Assembling a Kawasaki 650 X2 ,Sx,Ts jetski Engine and how to Lap a Lightweight aluminium Flywheel

Erickson's M&P goes through the step by step process of assembling a Kawasaki 650 x2 engine. I also show you how to lap a billet lightweight flywheel.
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MCMASTER part # 47465a612 (150 grit)
47465a613 (220 grit)
ericksonsmandp
/ ericksonmap247

[@Madcats1013]

just got me a 89 650sx rebuilt motor thanks to your video great help thanks dude!

[@EricksonMachinePerformance]

Glad to hear!! Thank you

[@christopherjames429]

Probably one of the best videos on putting a Kawasaki engine back together. Keep up the great work and the subscriptions and views will come. Be awesome to see some videos on pump rebuilds, midshaft bearing rebuilds, common carbs like mikuni 38, 44, 46 rebuilds, etc. Again excellent informative video!

[@EricksonMachinePerformance]

Carb video is coming in the next week or 2!!

[@Daddatogaming]

Awesome video man !!

[@EricksonMachinePerformance]

thank you

[@stevekrumdick9207]

Thank you this helped a lot

[@EricksonMachinePerformance]

Thanks for watching

[@daddyrabbitathappyhour9451]

Thank you for sharing

[@michaelgiuffrida4081]

Great video! Love all the ski videos!!! Maybe do some vids on electrical stuff on the skis like checking stator, CDI and basically everything else electrical!

[@EricksonMachinePerformance]

I have a bunch if electrical videos coming soon

[@dannywilson8443]

Great Video

[@EricksonMachinePerformance]

Thanks for watching!

[@skystyle]

i love to watch this and do you have sxr 800 engine rebuild?

[@geostlouis7652]

Awesome share and im learning how to for my 750 small pine Kawa, now question can a bigger motor be install in 92 super sport xi

[@markpuzas]

Great Video!!! Would love to see similar content (takedown/ assembly) for a Kaw 1100... Long story short, I might need to do a rebuild on one :-/

[@EricksonMachinePerformance]

The next stock rebuild I do I plan on making a video. Unfortunately MOST of the 1100s I do a ported race motors that have alittle Secret sauce that cant be shown😉

[@markpuzas]

@@EricksonMachinePerformance How close are you to seattle??? I got one you can rebuild :-) I can assist with camera work and editing haha

[@leviashley687]

Awesome video I was wondering if a1997 750 SS is basically the same? You'd machine the head for me I put it back together it was running awesome. I took it up to lake Powell and the engine was seized have no clue haven't had time to pull it out to find out.

[@gymshoedecoyco.5842]

Was waiting for the part when u put the coupler on and it was edited past. Great video but I have a broken coupler and am looking to change it out.

[@stevechester3730]

Great video! Do both piston rings face the same direction or opposite?

[@thediplomasta5891]

Good tips. Thanks. Now I have more stuff to buy. 🤣 😵 Me, realizing I don't have a flywheel holder! 😩

[@EricksonMachinePerformance]

You don't need 1. Just impact gun and your hand

[@nickcapozzoli]

Enjoyed the video, but I would’ve appreciated to see the removal and install of the crankshaft coupler that suddenly appeared at 18:40

[@HoneyBunches.]

Did you ever find the way to do it? 🤔

[@jamesf1393]

18:39 that was a cool trick

[@marcosrobertobenedito1046]

Gostei vou montar 650 ts

[@frederiko1982]

Hello mate. Great video but I have a similar motor that is making me crazy. works great when at the hose but fails me when I go to the river. After say 10min its boggs and dies. Could you help me out with values for vaccum lines?

[@markmancini]

Thanks for this! I usually use 1211 or Yamabond on the stock metal head.....thoughts?

[@EricksonMachinePerformance]

No need. Make sure gasket surfaces are good and clean and ur good to go

[@puch7261]

Can i use a 2005 yz250 rod on banshee crank? Or could it be done?

[@JetSkiBuyFixPlaySellChannel]

Any Seadoo engine rebuilds planned?

[@jakeriddle1717]

Great video man! Are the torque requirements the same for a 1997 Kawasaki SS 750?

