First JS440 build! - Page 2
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  1. #11
    PWCToday Newbie
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    Re: First JS440 build!

    So more progress!

    I drowned my phone last weekend so some photos have been lost. These were taken with my ancient iPhone 5.

    Today I split the case on the engine.

    This thing is is pretty good condition. The inner rear seal and the front seal are destroyed, but that is why we bought all new ones!

    The piston wrist pins are absolutely perfect, as are the crank bearings, thankfully!

    I will hopefully have this thing put back together by the end of the week.
    Attached Images Attached Images
    Last edited by tacopwr; 06-23-2020 at 09:12 PM.

  2. #12
    Top Dog 440Splash's Avatar
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    Jun 2010
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    Puyallup WA
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    1,314

    Re: First JS440 build!

    Subscribed

    Great pics to update your progress.

    I'm doing the exact same thing as you with a 76' 440 I just bought. It looks like I'm a day behind you. I have everything out of the hull except E -Box. I pressure washed the inside...Look amazing.

    keep it up.
    1990 JS440 (Original Owner) PJS Ski (Peek at photo album)
    1989 JS550 "Haulin' Harry G's" Westcoast Ski (Peek at photo album)
    1986 JS550 (Oldest daughter's Ski)

    1976 JS440 (Youngest daughter's ski)

    2011 GREAT LAKES WATERCROSS TOUR - Vintage 550 1st Overall
    2013 GREAT LAKES WATERCROSS TOUR - Novice Ski Lites 3rd Overall (KAW SXR #147)
    Thanks to SPONSOR S.Hyke Performace Racing Products

  3. #13
    PWCToday Newbie
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    Re: First JS440 build!

    Are you keeping the stock 440? I am nervous that its a better value to just install a rebuilt 550 from SBT.

  4. #14
    PWCToday Newbie
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    Re: First JS440 build!

    Finally got back to work today.

    Worked on cleaning up the engine today. Got the PTO couple off, all the old gasket material and sealant from everything.

    Reinstalled the two missing studs with locktite, and I also sanded down the scuffed Piston a bit. It is significantly more smooth.

    According to my calipers, the cylinder to piston clearance is still ok.
    The new piston rings are a bit meatier by .07mm and hopefully that should bring back some compression.

    I will try to hunt down a bore gauge to be absolutely sure of the piston clearance, but I can't find one to rent or borrow.

    Tomorrow is boating day so I won't have any more progress until this week. Hopefully gonna get the hull sanded down but who knows!
    Attached Images Attached Images
    Last edited by tacopwr; 06-27-2020 at 10:28 PM.

  5. #15
    I dream skis E350's Avatar
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    Jul 2015
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    Sacramento Delta, CA
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    600

    Re: First JS440 build!

    I have never seen or used a bore gauge, so please post up your use of one when you do it.
    Learning Slowly...

  6. #16
    PWCToday Newbie
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    Re: First JS440 build!

    Did a bit of honing today. Definitely not my best work as I didn't get the angle quite right. Should be enough for this little engine though.

    I apologize for the crap-tastic photo. My new phone is lost at USPS somewhere.

    Hoping to work on putting the engine back together tomorrow!


    IMG_3169.JPG

  7. #17
    PWCToday Newbie
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    Re: First JS440 build!

    Not too much progress since I have been hella busy lately.

    I finally removed the control panel and fuel reserve switch. Took a lot of heat with a heat gun but eventually got a bad through the adhesive.

    I cleaned up the rest of the engine bay. Next I just need to do one last pass with acetone or brake clean and then prime and paint the engine bay.


    Today I also removed the impeller. I used a block of wood in the blades and a pry bar to turn the coupler.

    Thankfully someone put some anti-seize on the impeller threads so it was not too hard to remove.

    Here is the stainless impeller and the old impeller side by side.
    IMG_0065.jpg
    Attached Images Attached Images
    Last edited by tacopwr; 07-11-2020 at 07:01 PM.

  8. #18
    PWCToday Newbie
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    Re: First JS440 build!

    Made a bot of progress on the hull yesterday.

    Ground off the leftover foam traction mats and removed the adhesive from the handlebar mount and control area.
    Did a bit of sanding in the footwell area and the nose. Lots more to do.

    ED4F636E-4823-4F39-B3E0-7AE046250C4C.jpeg

    8F8C9B96-5E87-4D0B-AD62-D0899713B85B.jpeg

  9. #19
    PWCToday Newbie
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    Re: First JS440 build!

    Finally put the motor back together today!

    I found that the base gaskets were worthless. The stud holes were too small. The two gaskets overlapped between the cylinders and that was not going to work.

    I just used Permatex as the base gasket instead and it worked a lot better. Maybe I got a tad more compression out of the deal. Lol

    Even reusing the scored pistons with new rings, and honing out most of the scratches in the bore, we got exactly 120 PSI on both cylinders!
    Itís not a perfect brand new engine, but itís a lot cheaper than paying a machinist and sourcing new oversized pistons and rings.
    Last edited by tacopwr; 07-19-2020 at 05:23 PM.

  10. #20
    PWCToday Newbie
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    Re: First JS440 build!

    Well I have run into a major snag.

    I either bought the wrong carb or the intake manifold is the wrong size.

    The manifold bolts are 3" apart, and the carb holes are 2.5" apart. Obviously not going to fit.

    Also I am googling stock js440 manifolds and none of them have the webbing like this one does.

    Can anyone confirm that I have the right carb before I buy a used manifold off eBay?

    IMG_0167.JPG

    IMG_0173.JPG

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