SX/SXi/SXi Pro 91 650SX makeover

[JohnnyB128]

I bought this ski last August from a friend for $700 after I got to test ride it for a day. It runs pretty good and feels like it has decent power to me. I think most of it is stock. It looked pretty horrendous with the original paint and graphics from 91 so I decided to try to give it a make over.
While I'm at it I would like to go through it and make sure it is mechanically reliable.

I am new to working on Jet skis and a beginning rider. I have experience working on MX bikes/quads/street bikes and cars but I don't really know much about these jet skis. My auto body skills are probably enough to make me dangerous. I have spay guns and a compressor that I will be using to paint with.

I have a lot of questions about fixing this thing up but I think about 90% can be answered by a service manual so my first question is does anyone have a copy of one in a pdf file or anything else I can download? I have found copies of a service manual supplement on ebay but I'm not sure if this is all I will need or if it is what it sounds like and just an addition to the service manual.

2 of the engine mounts are broken. The rubber portion that the engine bolts to is separated from the metal portion that bolts to the hull. Can these be made to work or is it best to replace them?

The intake grate is broken and I was looking at the different kinds on ebay. Do any of them offer different types of performance?

The ride plate is stock and I think is still serviceable but what type of difference will an after market plate make? Once again I have seen a couple different designs.

I want to run a compression test once I get it back together. What is the recommended PSI range it should fall in?

I guess thats it for now. Still have a lot of work to do.

 

[JohnnyB128]

bump.
so does anyone have a copy of a manual or some helpful advice?

 

[Crab]

go ride a strong running superjet and post your findings.....

 

[Wilke]

I have a lot of questions about fixing this thing up but I think about 90% can be answered by a service manual so my first question is does anyone have a copy of one in a pdf file or anything else I can download? I have found copies of a service manual supplement on ebay but I'm not sure if this is all I will need or if it is what it sounds like and just an addition to the service manual.

http://www.amazon.com/Kawasaki-1976-91-Clymer-Personal-Watercraft/dp/0892875828

2 of the engine mounts are broken. The rubber portion that the engine bolts to is separated from the metal portion that bolts to the hull. Can these be made to work or is it best to replace them?

Replace them. There is no good way to fix them. Buy some new OEM ones or someone on here was selling polyurethane mounts made from the base of the stock mount, might be the way to go, If you search I'm sure you'll find it.

The intake grate is broken and I was looking at the different kinds on ebay. Do any of them offer different types of performance?

The ones with the big scoop in them are the best for hookup, called a top loader. You loose a mph or two of the top speed with them, but the extra hookup they give in choppy water is well worth the trade off.

The ride plate is stock and I think is still serviceable but what type of difference will an after market plate make? Once again I have seen a couple different designs.

And extended plate will make the ski ride less nose up and help reduce propoising (uncontrolled bouncing up and down while riding straight). And there are finned ones that help it dig in more in the corners.

I want to run a compression test once I get it back together. What is the recommended PSI range it should fall in?

Stock should be somewhere around 140-155psi. Make sure the 2 cylinders dont vary by more than %10


A 650sx is a great first ski, get it running solid and looking decent and ride the crap out of it. Don't worry about doing tons of mods to it, once you get good with it start riding as many other skis as you can find and figure out what you want, odds are you'll want to get into something else so don't go dumping tons of money in it. If a stock 650 has decent power for you, Like Crab said go ride a strong running superjet.

If you have some more technical questions you might want to check out PWCtoday. There's not too many kawi riders in here, their oldschool kawi section is alot more active over there.

 

[Matt_E]

Welcome to the forum!

Lots of folks have started with the 650SX. It's a nice reliable beginner standup. I think you'll enjoy it.
You did well enough with the price.
Good luck on the painting process, it's a bit of a hassle and time consuming.

 

[JohnnyB128]

Thanks for the replies. I'll post a pic when it's painted and back together to finish this post off.