First JS440 build! - Page 4
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  1. #31
    PWCToday Newbie
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    Re: First JS440 build!

    Itís a Mercury 240 EFI Sportjet. One of the coolest engines ever IMO. Planes in 3 seconds and sounds awesome. I haven't had any issues with it and itís super easy to maintain. The boat consistently does 45 mph with the whole gang on board.
    Last edited by tacopwr; 08-22-2020 at 05:59 AM.

  2. #32
    PWCToday Newbie
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    Re: First JS440 build!

    Finally getting settled in the new house. Bought a truck project as a daily and had to rebuild the differential and a million other things.

    But now I finally have time to start back on the ski!
    Got the hull set up in the barn and will be sanding the bottom of the hull and sealing the cracks. Then bondoing the rest of the scratches.
    Wish me luck!
    A1B28BFC-F593-4E8E-9C02-77FEA6616C99.jpeg
    A86A4740-8AF4-4D79-AC90-2F4FA6990C65.jpeg
    Last edited by tacopwr; 05-27-2021 at 09:15 AM.

  3. #33

    First JS440 build!

    If it comes to it elongate the bolt holes on the carb to fit the manifold you have. Ive done it in a pinch and works fine. Just make sure the intake manifold and carb is the same diameter. If it isnít a Drexel on the intake side and match it up.


    Sent from my iPad using Tapatalk
    Last edited by 550headache; 07-04-2021 at 04:03 PM.
    1995 FX-1: Pro-Tec chamber~Skat swirl~Pro-Tec plate~Blowsion Destroyers

    1990 Square Nose: Blue ported Jetmaniac 718~#ZERO lightened/drilled flywheel~ADA girdled/32cc~701 B pipe/flow control~Hooker 9-15~AAA pole~Pro-Tec rideplate~Tom21 Tubbies and nose piece

    2014 Super jet waiting on a B pipe and Hooker....

  4. #34
    PWCToday Newbie
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    Re: First JS440 build!

    AF9C94B7-11CC-4165-B0D5-FE9F283878D3.jpeg

    Just a casual year long delay. Still working on house projects, boating, motorcycle projects and snowmobile issues.

    Finally pulling the ski back to the center of the shop this week. I did manage to get some sanding done and put some fiberglass reinforced filler on the crack in the bow... July of last year. lol
    I will be focusing on sanding, smoothing, and priming the bottom of the hull this weekend.

  5. #35
    PWCToday Newbie
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    Re: First JS440 build!

    I was pretty burnt out on bodywork after just a little time. Lol
    So I gave up and decided to start replacing parts and paint at the end. B81D6A0B-EDDA-4298-ABE1-2A619F9C89EB.jpeg
    Attached Images Attached Images
    Last edited by tacopwr; 08-11-2022 at 09:43 PM.

  6. #36
    PWCToday Newbie
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    Re: First JS440 build!

    I have finally gotten the engine back in the ski and am currently working on sorting out the torn apart ignition system.

    From the stator, someone depinned the 6 pin connector. I am MISSING the other half of the 6 pin connector from the CDI box side, and the regulator is all torn to shreds.

    One other thing I noticed, is the coil appears slightly different then the parts diagrams. Those show the coil with 5 wires, where mine has 4. There is no wire long enough to reach out to the missing 6 pin connector.
    I also noticed my regulator has 5 wires, but the parts diagrams show 4 wires off the regulator?


    My assumption is the red and gray wires on the coil which have been crimped together to a male pin, (see photo) should be longer and running to the missing 6 pin connection, and the regulator wires would also run to the 6 pin connection per the parts diagram. Does anyone have any up close photos of these parts to hep me sort where everything goes?

    IMG_9089.JPG

    IMG_9090.JPG

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    Screen Shot 2022-08-13 at 1.59.44 PM.png
    Screen Shot 2022-08-13 at 2.24.28 PM.png
    Last edited by tacopwr; 08-13-2022 at 02:26 PM.

  7. #37
    PWCToday Newbie
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    Re: First JS440 build!

    Ok so quick update:

    I browsed a bunch of eBay ads which showed the boxes opened up and determined where each of the wires go EXCEPT the third green wire from the regulator. Then I googled the part number and that appears to be a 650 regulator. So my logic was that the third gree wire is for an extra AC input that I dont have. So I just taped one green wire off, and connected the rest as shown in the diagrams and the photos from eBay.

    I hooked everything up to a battery and it turns over with spark!!! WOOOO!

    Now I just need to find a tidy way to replace that 6-pin connector and I can then move onto the fuel system.

    A2D9E633-F7A5-4908-A751-658FE71FDD4C.jpeg

    4986290A-BEA9-4C47-AB44-F31C620B3951.jpeg

  8. #38
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    Re: First JS440 build!

    Another quick update.

    I primed the carb and the Ski fired up first try! I couldn't believe it.

    Going to have to wait on new fuel lines, clamps, and a 6 pin connector for the ignition box. Once those come in we will be ready to rock.

  9. #39
    PWCToday Newbie
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    Re: First JS440 build!

    Ordered some 6pin molex connectors a while back and had to do some trimming to get it to fit, but all is well!
    Next up:
    Finding some 80mm M6 bolts to hold the CDI box on and I can put the rest of the engine bay and fuel system together.

    4AC9A884-B128-4DBE-8F92-136F1DCB1F77.jpeg

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