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  1. #21
    PWCToday Regular ZacFlyer's Avatar
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    Re: JS440 / 550 Swap Ski Refresh

    Today's efforts come with a reward, but also frustration... I acquired new T-Bolt clamps from Fleet Pride. They are TB-475 if anyone is asking. Anyway, they had a variety of sizes and these seemed to fit the range that I was requiring. I picked them up on Thursday and ventured down to the lake today. The very first thing to do was replace the stock exhaust with the West Coast pipe. The pipe fit in with some effort and grunting. Re-plumbed and ready for a start-up we went! I did not bring a big enough drill bit for the primer, unfortunately, nor did I make an attempt to put on my fresh red bars. Here is why I did not get to everything.

    I put it in the water and let the ski get nice and warm ready for some tuning, checking for leaks, etc. My entire afternoon consisted of idling in my slu. The ski would not make it above a third or so throttle. I tried walking it up, punching it, adjusting the low and high-speed screws extensively, and going through the Mikuni manual.

    So I settled on a conclusion let's see if you all agree.
    The pop-off pressure is too high. As I roll on the throttle it would stay happy until just about plowing speed. Any more throttle and it would surge (depending on the carb setting).
    With some exceptions being:
    -Straight dying (likely incorrect needle setting)
    -Sputtering / bogging (likely incorrect needle setting)
    -Making good power and nearly ripping me from the bars due to sheer surprise then, surging again.
    When I removed the water component and had the ski unloaded it would do the same thing. The process was just faster of course. As you know above yes, a fresh engine case that holds pressure, clean fresh gaskets, and a clean SBN 38 with settings of:
    -Spring silver
    -High 130
    -Needle seat 1.2
    -Low unknown
    -Pop off 38psi

    I will be doing far more reading through the night to determine if my conclusion is correct, rather I should say my hypothesis. If you think the same or different let me know your thoughts. Below I have attached a video accessible only through the link for all to observe my findings.
    https://www.youtube.com/watch?v=hCNu...ature=youtu.be

    As always thanks for tuning in for another episode.
    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. #22
    PWCToday Regular ZacFlyer's Avatar
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    Alabama
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    Re: JS440 / 550 Swap Ski Refresh

    Once again I made it to the lake to work on a Saturday. Today's task: move items from our old attached garage to the new building on our property. After all of that was finished it was time to actually work. Some of you may have noticed that I posted on the Technical Discussion page my notes from last time. You all gave me some suggestions so I went shopping. I made the long journey from my couch to my office and grabbed my laptop to buy a 2.0 Needle and Seat, a 100, and 95 high, and a 90 low. I installed the 100 high as well as the needle and seat. It did not disappoint! We made it up on plane, splashed around a bit, and I fell in from being so rusty! No actual tuning progress was made because on my second ride after adjusting the needles a little the cooling line from the hull popped off... Things were hot, water was present, Zac was frustrated. It does not seem that any harm was done, an inch or two of water was removed with a sponge, and the engine cranked again. Now to add items to the to-do list.

    List:
    Replace clear, cheap, junk cooling lines with strong, reinforced lines.
    Install a bilge with automatic switch
    Re-silicone bearing box to firewall. (Either, remove the tank and shift engine forward, or remove the engine).
    Examine the pump and impeller to locate rear rattling noise.
    Attached Images Attached Images
    Last edited by ZacFlyer; 04-04-2020 at 08:05 PM. Reason: Touching things up.
    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


  3. #23
    PWCToday Regular ZacFlyer's Avatar
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    Alabama
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    110

    Re: JS440 / 550 Swap Ski Refresh

    Yet another week has passed and I have made it to the lake and not worked on the 440. Although I picked up the next project and gave it a bath.

    Happy Easter to all.


    979E530E-A4DE-4DE2-8C53-B936774CEA15.jpeg
    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. #24
    PWCToday Regular ZacFlyer's Avatar
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    Alabama
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    110

    Re: JS440 / 550 Swap Ski Refresh

    I write with good news this week. I made it down to the lake Saturday and was able to get some good work and riding done! Now that the new garage has been completed (for now) and I was able to do some work previously, progress has been made. I picked up some 3/8's water lines. These are very thick and have pretty white braids going through them.

