300/440/550 1990 550 tear down and rebuild, lots of pictures

[bumperlt]

Got my first stand up last week and tore into it. The engine needs to be rebuilt, and the hull needs a little cosmetic love. Here's a bunch of pictures. I know almost nothing about jet skiis, but I'm learning pretty quick. Any input would be great!

Other side of garage

piston carnage.

 

[Mark Gomez]

Those cases may look cracked but they are actually fine. its just the crappy Casting from kawi that doesnt look pretty. Almost everything else you need to rebuild that thing, Crank, seals, Pistons, boring, electrical grommets, head, carb kit, gaskets, reeds, fire ext. cap, stators, coils, and more is all located at Pacific Motorsports in Brea, CA. They ship all the time and have almost EVERYTHING you need for that 550 I listed above. give Gordon a call and tell him I sent you 714 671 1145 You have a cool project and a reed motor is always a plus give Gordon a call at Pacific motorsports and he will get you all dialed in with everything you possibly need to get that 550 back together.

 

[cookn]

In my opinion you should just look for another motor.I would question your crank after a failure like that. Your cylinder will have to be bored. It would probably be the cheaper route. Then you could rebuild that motor for cheap before it blows. I put new pistons in my piston port 550 for like 60 bucks off of ebay. You may have a harder time finding a complete replacement reed motor like you have, but ebay is a good place to find some cheaper stuff, but watch out for crap. Brand new cranks are a crazy price just to put in a 550. You have a good exhaust manifold. Factory pipe and coffmans make nice half pipes for them that make good power. Search the 550 threads for good ideas and mods.

 

[Riding The Right Way]

Hey Mark .... I've been looking for a new shop to go to .. This guy Gordon that good ..?? (I used to go to affordable cycle and marine, but they've pissed me off one too many times)

 

[astandupguy]

i have 2 550 motors im not doing anything with, one looks to be a reman, still together, the other i took apart to inspect, and all seems ok, im in socal - ill practically give em to ya- im a 750 guy now

 

[bumperlt]

Are they reed motors? How much do you want shipped up to washington? How complete are they?

 

[Mark Gomez]

Hey Mark .... I've been looking for a new shop to go to .. This guy Gordon that good ..?? (I used to go to affordable cycle and marine, but they've pissed me off one too many times)

Yeah I dont know too much about those guys Only been there once to pick up a part but Gordon is a good guy. I will be starting to work there again tomorrow tues-Thurs. My old freeride 550 was completely built by the support and parts that Gordon has so I cant say enough good things.

 

[bobob729]

talk about alot of detonation. i havent seen that for awhile. if you want a crank and cases hit me up ill sell them for say 50 plus shipping. but hopefully it all comes together great. 550's are a great start. Ull have a blast!!

 

[B3IS]

Just cracked right into that thing... Get it. Whats up with the Manx...???

 

[bumperlt]

Well I finally got a call back from my cylinder guy, he found a crack in one of the cylinders, luckily the same side that all the damage was in. So it looks like I'm going to have the bad cylinder resleaved and then have them both bored .5 over, as the good side would probably be fine, but I'm boring it anyways. Sleeved and boring is costing me 250. Then I just need a top end kit, reeds, and a battery. Braaaaap. Anyone has some good condition reeds?

 

[bumperlt]

Oh and the buggy is another project. It runs perfect but anything on it that rolls needs replaced. as does anything electrical. All in the works. The boxer engine sounds amazing with just glasspacks.

 

[cookn]

What are you going to do for a crank. The one that was in there probably has shot bearings and you should put new crank seals in at the very least. It would be a waste to spend that kind of money on the cylinder and not build a solid bottom end. Also if the shop that is doing your machine work will bore your cylinder without the pistons then i would take your parts and run because they have no idea what they are doing.

 

[stagesrt4]

i have a 550 sx bottom case in perfect condition if you need it...


$20

pm me if so