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Kawi 550 Resto

Dennis-19

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I like that tank!

Side note, I just grabbed 2 hulls for free last week, one has a ton of parts in it, including the pick up tubes Im pretty sure. If you need other odd stuff, let me know. I have 3 complete skis and one complete project, then these 2 other hulls. I might have a problem lol

Awesome! Do you have a water separator filter element? I just need the filter element with spring. The one I have is broken. If I can't find one so I was just going to delete it all together and just run an inline fuel filter.
 

warpt71

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Awesome! Do you have a water separator filter element? I just need the filter element with spring. The one I have is broken. If I can't find one so I was just going to delete it all together and just run an inline fuel filter.
Ill check, may not get to it today though
 

ridebig

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Awesome! Do you have a water separator filter element? I just need the filter element with spring. The one I have is broken. If I can't find one so I was just going to delete it all together and just run an inline fuel filter.
Most guy's are removing it and going with the inline filter.
 

Dennis-19

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Most guy's are removing it and going with the inline filter.

That's what I've noticed. With the fill neck gone I'm not too worried about water in the fuel tank. I bought a bag of inline filters on Amazon.
 

Dennis-19

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Blocking. Hope to be shooting primer in the next couple weeks.
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Dennis-19

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Pretty stoked on how these hull braces came out. Not bad for a band saw and jig saw. One side has the bildge dumps and bypass “pisser” running through the plates.

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I’m finally ready for powdercoat and paint!
 

Dennis-19

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Managed to make some progress...

It’s all blocked and wet sanded. That took more time than I figured it would...

I plan to have paint on it in this week and hoping powder-coat will be ready next week. I’m shooting for the 4th....


Rebuilt the stator

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Drilled all the holes for front and rear sponson before paint. The front sponsors came with SS screws and I can’t do that, I don’t want sharp tips inside to cut myself on later and the risk of coming loose so though bolted them.



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Boat211

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I have recently become interested in these. Going on a houseboat trip next month. Thought it would be fun for my kid to ride.
 

Backlash

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I'm also looking at picking one or two up in the next year. Thanks for the motivation! Yours is coming along great! I can't wait to see the new paint on it! 👍
 

Dennis-19

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Reached a big milestone!

Shot the bottom first, let it sit a few days then flipped it and did the top, hood and handpole.

Next up is to to paint the bilge and underside of hood w/ Total Bilge.

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Dennis-19

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Bilge painted and hood seal on

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Pump stuffer


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Front sponsons on


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Rear sponsons

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Figured this would make putting it on trailer easier. It will have a tow loop around bow eye as well to be compliant with IJSBA and Jet Jam.

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I didn’t want to fill these incase I ever decide to put factory sponsons on. It’s highly unlikely but just in case...
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I’m kind of at a stand still until I get powdercoat and ride mats. Powdercoat is running behind. Jet Trim was out 8 weeks when I ordered 9 weeks ago. I’m told it will be a few more weeks.
 

77charger

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Wow looks good being into stand ups myself dont see how i missed this.I have 2 550s a 90 and a 94.I like riding mine gets more use than my boat does these days too.Had one in 90s but it broke and i was over it then saw a big pack of them in 2016 at needles running down river i got a sudden urge to get another.I rebuilt quite a bit on mine as well its pretty solid and did put a good amount into it too. 2 years ago id be way upside down right now i might only be a couple hundred down with todays pricing.
 

Dennis-19

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Wow looks good being into stand ups myself dont see how i missed this.I have 2 550s a 90 and a 94.I like riding mine gets more use than my boat does these days too.Had one in 90s but it broke and i was over it then saw a big pack of them in 2016 at needles running down river i got a sudden urge to get another.I rebuilt quite a bit on mine as well its pretty solid and did put a good amount into it too. 2 years ago id be way upside down right now i might only be a couple hundred down with todays pricing.

Nice. I'm really excited to start riding again. I plan to build another 440/550. I really want to find a clean factory red one.

One of my real estate clients just gave me a brand new double trailer with a 1996 TS 650 sit down that was used less than 10 times. It was stored indoors and it's super clean. I'm going to pull the engine and components then sell the hull, so I'll be ready to drop the 650 in my next build. I feel with stand ups, you always need more than 1.
 