[@EricksonMachinePerformance]

Yes

[@riveradventures7185]

I noticed you put the head gasket on dry, how's that workout for you? Would you have any information from Kawasaki on that topic.. have a great day I enjoy watching you do what you do.

[@EricksonMachinePerformance]

That's how they are ment to be put on

[@jrodb888]

Hey I have a 89 650sx with a 94 750XIR engine in it. I’m noticing water coming from from the cylinders. I pulled the head and exposed the pistons and still see water coming out. I noticed water spewing from the exhaust manifold and figure its time to replace some gaskets. I figured i would replace the head gasket as well so i pulled the head. However, I still notice water coming from the cylinders. Is it possible to have water get into the crank case? Please keep in mind i had great compression. Motor ran just wouldn’t idle. I was leaning towards crank seals but I ended up noticing a water issue! PLEASE HELP.

[@kylemcweeny878]

Using that belly to hold the block puts food on the table as much as it takes it off lol

[@MrMGutierrez84]

How do the valve reeds go on these? I bought a motor without them and sourced them separately. There's a small hole on the center edge of them. Does the whole go toward top or bottom? Any help is appreciated thanks.

[@HoneyBunches.]

Hey man, thank you for all your videos. Have been a life saver 🙏🏼 Putting my crank back together, do you know anything about the alignment pins and the alignment rings? My 88 650sx had a “half ring” alignment ring inside. Do I need to reuse it or can I get away with just using the dowel pins and some sleeve retainer compound? Thanks in advance!

[@EricksonMachinePerformance]

Yes I use a fixture to align 180° apart. Also, you should relain the crank the way the cases were set up. There are some reasons to do differently, BUT as a rule of thumb, keep it the same

[@HoneyBunches.]

@@EricksonMachinePerformance thanks a lot, I’ll do my best to align them as they were!

[@mr.appalachian8252]

Awesome video... I have a question for you, maybe you could help, I have replaced my crank seals and other gaskets. If the gasket that goes in between the crankcase and the jugs was leaking, could that cause a run away condition? I have replaced every gasket and seal on my 750 besides that gasket and the head gasket. Compression check is 135psi for both.

[@EricksonMachinePerformance]

Yes it could.

[@zoidelux]

Are there inner seals that need to be replaced on the crank? I have a 96 KAWA 750 SS, thanks for the great video!

[@EricksonMachinePerformance]

Do you mean in the middle of the crank??? On this engine no it's a labyrinth seal that doesn't need to be replaced. Certain Seadoo's and other 2 stroke engines do have inner seals though. But that's mainly on engines that have oil filled balancer shafts that run through the middle of the block

[@zoidelux]

@@EricksonMachinePerformance Yes between the cylinders, had someone tell me to check that, but thank you again, nice knowing i dont have to worry about that at least

[@primzei1953]

Great help! Needing to replace my pistons. The damage doesn’t look to bad to where I need to bore but I was wondering what you would recommend? Piston size says .50 on it so I’m guessing it hasn’t been bored? It is a west coast aftermarket top end. Not sure how far I could or should bore out? How far is that jug bored out?

[@EricksonMachinePerformance]

If it says .50 it have been bored .5mm oversize. If you want email me pictures of the damage and I can point you in the right direction

[@primzei1953]

Erickson Machine & Performance sure thank! What’s your email so I can do that. I’ll send pictures of the wall as piston

[@EricksonMachinePerformance]

@@primzei1953 [e-mail]

[@lyt_w8t]

Is this video a good guide to assemble my JH 750 C from a ZXi? Many thanks

[@EricksonMachinePerformance]

Yes its very similar. There will be an 800 assembly video out soon that will be the same

[@Mr.WS6]

Another video idea, make a cylinder porting video for the 650/750s. Explain the science behind the different castings even though it's a 650/750 black cylinders vs silver why everyone perfers silver motors over black and the 750s why no number cylinder are more desired than numbered 22 etc. Then show how a port process goes and what your looking for. Bad port jobs vs good port jobs. to much off to little off, what that does.

