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  1. #1
    BigDaddyPT's Avatar
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    Big Daddy Primetime's 650

    The background

    Bought a 92 Polaris 650 for $350 that I was told needed a piston replacement. I haven't worked on a PWC motor before but I'm mechanically inclined so I got it as a winter project. The hull is in near perfect shape.

    Pulled out the engine and found a bunch of JBWeld on the crankcase so I took the entire thing apart to find out basically the crankcase was junk. I was thissssssssssss close to getting a SBT motor until I found this site.

    Got a few ideas and decided to rebuild the engine myself and convert it to a 780 motor.

    Here are some pics of what I got...
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  2. #2
    BigDaddyPT's Avatar
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    Upgrades to date (2/7)

    So after talking to people on this site I decided to convert to a 780 motor and have a little fun...here is what I have so far....

    Sold my 650 jugs and heads, electrical box, crankshaft, pump, driveshaft on eBay for like $350 total to raise some funds for the crank rebuild

    Ebay fun
    - 750 crankcase in perfect condition
    - $12 crank with a bent rod and seized bearing for a rebuild
    - mirrors
    - sponsons
    - trim setup

    Shoutout to members
    - 3 780 jugs, heads, reed spacers, and exhuast manifold thanks to Zig
    - Pro 785 CDI thanks to Addicted
    - extended pump, shaft, and steering cable thanks to mccann
    - trim extension and instructions thanks to BeerDart
    - rebuilt/trued and welded crank thanks to Sharp's Marine
    - Oil block off and ThreeBone 1211 thanks to Randy @ Watcon

  3. #3
    Bing-A-Ding-Ding-Ding, Brrrrrap! Brrrrrrrrrap!!! Polaris_Nut#1's Avatar
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    Off to a NICE start! That hull looks nice for being 15 years old.

  4. #4
    BigDaddyPT's Avatar
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    yeah, everything on it is mint except for a little bit of the paint in the back underneath the ski...but the jet pump but that's not even that bad and is an easy fix.

  5. #5
    ph2ocraft's Avatar
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    Nice start BD.
    I want to make the list what do I have that you need?? LOL

  6. #6
    BigDaddyPT's Avatar
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    HAHAHAHAHAHA.

    Well here is what I need...

    - Boyesen Pro series High-Performance reeds
    - 6 vein SS stator with bearings and seals (don't NEED it but it'd be nice)
    - WSM pistons (i see them on eBay)
    - Triple outlet pump (I will win that Pentago on eBay...lol
    - bigger jets
    - 12/17 or NuJet 4.7 impeller
    - primer kit
    - fuel lines to redo all of them
    - crank case seals
    - flame arrestors
    - intake grate

    I think that's all! If anybody can hook me up that'd be great...

    Zig, you'll be hearing from me as soon as the tax fairy makes a nice deposit into my bank acct.
    Last edited by BigDaddyPT; 02-07-2007 at 08:38 PM.

  7. #7

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    intake grate

    I have a R an D intake grate that i am not using. And a bunch of other stuff. you can call me (201)638-4230. good luck i started with a 780 and now have a pro785 and and starting a rebuild on a genesis.
    thanks jim

  8. #8
    She likes the bike. But the ski gets her wet!!!! xlint89's Avatar
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    Just a FYI, you need a 780 crankcase for more HP gains. It has large channels plowed out for more air/fuel to enter the cylinders. Also you'll need a 780 exhaust manifold. And a Nujet 4.5 would be compareable to a 12/17. Good luck with build up.

  9. #9
    BigDaddyPT's Avatar
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    I got the 780 manifold from Zig. I know about the 780 crankcase but it's a BITCH to find them. I see one that Louie (glassiccar69) is selling on eBay for $200 starting bid...I got mine for I think $40. Is is THAT much extra HP that it's worth it?

    4.5...you're right...I don't know why I said 4.7. NuJet says a 4.7 will work on a Pro785 that is heavily modified...which clearly mine isn't...lol

  10. #10
    She likes the bike. But the ski gets her wet!!!! xlint89's Avatar
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    Quote Originally Posted by BigDaddyPT View Post
    I got the 780 manifold from Zig. I know about the 780 crankcase but it's a BITCH to find them. I see one that Louie (glassiccar69) is selling on eBay for $200 starting bid...I got mine for I think $40. Is is THAT much extra HP that it's worth it?

    4.5...you're right...I don't know why I said 4.7. NuJet says a 4.7 will work on a Pro785 that is heavily modified...which clearly mine isn't...lol
    I'm sure the others can answer better than I, but 650 is 68HP, 750 is 80HP and 780 is 90+HP straight from the manual. 780 is only 10cc more per cyl which is like a 750 slighty bored oversize. So another 10+HP comes from the 780 case (in which you only need the top half) and the 2 added exhaust ports in the 780 cyls. I'd wait and see if you can get the case for as long as you can. There's a 780 bottom end on Ebay starting at $250 right now. Maybe get that one and sell the crank seperately. Just a thought.

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