77charger

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Nice. I'm really excited to start riding again. I plan to build another 440/550. I really want to find a clean factory red one.

One of my real estate clients just gave me a brand new double trailer with a 1996 TS 650 sit down that was used less than 10 times. It was stored indoors and it's super clean. I'm going to pull the engine and components then sell the hull, so I'll be ready to drop the 650 in my next build. I feel with stand ups, you always need more than 1.
650 makes a good swap and yeh about all a ts is good for is a donor engine.LOL I got my 550 at right time 500 for a solid runner 90 sx.My daughter last year this time said she wanted to learn to ride i said ill buy you your own.Prices were high for a beater i figured in the end ill pay more for a clean one knowing it will take 500 minimum to make it solid so 1200-1400 plus 500 and its still a piston port or a little more get an sx reed powered so found a 94 550 in clovis and picked it up for 2200.
 

Dennis-19

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650 makes a good swap and yeh about all a ts is good for is a donor engine.LOL I got my 550 at right time 500 for a solid runner 90 sx.My daughter last year this time said she wanted to learn to ride i said ill buy you your own.Prices were high for a beater i figured in the end ill pay more for a clean one knowing it will take 500 minimum to make it solid so 1200-1400 plus 500 and its still a piston port or a little more get an sx reed powered so found a 94 550 in clovis and picked it up for 2200.
Ya prices have gone way up. I'd estimate that I have $4,500-5k into mine and I got the ski for free. LOL. However my 550 will be better than new and I never plan on selling it. I also replaced everything and purchased just about every upgrade I could find. I see super clean 550s going for north of $2,500, but in my opinion, many of them still need a grand minimum in work. It's difficult to find one that is not thrashed.

Some might think I should have my head examined for spending so much time and money on a 550, but I have always wanted one restored and the process has been a lot of fun (well minus all the sanding). LOL

If I wasn't so meticulous and didn't care how it looked, I could probably be into it for about half.
 

77charger

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Ya prices have gone way up. I'd estimate that I have $4,500-5k into mine and I got the ski for free. LOL. However my 550 will be better than new and I never plan on selling it. I also replaced everything and purchased just about every upgrade I could find. I see super clean 550s going for north of $2,500, but in my opinion, many of them still need a grand minimum in work. It's difficult to find one that is not thrashed.

Some might think I should have my head examined for spending so much time and money on a 550, but I have always wanted one restored and the process has been a lot of fun (well minus all the sanding). LOL

If I wasn't so meticulous and didn't care how it looked, I could probably be into it for about half.
True but atleast you know everything is solid.I built mine the way i wanted to back in early 90s plus the new tubbies.
 

Dennis-19

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True but atleast you know everything is solid.I built mine the way i wanted to back in early 90s plus the new tubbies.

Ya I want to put gas in it and ride. I don't want to spend my weekends trouble shooting. That's why I didn't go all out with a high compression deal. When I'm ready to go faster, I'll add a superjet, SXR or Kommander to my collection. My next one will have to be a 3 seater couch for the wife.
 

Dennis-19

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Got a trailer and 96 TS 650 for free. Pulling out the motor for a future 550 project then going to get rid of the hull. Anyone want it? LOL

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warpt71

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saw a big pack of them in 2016 at needles running down river i got a sudden urge to get another.
I might have been in that group? We did a ride from Jack Smith back to Site 6. I had my 550 and 440 out, there were a couple X2's, superjets and maybe a 650.

@Dennis-19 do you still need some parts? I have 2 hulls full of stuff
 

Dennis-19

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I might have been in that group? We did a ride from Jack Smith back to Site 6. I had my 550 and 440 out, there were a couple X2's, superjets and maybe a 650.

@Dennis-19 do you still need some parts? I have 2 hulls full of stuff
I have everything I need for the current build, but thanks! I was able to grab some spare 550 compatible parts of the TS.

Let me know next time there's another ride like that. I really wanted to attend Run What Ya Brung in Parker, but I wasn't ready.
 

warpt71

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Let me know next time there's another ride like that. I really wanted to attend Run What Ya Brung in Parker, but I wasn't ready.
I have done RWB and had a good time. My buddy that organized the big rides doesnt seem interested anymore. I would do it again though, I would have to get a ski running though. We had a pontoon follow as a chase vehicle and had fuel onboard too. That ride was AWESOME! We did another one down in Blythe, from Lost Lake to the Big River Dam and back.
 

