First JS440 build!
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  1. #1
    PWCToday Newbie
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    Apr 2020
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    MI
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    First JS440 build!

    Hello everyone!
    I just finished up a Tigerskark TS1000L and sold that off a couple weeks ago. I had the itch to try a standup ski and found this old turd a state away.

    Drove 3 hours and packed this pile of parts into my van. I paid $400 and I am not quite sure if I overpaid. lol

    The goal is to get this rebuilt for under $1500 and most of that budget is already spent.

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    Almost everything is there except the Carburetor and a battery.


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    A couple hours of pressure washing and turf scraping and it is looking a LOT better!

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    The engine is in decent shape, and ALL ORIGINAL 67.75mm bore!
    This has proven to be an issue because I could only find oversize pistons and rings. I decided to try resurfacing the pistons and I bought the last two piston rings on the internet for way too much money.

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    So the tentative plan is to gut everything and repair nad refinish the whole boat to better than new. I will be filling, bonding, and spraying a whole new color. My lady would like it to be a burnt orange color. I was initially thinking a dark gray.

    Any suggestions on color?

    I am excited for this new type of build! This website has been a huge help for all of my past questions so thank you!

  2. #2
    I dream skis E350's Avatar
    Join Date
    Jul 2015
    Location
    Sacramento Delta, CA
    Posts
    600

    Re: First JS440 build!

    Please keep posting. We have a JS400 which was my wife's first ski. Which she had converted to 440 SuperStock when she bouy raced in the 1980's-1990's and which was later replaced with a regular 440 when the 440 SuperStock blew, and now the regular 440 has a seized rear piston.

    I know I can't sell it due to sentimental value, but I don't know what to do with this ski. Maybe how you restore your ski will help.

    As far as color goes. I like white skis with oem decals. Like Mikesx says, "I like my skis oem and minty fresh."

    Pam's Jet Ski Racing Bouy 2.jpg


    White is the easiest color to see on the water, which is good if you are looking for your wife or kid with a broken down ski.
    Or if you want to be seen by a power boat driver pulling kids on a boat toy who is more often looking in the rear view mirror than ahead where your wife or kid are in the water trying to restart their ski.
    Last edited by E350; 06-16-2020 at 12:11 PM.
    Learning Slowly...

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

    A fresh white paint and decals looks cool, but decals cost at least $150 and a white ski will always look a bit dated. Modern skis are solid colors because it looks cooler IMO.

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

    That is wicked awesome photo btw! She seems like a keeper!

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

    Re: First JS440 build!

    Definitely a better skier than me and definitely a keeper.

    Since its Tuesday and because of your user name I feel compelled to post this as your build's theme song:

    https://youtu.be/cuI0u1Xvh2Q
    Learning Slowly...

  6. #6
    I dream skis matt888's Avatar
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    Apr 2005
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    CENTRAL FL
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    52
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    657

    Re: First JS440 build!

    Diamond in the rough, now I want a Miller.

    SOLD! HONDA AQUATRAX 2 SEATER
    1987 JS440 SUPERSTOCK
    1988 JS440 FREESTYLE
    1987 JS550 LIMITED
    SOLD AND MISSED VERY MUCH, 1994 WAVEBLASTER LIMITED
    WWW.HONDAOFWINTERHAVEN.COM
    1987 AM. WORLD CUP CHAMP
    My album http://www.pwctoday.com/album.php?albumid=2000
    https://youtu.be/S3KAF71mm4o

  7. #7
    PWCToday Newbie
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    Apr 2020
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    MI
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    Re: First JS440 build!

    I do love tacos!


    Day two went well!

    Got the Pole totally stripped and the front half of the ski gutted.

    Any tips on removing the Choke and Fuel reserve switch plate? It appears glued on. Will a heat gun do the trick or is there more to it?

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    The parts bucket monsters are well fed!

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    Last edited by tacopwr; 06-16-2020 at 09:36 PM.

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

    Day three has completed with a bit of progress. I ordered a crap-ton of painting supplies from Eastwood so that should be here soon. The new Carb showed up as well and I didn't realize that it didn't have a choke, so I need to find a priming bulb somewhere.

    I built a jet ski stand using a harbor freight moving dolly, all of the scrap 2x4s on the side of my house, and some Pipe insulation. Turned out pretty sweet!

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    Now that the ski is off the ground I can remove the pump.

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    Looks like this impeller is in rough shape. Any ideas on a replacement? Does Solas even make something for the 440? I guess I could google around.

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    None of the adhesives anywhere in this unit were still holding anything. This pump would cavitate like crazy if I tried to run it.


    PX9l3kI.jpg


    Also I found one of the ride plate bolts had broken off. But there was just enough threads sticking out to grab with some baby vice grips. Got it out!

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    Last edited by tacopwr; 06-18-2020 at 08:46 PM.

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

    Second update:

    I just started tearing down the pump and it appears that there are nw roller bearings in the stator assembly? Just a pressed in bushing and two seals back to back. Is that correct?

    The seals were toast so I will order more of those.

    These things are so simple it’s kind of blowing my mind.

    I have never worked on a piston port engine, and I've service a bunch of jet pumps but never one without bearings in the stator. That is wild!


    UPDATE:

    I found a used Skat Trak impeller and a new set of pump seals and they should be here
    Last edited by tacopwr; 06-18-2020 at 09:39 PM.

  10. #10
    I dream skis E350's Avatar
    Join Date
    Jul 2015
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    Sacramento Delta, CA
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    Re: First JS440 build!

    Dang, I should tear into our JS400, just so I could shadow you in real time. Thanks for documenting everything with text and pictures and sources!
    Learning Slowly...

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