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  1. #1

    Join Date
    Sep 2009
    Location
    Chicago
    Posts
    144

    WR500 with Pipe Project

    Wifes 1989 WR500F Waverunner was having problems last season with the engine shutting down and not restarting, power loss, and a knocking noise. This happened last year in the Fall time. So I pulled the engine and removed all the electronics and gas tank from the ski. What I found was that the bearing on the drive shaft was failing. That would explain the knocking and loss of power. The crank case seal is probably not sealing because of this and also causing loss of power. I also found a higher resistance on the ignition wire to the spark plug spring clip. These are non suppression wires and plugs. I will be replacing the spark plug clip with a crimp on style plug connector .

    This was our first ski and my wife really likes this ski alot and she does not care about speed. She says she likes riding her ski better than mine which is really fast compared to hers. But she would not mind if it went a little faster. So my goal is to get as much top end out of this ski as possible without putting much money into it, just elbow grease. And I would like to keep running 87 pump gas.
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  2. #2

    Join Date
    Sep 2009
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    Chicago
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    144
    I have a spare engine that I got in a package deal with some other equipment a while ago, so I am going to see if I can use that engine for this project instead of rebuilding the original engine. My original engine is completely stock and the spare engine has performance parts on it. I researched about the performance parts on this engine and found that this was a kit back in the days that was developed by a jetski rental company in Arizona called J's. They supposedly sold this kit thru magazines and it was a large performance increase for this engine. I have tried to lookup this company on the internet but had no success. I would really like to get some more information on this setup so if anyone has any information or has a vintage magazine/catalogue with this setup it would help. I only saw one other Yamaha WR500 on the internet a while ago with this setup. The pictures below shows the original engine on left and the performance engine on right.
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  3. #3

    Join Date
    Sep 2009
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    Chicago
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    Mods that came with the performance engine are as follows:

    Exhaust side there is a custom plate that was made by J's that mates the engine to a Westcoast EX 4480 exhaust manifold (kawasaki exhaust manifold). This plate is made of cast aluminum and it redirects the exhaust to flow straight out the side of the engine like it should instead of the convoluted path thru the engine block. The reason for the convoluted path was that the WR500 engine was originally an outboard engine that was converted to be used on a PWC. Attached to the exhaust manifold is an elbow made by J's that has a water cooling jacket. A rubber coupler attaches this elbow to the pipe (manufacturer unknow, maybe J's). The pipe came with the dents from the previous owner and I will leave it for know for the install to see if this was done because of clearance issues with the gas tank. I polished the pipe nice an shiney.
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  4. #4

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    Sep 2009
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    Intake side there is a 44mm intake manifold. You can see from the pictures below the difference in size between the original intake manifold and this one. The measurement for the original intake was approx. 39.18mm and the performance intake 44.22 mm. That is a 5mm increase in diameter. Also you can see in one of the pictures that the runner length of the performance intake is much shorter. The carb is a Mikuni SBN 44. The original Mikuni 38 had a choke and this one does not so I am adding a primer to it. I am rebuilding carb and cleaned it up and painted with Dupli-color High temp 500 degrees ceramic enamel. It came with carb adapter and I purchased a PRO-TEC (K&N) flame arrestor.
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  5. #5

    Join Date
    Sep 2009
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    Chicago
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    144
    The Flywheel is a modified lightened version. I do not know if this was part of the kit, or this is a modified version done by PRO-TEC or a machine shop, ?????. Picture of lightened and original flywheel.
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  6. #6

    Join Date
    Sep 2009
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    Chicago
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    The electronics box that came with this was from a 650 engine and the stator is a 500 stator. I cleaned up the box and painted it but I do not know if I will be using this electronics box and CDI. Number one, I do not know if this was part of the original kit or someone elses addon. Number two, I do not think you can mix a CDI (6M6) from a 650 with a 500 stator because the resistance values are different. Number three, the timing is different between the 650 CDI (6M6) and the 500 CDI (68K). I am hoping to find some information on modifying my 500 CDI or disabling the rev limiter. The 500 CDI factory rev limit is 5500 rpm. The 650 CDI factory rev limit is 6500-6600 rpm.
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  7. #7

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    Sep 2009
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    Compression is 160lbs on both cylinders cold engine. I looked at cylinders thru a scope and found some scuffs on the cylinders. So I decided to pull the head. I could not catch my finger nail on the scuffs except for one that I can barely feel. I checked bore with a dial bore gauge and I am still above the wear limit anywhere from .0005 to .0030 . So my largest part of the bore is a 1/2 thousand to the wear limit and the smallest part of the bore is 3 thousands to the wear limit for a standard bore size. I was originally going to just lightly hone cylinders and re-ring pistons but I found a real good deal on .50mm over pistons and rings so I am going to resize using my sunnen hone.
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  8. #8

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    The reeds are boysen dual stage reeds.
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  9. #9

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    That pretty much sums it up for the performance engine.

    On the ski I have an aftermarket Stainless Steel impeller, brand and pitch unknown until I open up. I have a scoop intake grate maybe Jet Dynamics , I don't know. I will be replacing this grate for the stock intake grate. The reason for this is that I want to pickup a little more speed on the top end. I do not know what the outcome of that decision will be because sometime on the weekends our lake can be a little choppy but the weekdays it is not. And the 2nd reason is that the scoop intake grate snags alot of floating weeds which plugs up the intake grate and then I have to beach the ski and tip it over on its side and remove the weeds all the time for my Wifey. I never have this problem with my ski. I will put the original intake grate on and remove the two outer bars or just the center bar on the grate to get a bit more water into the pump. I also have an aftermarket Ocean Pro ride plate that I am going to swap out and put in the original ride plate to make the ski a bit more unpredictable and playfull for spinouts. I am thinking of putting in a rule 500 automatic bilge pump and pluging up the bilge siphon holes in the pump and plate for a little better performance if I can find an inexpensive used pump.
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  10. #10
    Addicted Member 5001craig's Avatar
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    Great thread--thanks for taking the time to document everything. Seems like you know what you're doing.

    There's a ton of these ski's still on the water so I'm sure your info will be appreciated.

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