77charger

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I have done RWB and had a good time. My buddy that organized the big rides doesnt seem interested anymore. I would do it again though, I would have to get a ski running though. We had a pontoon follow as a chase vehicle and had fuel onboard too. That ride was AWESOME! We did another one down in Blythe, from Lost Lake to the Big River Dam and back.
I made it to RWB for Saturday was great and a shit ton of stand ups. Few of us rode up to the damn on our 550s.
 

77charger

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Its a 650. Came out of a TS 650.
Even has the matching Kawasaki ice chest that mounts to the floor.


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Didnt think 650s were green usually black and i think silver some had a red head others a black head.Id check the cylinder stamping.Either way you scored good 650 makes a nice swap engine.I rode one was torquey almost bought one to swap mine but thought 300-350 was high LOL missed one at 250
 

Dennis-19

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That’s really coming out clean! You must be chompin at the bit!
Ya, I've put in a few late nights this past week trying to get it done. I got her running yesterday. Need to adjust the carb, put the matts on and I'm done! Perfect timing, I'm headed up to river tomorrow.
 

MK1MOD0

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Kick ass! You’ll have to give us a ride report on how all the mods worked out. Look great!
 

warpt71

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Damn that came out super clean!!!!

I wish I had the time and $$$ to get my fleet that sano 👍👍
 

Dennis-19

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Thanks guys. I'll get some pics up after I get the mats on. My wife walked in the garage last night as I was cleaning up and asked when I'm going to start on the next one. LOL. I need a little break.
 

King295

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Incredible work, this thing looks super clean. I will always have a soft spot for 550's due to growing up riding one all day long at the river.

Can't wait to see the final product and the ride report. Enjoy!
 

HotRod82

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Great work man! So many great memories from the early 90's at the river with the whole gang on 550's. I'm pretty sure all the speed limit signs in the back channels were put there because of us!
 

Dennis-19

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How did it do last weekend? Look's awesome Dennis!!!
Thanks. I really like the way it came out. I need to get some finished pics up.

I didn’t launch it. It was a dash to the finish line then took it up. It was flooding and bogging and I didn’t want to paddle back to shore if I couldn’t get it to start. I think when I rebuilt the BN38 I put too hard a spring in. Everything I read says to toss the 38 carb and go to SBN44. So I ordered everything for the swap. Carb, WAX Racing throttle wheel, 550SX throttle cable with the different end to work with 44 and new flame arrestor adapter. Already had a 44mm manifold and spacer that I got power coated just in case. Just waiting on the new cable then I’ll button it back up and probably take it for a quick rip at Puddingstone later this week.
 

77charger

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Thanks. I really like the way it came out. I need to get some finished pics up.

I didn’t launch it. It was a dash to the finish line then took it up. It was flooding and bogging and I didn’t want to paddle back to shore if I couldn’t get it to start. I think when I rebuilt the BN38 I put too hard a spring in. Everything I read says to toss the 38 carb and go to SBN44. So I ordered everything for the swap. Carb, WAX Racing throttle wheel, 550SX throttle cable with the different end to work with 44 and new flame arrestor adapter. Already had a 44mm manifold and spacer that I got power coated just in case. Just waiting on the new cable then I’ll button it back up and probably take it for a quick rip at Puddingstone later this week.
I run the bn 44 on my 90 but i rebuilt it once and somehow pop pressure changed it wouldnt start or would with a shot of primer then shut off.Adjusted pop off pressure got it to run again.

Another thing i did was got my ski starting and running i recorded the mixture screw setting and wrote them on the gas tank.As i go out i fine tuned it but you knmow if theres an issue and went to far and something aint right you now have a base to go back too vs guessing as one adjustment can effect another
 

Dennis-19

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Fired it up the other day had it running for a while on the stand with water going through it idled well and revved up Bitchin. Went to fire it up the next day and I had no spark. Ohm Tested the coil wires- they're within spec . Pulled the fly wheel back off to make sure no issue with stator. Will check resistance on coils and make sure no ground issues.
 
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