[@EricksonMachinePerformance]

There are Some Porting videos in the works. Stay tuned!!!!

[@beeewarned]

I didn't catch you mention the orientation of the rings on assembly. Are the gaps 180 degrees apart and does it matter where the gaps are located when you put the head on?

[@EricksonMachinePerformance]

2 stroke engines have pinned rings so the only go in 1 way and the rings don't rotate. and that is located on the pins in the pistons which are opposite of the exhaust port

[@lucas93871]

Excuse me, what measure do you use in the tool to adjust the torque, when you say 11 and then 22. I am from Argentina, good video!!!

[@lucas93871]

Foot pounds???

[@EricksonMachinePerformance]

Yes ft lbs

[@sharonbates9525]

Great video be the electronic are confusing I’ve been trying to put my 89 650 sx stator back together and can’t find a five wire stator anywhere should you know any way I could make it work with a 4 wire stator or where to get a 5 wire!?

[@EricksonMachinePerformance]

Let me look through my parts I might have 1

[@sharonbates9525]

Erickson Machine & Performance omg you would be a life saver dude!!!!!! I have litterally been looking for the past 4 months

[@bendavis998]

Could you please show me (us) how port a 650sx cases??

[@millionare46pk]

Theresa torque sequence on the head for a reason

[@EricksonMachinePerformance]

If you work your way from the middle out you will be fine. It's putting even torque and setting the head gasket. I assure you the engine doesn't know the difference. And the heads don't crack, leak or warp MY WAY! 😉 middle out. There's a REASON I work from the middle out. Milled heads can crack when they are thin if you don't start in the middle. 😉 Best of luck. Have a great day

[@sleepyreseller7946]

Hey! I'm looking at Kawi 650sx and the owner says it probably needs a new top end. Apart from the top end kit, what materials/resources would you recommend me using?

[@EricksonMachinePerformance]

email me [e-mail]

[@mikecataldo4398]

Awesome video, I'm rebuilding a Kawi 750 motor, any major procedural differences from what's in this video?

[@EricksonMachinePerformance]

Exactly the same

[@mikecataldo4398]

Awesome, thank you. Sorry if you already answered this question, what case sealant do you use?

[@EricksonMachinePerformance]

@@mikecataldo4398 I like hondabond the best. I feel it cures best and is the least messy. But all are good

[@lucaspatterson]

is it okay to put assemblee goo in the crankshaft bearings and wrist pin bearings? Also, can I put gasket sealer with the crank bearings sit?

[@EricksonMachinePerformance]

NO its a grease. Seals ONLY. If a little got on from the seals thats fine but thats it. It is not meant for bearings. Also no sealant where the bearings sit.

[@detroitdeb]

How do you remove drive shaft from Kaw ts 650

[@camilovelez2023]

Hi for a RAD aluminium no charging Fly Light Wheel for 650 SX Kawasaki Motor do you put 3 Degrees or 5 Degrees were is the best point Thanks

[@EricksonMachinePerformance]

it depends on your setup

[@jimgarrett7078]

If a guy can rebuild a zero turn mower transmission, can he rebuild one of these motors?

[@areliablesource4558]

Do a rebuild video on GP 1200r power valve

[@EricksonMachinePerformance]

The next 1 I get in ill do a video

[@areliablesource4558]

Erickson Machine & Performance awesome.cant wait!

[@slpsedundnes]

Can u do a custom wiring harnass video?

[@EricksonMachinePerformance]

What are you thinking. Email what you would like to see and ill try to make it happen

[@richardbonfanti8028]

Sbt told me to put case glue on the crank seals. Which rtv do you recomend?

[@EricksonMachinePerformance]

You shouldnt use case sealant around the seals just in the corners where the cases meet. IF USING GOOD SEALS DONT GLUE THEM IN!!! Crank seals are designed to seal if they seal on the spinning part of the crank shaft without sealant they obviously would seal on the part that stays stationary. When seals are put in properly with high quality seals they do not come out or need to be glued in ( just makes a mess!!) I'd also recommend using OEM seals or WSM. For case sealant I use Hondabond personally but YamaBond, Threebond 1211, or and other case sealant is fine.

