Seadoo 787 - 951 to Kawasaki coupler tutorial

WFO Speedracer

A lifetime ban is like a lifetime warranty !
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o one of the biggest holdups on finishing the 787 powered X2 has been the coupler ( besides me have way too many projects to finish ) , I followed the 951 X2 build intently and saw his solution which of course works just fine.

Here is what I have come up with for the 787 , it may get a bit more involved when I try to get everything bolted up but right now I am focusing on making the two couplers fit together.

I am installing a 951 in my 3D so I won't be using the PTO flywheel and coupler, on a 3D the coupler bolts onto the PTO just like on a 951 and it uses the same dampener , same bolt pattern and the same coupler as a 951 XP , the PTO for the 787 powered XP is totally different and of course won't work, that would be too simple.

In the photos you can see some slight differences in the way the couplers are made , but it looks to me that the 650-750 style driveshaft coupler can be modified to fit the 951 dampener , the couplers are also very close in diameter , with a minimal amount of lathe work the two will become the same diameter. I have a buddy that has a lathe I can probably get some time on.

I am modifying the leg on the 650 coupler with a die grinder to be straight like on the Seadoo coupler, I will also have to slightly enlarge the rounded part of the coupler , I am using a socket that fits the profile on the Seadoo coupler as a gauge on the Kawi coupler. The Kawi coupler is on the left the Seadoo is on the right , the dampeners are in the same order.
 

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WFO Speedracer

A lifetime ban is like a lifetime warranty !
Location
Alabama
The two now are mated in an unholy union and it looks like it will work quite well, I am not totally happy with the machining on this one but I know what to do better next time and I figured I would mess up a few before getting it like I want it.

On the next one I will cut less and finish more of it with a sanding drum on the die grinder for a better fit and finish , I am sure this would work just like it is but it never costs any more to go first class.

There is plenty of meat on the Seadoo coupler to get it to the correct diameter as well as cut down the length a bit for better fitment .
 

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