    IMG_2554.jpg

    IMG_2552.jpg

    The new lines got a little creative towards the pisser. As you can see the pipe is quite short, by a previous owner. Luckily it worked out very well. It did not take super long but with a few phone calls, I was distracted and the task took far longer than I had wished. Thankfully I set aside the day and moved to the water next. It cranked up and purred along nicely, I let it warm up as I idled over to the other side of my lot. I moved my tools so that I might begin tuning and stopping any leaks from the new water lines. Cranked back up and upon giving it throttle I noticed the ski did not enjoy much over a plow to planing speed and a little past. My fears were coming true, despite the carb. settings recommended by fellow jet skiers I did not change out the low setting. I suspect it was too rich but I was unable to ever read the markings due to it being stripped out when I received the unit. So this meant having to pull it apart.

    IMG_2558.jpg

    The ski ran great anywhere above half throttle (I had it slightly rich indicated by heavier than normal smoke) upon pulsing the throttle I could ride in the range of speed that I liked. Just barely on plane and cruising. I am sure that I was rather annoying to my neighbors for the time that I rode, but I had fun.

    IMG_2572.jpg

    The bad little low jet...

    IMG_2574.jpg

    With a small bolt extractor, it was no match, and the remnants remained on the tip. I exchanged the old with a 90 low as recommended by some industry leaders. Saturday I hope to slap the carb. back on and try my luck. Hopefully, I can get it all dialed in.

    The new pipe sounds awesome.
    https://youtu.be/RQJ3JrNfxzM
    Last edited by ZacFlyer; 04-20-2020 at 07:04 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


  5. #25
    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

    I can't believe how long it has been since I updated this thread. Life has been busy, my summers go nuts and I rarely have time to get bored. With that said the 440 now has a bilge, and a switch that failed literally once water touched it... That seems to be the case with all switches though. So I bought another today to try out, but it sucks that I soldered it in... Anyway, I made it a little spot for it next to the fuel selector, very tasteful. The carb is still a headache, apparently, I cant tune for s*&t when it has jets. But flying R/C nitro planes most of my childhood I could tune them great because it was an easy needle. So it runs enough where I can go and play but its still aggravating. I need to still spend some serious time with it to get it fixed. One of my friends has offered me a 650 to throw at it, and it has its own carb so I am pretty enticed with that too. I threw a new sticker on the pole that makes it really stand out now too. In aviation, there are aircraft that have not been certified by the FAA, and these are required to display a sticker that says EXPERIMENTAL. Being the pilot that I am, and an avgeek you can already guess what that new sticker says.

    Thanks for reading, talk soon friends.
    Attached Images Attached Images
    Last edited by ZacFlyer; 06-03-2020 at 11:55 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


  6. #26
    PWCToday Regular ZacFlyer's Avatar
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    Aug 2016
    Location
    Alabama
    Posts
    110

    Re: JS440 / 550 Swap Ski Refresh

    Here we are after another fun weekend in the sun. The 440 has returned to the suggested jetting of 100hi and 90low as that was the closest to perfect. I have spent too much on jets to continue fiddling with it so until the 650 gets dropped in this setup will remain. One of my friends came this weekend and brought his '97 GTI project, so fun was had with him. He actually provided me with a tow when my throttle cable came off the bracket and it died. These things happen I was just happy to have had a helping hand otherwise that would've been a long swim back. The 650 gaskets arrived Friday but I am still waiting on the adapter plate from John at WatCon. Then all I need is a blockoff plate or to throw a tap at it with some bolts. Somewhere in the mail should be an adapter 550/650 plate.
    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. #27
    PWCToday Regular ZacFlyer's Avatar
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    Alabama
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    110

    Re: JS440 / 550 Swap Ski Refresh

    Time continues to pass, and here I am with loads of progress and a thread that deserves updating. Heres a sneak peek for what the necxt topic will be about...
    Attached Images Attached Images
    Last edited by ZacFlyer; 07-21-2020 at 11:22 AM.
    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


  8. #28
    PWCToday Regular ZacFlyer's Avatar
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    Aug 2016
    Location
    Alabama
    Posts
    110

    Re: JS440 / 550 Swap Ski Refresh

    So as many of you have guessed from the last image I got another motor. But this time it's BIGGER!! One of my very close friends gifted me a 650sx engine to swap in. Coming from the 550 this will be a nice jump.

