2008 Superjet "The Basketcase" Build

Joined
Aug 16, 2011
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112
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cape may, nj
#1
Here is my start of my 2008 Yamaha Superjet Basket Case. Front to back, top to bottom something was wrong. I got it at the right price so it's worth it to me getting it back up to par. Ski is going to be used for rec riding. Ski will be mostly stock with a few upgrades. Original engine was a rebuild but is toast again from water intrusion. Body wise, well there isn't any holes. The paint needs addressing. Tried wet sanding and buffing. That was a waste. Pump housing seized from sitting when original owner couldn't decide what to do with it. Surprise!!! Drive shafts were stuck also. Going to try to put pics up with the updates on how it's going. Sometimes I get ahead of myself and forget to take pics. Or don't know how to put them up, lol. Probably will be asking some questions, so feedback is welcomed.
Thanks, Chris
 
Joined
Aug 16, 2011
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112
Location
cape may, nj
#2
Ok, I pulled everything out and pull apart the engine before I joined XH2O. Only thing left on the hull was the stuck drive shafts. Finally got some time after a few months to get back into it. So after using a little persuasion the pump wouldn't budge. Well it did move about 1/2 inch before it stopped. So I had to jam a pry bar into the pump to take off the coupler. Then stood the ski up the spray down the inside of the short shaft with PB Blaster. After 2 days of soaking. I put a punch into the shaft and it took about 5 good whacks to get the shafts unstuck. Next, I started to go through the boxes of parts and clean up the good. Got a few pieces that are going to get bead blasted before new paint. Also to remove all the crusty salt deposits.
 

SkiPro

Trim down for what!?!?!?
Joined
Jun 8, 2012
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458
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E-Town, Ok
#7
check those cooling lines.. Looks to be siliconed in or something. Make sure there not leaking water into the hull. Your so deep into it you might as well refoam it and replumb it so you know its right..
 
Joined
Aug 16, 2011
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112
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cape may, nj
#9
Yeah I was thinking about cutting open the tray. I've seen so many people do it on here it seems to be a usual problem. With mine being sunk at one time, it wouldn't be a bad idea. Plus I want to install drain plugs with tubes going through tray like as scupper but with a OEM plug. I'm not doing foot wells, so I don't think I have to cut up the sides to remove foam. Or do I? Where's is the best place to buy the foam and kind. Yeah the silicone around the rear tubes look suspect so they were going to get redone also. Want to put a Blowsion or equal exhaust exit for looks.
Things to do and want to do.
1)Glass in gas cap and make gas fill direct on fuel tank.
2)Paint ski and have an idea already brewing
3)Reinforce the sides of engine compartment (glass or carbon?)
4)bead blast engine components, rebuild and repaint.
5)paint inside hull (most durable?)
6)turf the tray n rails
7)install different steering. Using stock pole for now. Have UMI bars already.
8)redo chin pad (turf or cover)
9)install new ODI grips, billet throttle n kill switch thing for no lanyard. (Have handle bar bilge switch already with pump)
 
Joined
Aug 16, 2011
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112
Location
cape may, nj
#10
Parts list so far...
...Engine) Crank, pistons, gaskets, seals, 3 broken 10mm bolts on exhaust (removed already), redo carbs (might send to JSS bc they got even worse from sitting. Throttle shafts are tight. Choke is removed already from primer install) and mounts (probably RAAS with Kenny Keepers. The colored ones I like too)
...Driveline) New couplers & rubber dampner (pump side cracked, OEM bearing housing (original fell apart when trying to get drive shafts apart), Solas impeller for stock engine specs, OEM pump bearings, Steering ring (orig was cracked), new pump shoe (probably metal kind), impeller housing (pic says it all), 4 long pump bolts, will be painting pump with zinc paint and primer then with out drive paint.
...Controls) ODI grips, billet throttle, new chin pad cover, have to get a new/used handpole bracket (orig is broken in one corner)(guess OEM bc the after market ones are lowered and can't use stock hood?), Hydroturf mats and rails (tray padding?), rear mat holder from Blowsion.
...Looks) new paint top n bottom, graphics, registration numbers (3D kind), rear exhaust outlet, bilge pump outlet, bow bushing, tow ring for front, colored water lines, using OEM fuel lines but want to find colored covers for them. Colored coil wires or covers, battery tray (original is broken), front nose cover (missing)
...I'm sure I missed things. Keep you posted on more future work.
 
Joined
Aug 16, 2011
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112
Location
cape may, nj
#11
It is burnt, tried heating up for about 10 seconds on the torch to loosen drive shafts. The paint is just burned up. Structure is good. The pump was the 1st thing I tried taking apart. So I tried a couple of things before I pulled the engine. Engine was coming out anyway because it was seized. Was ahead of myself.
 
Joined
Aug 16, 2011
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112
Location
cape may, nj
#13
Sounds good, trying to get stuff in order now to get ready for bead blasting. Yeah, I keep pushing the carbs away further and further because they are probably in my eye the roughest in shape.
 
Joined
Aug 16, 2011
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112
Location
cape may, nj
#14
So here is what is left of the original battery tray. So no more plastic. Metal tray for the future. Also after going through the box of parts, I found the handpole bracket. I was wrong. The mounting bolts are still connected. The little rubber piece that does ? rotted apart. It took out part of the mount with it. After it gets blasted I'm might either fill with metal epoxy puddy and sand, or grind out and make it look like it was supposed to be that way. Of course make the good side match. image.jpeg image.jpeg
 
Joined
Aug 16, 2011
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112
Location
cape may, nj
#17
Ok.....I haven't slacked off. I've been working on the ski. Getting everything sorted out, cleaned up to be ready for install and making parts list. I'm about the price I was figuring to get it going and looking good but of course you always want more. So then I had to figure out the "wants n needs". Also the "wants" that are a pain to install after all done. They ended up on the need list. Wish I was farther ahead but I have lots going on. If I get an hour or 2 I'm lucky.
 
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Joined
Aug 16, 2011
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112
Location
cape may, nj
#18
image.jpeg image.jpeg image.jpeg image.jpeg image.jpeg So here is some progression shots...
Hardware getting wire wheeled and tagged, parts cleaned and ready for install, box of metal ready to go in my best friends blasting cabinet.
Oh, and my handpole mount. Started to take out the mounting area for the rubber thing that I found out was a stopper plate. Going to do the same on other side to match it up
 
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Joined
Aug 16, 2011
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112
Location
cape may, nj
#19
image.jpeg image.jpeg Plus I have my parts skis aka donors. When I bought my house there was this vxr pro next to my property line. Saw the neighbor one day and ask about it. It was his and he said it's been sitting because the wear ring had seized up n he didn't want to fix it. He said it ran, no catastrophic failure. Well, it's my POS now. Pulled out engine n all hardware and now it's ready for the crusher. So now I have a spare 61x for a future project.
 
Joined
Aug 16, 2011
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112
Location
cape may, nj
#20
I also have a vxr 650 for the same thing. Was one of my customers. I put a center bearing housing in it n a wear ring n it hasn't gone anywhere for 3 yrs. Customer abandoned it so once I get it from my best friends shop I can get some of my money back that I put into it.
 
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