80 SurfJet 9ft White Build Here: http://www.pwctoday.com/showthread.php?t=492092&p=4550438#post4550438
    ‘82 JS440 / 550 Swap Build Here:
    http://www.pwctoday.com/showthread.php?t=491239&p=4543624#post4543624
    '92 750sx Barn Find Build Here:
    http://www.pwctoday.com/showthread.php?t=493981&p=4561610#post4561610
    '95 Yamaha Wave Raider 700
    '97 Yamaha SuperJet Build Here: http://www.pwctoday.com/showthread.php?t=494510&p=4564967#post4564967
    '16 Yamaha VXR


  4. #14
    Top Dog Boz Mon's Avatar
    Join Date
    Jun 2005
    Location
    Kankakee River
    Age
    33
    Posts
    1,881

    Re: JS440 / 550 Swap Ski Refresh

    Subscribed. I wanna see this thing finished!


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

  5. #15
    PWCToday Regular ZacFlyer's Avatar
    Join Date
    Aug 2016
    Location
    Alabama
    Posts
    110

    Re: JS440 / 550 Swap Ski Refresh

    Quote Originally Posted by Boz Mon View Post
    Subscribed. I wanna see this thing finished!


    Sent from my iPhone using Tapatalk
    Welcome aboard!
    ‘80 SurfJet 9ft White Build Here: http://www.pwctoday.com/showthread.php?t=492092&p=4550438#post4550438
    ‘82 JS440 / 550 Swap Build Here:
    http://www.pwctoday.com/showthread.php?t=491239&p=4543624#post4543624
    '92 750sx Barn Find Build Here:
    http://www.pwctoday.com/showthread.php?t=493981&p=4561610#post4561610
    '95 Yamaha Wave Raider 700
    '97 Yamaha SuperJet Build Here: http://www.pwctoday.com/showthread.php?t=494510&p=4564967#post4564967
    '16 Yamaha VXR


  6. #16
    PWCToday Regular ZacFlyer's Avatar
    Join Date
    Aug 2016
    Location
    Alabama
    Posts
    110

    Re: JS440 / 550 Swap Ski Refresh

    Here is a little sneak peek of the progress that I made today. I drove to see the ski today and spent about 5hrs working on it. I will have a full write-up with all my content from today very soon. My day is not over yet so I must continue to progress my life leaving you all with this.


    *Disclaimer:* This is not the final form of the ski when I left! Is that good or bad??? Find out soon.


    IMG_2070.jpg
    ‘80 SurfJet 9ft White Build Here: http://www.pwctoday.com/showthread.php?t=492092&p=4550438#post4550438
    ‘82 JS440 / 550 Swap Build Here:
    http://www.pwctoday.com/showthread.php?t=491239&p=4543624#post4543624
    '92 750sx Barn Find Build Here:
    http://www.pwctoday.com/showthread.php?t=493981&p=4561610#post4561610
    '95 Yamaha Wave Raider 700
    '97 Yamaha SuperJet Build Here: http://www.pwctoday.com/showthread.php?t=494510&p=4564967#post4564967
    '16 Yamaha VXR


  7. #17
    PWCToday Regular Mokarran's Avatar
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    Feb 2019
    Location
    Florida
    Posts
    65
    Blog Entries
    1

    Re: JS440 / 550 Swap Ski Refresh

    Looking sweet! What fuel tank are you using? Looks like there is room for a bigger one.

  8. #18
    PWCToday Regular ZacFlyer's Avatar
    Join Date
    Aug 2016
    Location
    Alabama
    Posts
    110

    Re: JS440 / 550 Swap Ski Refresh

    Quote Originally Posted by Mokarran View Post
    Looking sweet! What fuel tank are you using? Looks like there is room for a bigger one.
    I am running the stock tank, it was pretty clean, and not extremely yellowed like some. So for now, it works!
    ‘80 SurfJet 9ft White Build Here: http://www.pwctoday.com/showthread.php?t=492092&p=4550438#post4550438
    ‘82 JS440 / 550 Swap Build Here:
    http://www.pwctoday.com/showthread.php?t=491239&p=4543624#post4543624
    '92 750sx Barn Find Build Here:
    http://www.pwctoday.com/showthread.php?t=493981&p=4561610#post4561610
    '95 Yamaha Wave Raider 700
    '97 Yamaha SuperJet Build Here: http://www.pwctoday.com/showthread.php?t=494510&p=4564967#post4564967
    '16 Yamaha VXR


  9. #19
    PWCToday Regular ZacFlyer's Avatar
    Join Date
    Aug 2016
    Location
    Alabama
    Posts
    110