    **Spoiler Alert!! For your reference, I have already installed the 650 and have been riding, but I will continue to update as a timeline of events.**

    The engine is pretty dirty but I can make it work. It looks kinda like its been sitting in some muddy water for the past while. Its got a line on the flywheel and the inner flywheel case. So I assumed the crank was going to be no good but I thought I might crack the bottom open. As you see above it all looks really good. The crank seals actually looked brand new, which took me by surprise. I continued to go through the engine in search of any water. I found only a teeeny tiny couple of drops in the piston cups (motor was upside down). I gently shook all of that out and proceeded to add some marvel before buttoning it up. The rest of the engine looked very clean (after I cleaned it myself). The carb is what continued to hint me on to an idea for the next post. It was freaking clean. Not a single spot inside the diaphram, which was firm, and not a scratch on the outside besides a little surface rust.

    Thats all for now, thanks for reading and I will update you all very soon!
    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. #29
    PWCToday Regular ZacFlyer's Avatar
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    Aug 2016
    Location
    Alabama
    Posts
    110

    Re: JS440 / 550 Swap Ski Refresh

    Like mentioned before the goal was to clean up the 650 and drop it in. It was already pretty clean with a few exceptions. Surface rust on the carb, screwed electrics and, screwed flywheel. My friend has an electrolysis setup that we used on the flywheel.

    IMG_0779.jpgIMG_0780.jpgIMG_0818.jpg

    It came out extremely well, I had never used this method before, I find that the credit card method generally works great. Needless to say, I was impressed. Next, I moved to getting a carb, I got a BN44 from a friend and ordered the adapter from John at WatCon. Threw it together and slapped it on. Easy peasy, and it even comes with the hardware needed.

    IMG_0879.jpg

    Next, I had to make holes in the bedplate. This was certainly my least favorite part of the build. I mean it SUCKED grinding all this down. But eventually, I did get it together and it sits just like it should, nice and flush with no room for movement. This is a second-hand plate, I think it is a WatCon one, but I got it second hand from the depths of Facebook. I opted to mount it facing rearward to use a 550 coupler. This helps bring the engine more forward and prevent porpoising.

    **Earlier on the timeline I did block off the crankcase. I very carefully tapped the lower holes and threw in some bolts. Its an easy solution and for about the same price as a block-off plate and I get to keep a tap! I cleaned out all of the metal shavings and bolted the cases back together that evening. Here is the results:

    61526529953__2F24D95A-D987-4F79-8BF4-72F5686F937C.JPG

    Here was the other hard part. I had starter problems. Originally, the starter was trashed by rust. The front bearings were toasted, and the backside was less than fresh. So I swapped it with friends. Heres where the trouble began. But I will pick up on this part later.

    61526669093__6378C226-0B84-4AB6-A428-A91A6922F1CD.JPG

    So I began by ripping out the 550. It was already bought and paid for along with the exhaust. I gave the guy a pretty good deal since he would be lacking a carb, and coupler. Easy enough I made more room by pulling the tank. Fitment was not very pleasing, I had a hard time getting the engine and couplers to all POP into place at once. But once they did it was smooth sailing.

    61637307305__732BF614-EF73-476D-976D-49CA68617FF3.JPG61636141261__05CEEB0F-5697-4CCE-B875-B90AF4B91C23.JPG61628786548__03C7D082-BEFA-458A-8E2D-1E5AFC131419.JPG61637792743__BD96F7F7-291B-4443-A8FB-A73278845CE0.JPG

    From there the electronics work began, I had my friend help me out with wiring since he had just done a 550/650 swap. We ran into a little trouble, but the biggest problem was that starter I mentioned earlier. It was so bad that the ski would crank over 5-10 turns then act dead. If I reached for the stator wires they would be extremely hot. I dumped that starter and the 650 finally showed signs of life.

    https://www.youtube.com/watch?v=zp9M8VuK4mU

    Yes... yes, I jumped like a little chicken because after all the trial and error I had my doubts. But things were looking my way! Finally I began buttoning up the exhaust and putting the cooling lines together. She made it to the water that evening for a short run on the rope just to see that everything was operational. Below you will also find the splatterings of Marvel Mystery Oil that was left over, the stuff went everywhere.

    https://www.youtube.com/watch?v=Sv680hK891g

    IMG_1298.JPG

    So that's how she sits now. I am very happy. In the next post, I hope to put fingers to the keyboard and portray the difference of 550 / 650 engines in a JS hull.
    Last edited by ZacFlyer; 10-12-2020 at 01:50 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


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