    Re: JS440 / 550 Swap Ski Refresh

    https://www.youtube.com/watch?v=Di53S-2KMSo

    Here is the real treat from yesterday. This is the majority of my work assembling the ski. More detailed posts and storytime coming later.
    ‘80 SurfJet 9ft White Build Here: http://www.pwctoday.com/showthread.php?t=492092&p=4550438#post4550438
    ‘82 JS440 / 550 Swap Build Here:
    http://www.pwctoday.com/showthread.php?t=491239&p=4543624#post4543624
    '92 750sx Barn Find Build Here:
    http://www.pwctoday.com/showthread.php?t=493981&p=4561610#post4561610
    '95 Yamaha Wave Raider 700
    '97 Yamaha SuperJet Build Here: http://www.pwctoday.com/showthread.php?t=494510&p=4564967#post4564967
    '16 Yamaha VXR


  10. #20
    PWCToday Regular ZacFlyer's Avatar
    Join Date
    Aug 2016
    Location
    Alabama
    Posts
    110

    Re: JS440 / 550 Swap Ski Refresh

    Yesterday I woke and drove down to the house to find the yard filled with mud and miscellaneous construction items. Besides the point, I was very excited to be there and assembling.

    I started out with the bearing box. As shown in the video I removed the tank and bolted it in. Smooth sailing, tightened down. Cleaned up the pump silicone and threaded the new to me prop on. Easy enough. I picked up the pump and started to slide it into place keeping in mind that I need to connect the cooling hose and bilge hose.

    Then I pulled the choke cable and made an attempt to install the plunger. I hadn’t realized it was larger so I will take a drill next time I go. I bagged up all the parts and moved onto moving everything in the engine bay out. Moved plug wires, cables, and removed the motor mount bolts from the mounts.

    I got the engine in with no problem but I was having a hard time fitting the WestCoast pipe into the ski. I reluctantly removed the engine and split the pipe so that I might install half the pipe with the engine. Yet again no luck….

    I had to remove the fuel filter and it eventually fell into place and mated with the coupler. I wrestled with it for longer than I had wished. But it did fit into place. This was my first problem of the day.

    I began connecting the ground wires, starter wires, plug wires, hoses, and cooling lines. No problems there either.

    The time had arrived for me to turn it over. If you have ever rebuilt or partially rebuilt an engine, or any component on a ski then you know the feeling that was coming over me. Fear, excitement, and hope all at the same time. I made sure to throw some gas down the carb to not kill the battery trying to prime it. And it kicked! I pushed it outside and continued to give it some gas. With my hand over the intake it ran and idled happily. So the carb needs a little tuning to richen it up.

    But my last problem showed its face. The cone on the pipe would move in and out rapidly higher in the rpm range. It leaked severely with the hose clamps that I purchased. No matter how tight I got the clamps I think they just weren’t able to close as tight as I need. So I pulled the pipe off with some effort and replaced it with the stock pipe and re-installed the 440 restrictor.

    Moving to the boat ramp I wanted to get some heat in the engine and just let it run for a few minutes. So with my hand over the intake to prime and make it rich we were kicking and running happily on the ramp. I fixed a few leaks in the cooling lines and was rather satisfied with the engine's performance. Throughout the rpm range, it appeared to be happy.

    Here is the pump and ride-plate installed nicely. New bolts are in the works. After I try out the performance mods I am going to add the extended plate and see if I like it. Yes, yes, I am a sell out on the handling scene! My lake has nothing but wake boats and remains choppy throughout the day so I am going to cheat a little with this and 4-degree bars.
    IMG_2075.jpg

    Note my cooling madness... it did not even make it to the water in this condition. My goal was to have the cone take the 90degree as to not load up the waterbox so much. You experienced folks woll know what is best on that front.
    IMG_2078.jpg

    Here is the final configuration that I left the ski in and had it running at the ramp. I luckily did not have to cut any more line.
    IMG_2081.jpg


    Next time's goal? Acquire smaller T-Bolt clamps, install the painted bars, tune the carb, re-install the new pipe, install the primer, and hopefully go for a ride. As always thanks for checking out the build!
    ‘80 SurfJet 9ft White Build Here: http://www.pwctoday.com/showthread.php?t=492092&p=4550438#post4550438
    ‘82 JS440 / 550 Swap Build Here:
    http://www.pwctoday.com/showthread.php?t=491239&p=4543624#post4543624
    '92 750sx Barn Find Build Here:
    http://www.pwctoday.com/showthread.php?t=493981&p=4561610#post4561610
    '95 Yamaha Wave Raider 700
    '97 Yamaha SuperJet Build Here: http://www.pwctoday.com/showthread.php?t=494510&p=4564967#post4564967
    '16 Yamaha VXR


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