[@richardbonfanti8028]

@@EricksonMachinePerformance got an sbt 750 on the work bench. 7 hrs on her never mad over 125psi and always ran away. Kinda new to these engines but i work on various other engines so no pro. But no machine shop in town wants to bore and hone my jugs so could i send you some pics one cylinder has a little ring wear but not too bad. One piston is brown at the bottom. Suggestions would be great. Solid video and expect the comments and views to roll in.

[@EricksonMachinePerformance]

@@richardbonfanti8028 send the pictures to my facebook account facebook.com/ericksonsmandp I'll be happy to help you out

[@dalejrfan820002000]

I have a question what should I do about my jugs because some went through the piston and Mark up the walls.

[@EricksonMachinePerformance]

have them bored

[@STREEF90]

Do you have a link for the tool that you use for torking de cilinder?

[@EricksonMachinePerformance]

amzn.to/3NZT56G

[@ToddleyProductions]

What torque wrench do you use?

[@EricksonMachinePerformance]

Snapon atech2f125vh

[@frankg4765]

Is the green assembly goo ok to use? Or is it too heavy of a tack? Thank you!

[@EricksonMachinePerformance]

I use both. The benefit to the green is it's thicker so if you have an oring and it doesn't want to stay in a groove that works even better for seals and stuff like that it doesn't make a difference. Well in all honesty it's really just a preference thing they both work the same just one is thicker than the other

[@frankg4765]

Thank you!

[@EricksonMachinePerformance]

@@frankg4765 thanks for watching

[@benselby6171]

14:26 what do you mean by make sure the pins are facing the intake? What pins

[@EricksonMachinePerformance]

The piston ring locating pins. They are what stop the rings from spinning

[@michaelheslet9024]

At 6:00 when you drop the crank in, is there a key that aligns with the middle bearing and the case? Or does the hole between the oil galleries remain empty? Pulled mine apart and can’t seem to find anything that would go there. Thanks!

[@EricksonMachinePerformance]

Thr tricky thing is there are differences in some 650 and 750 cranks. The center is the Labyrinth seal. And yes there is a pin to locate it. Other then that they can be pins or snap rings that or a mix of the 2 depending on the year to locate the bearings

[@EricksonMachinePerformance]

Email me a picture [e-mail]

[@michaelheslet9024]

@@EricksonMachinePerformance thank you, I’ll email you now

[@michaelheslet9024]

Sent you some pictures of what I’m looking at. Might have gone to the junk folder

[@mikecataldo4398]

What case sealant do you use?

[@EricksonMachinePerformance]

hondabond 4 is what I use and like the most

[@jordantinjaca6238]

How did you get those cases so clean? (Water jackets and all)

[@EricksonMachinePerformance]

Parts washer , ultrasonic cleaner, sand blaster or Hot tank. Its depends how bad they where to start. Those where just the parts washer. Cleaning and engine correctly is super important before assembly

[@jordantinjaca6238]

Thanks for the quick response, awesome video🤙🏼 yea I have a lot of salt build up in water jackets, so I really wanted to get it cleaned out. Have you came across leaking exhaust water cooling gasket into exhaust manifold side jugs, Causing milkshake bottom end

[@EricksonMachinePerformance]

@@jordantinjaca6238 not that problem. That would be rare and cause MAJOR damage Normally the exhaust air flow would keep the water out .IF the leak was big enough maybe.

[@gasousman]

I'm trying to seal an ultra 300x set of cases and the repair manual says to not apply the liquid sealer to the crank journal area. One end of the case/crank takes a seal but the other end does not. If I don't apply sealer to the end without a seal, won't it leak?

[@EricksonMachinePerformance]

You are comparing assembling a 2 stroke to a 4 stroke. They are TOTALLY different.

[@gasousman]

@@EricksonMachinePerformance umm

[@zoidelux]

What crankcase sealant do you recommend?

[@EricksonMachinePerformance]

I like Hondabond, or threebond 1211.

[@zoidelux]

@@EricksonMachinePerformance thank you, can't say it enough!

[@bradleyburnett4470]

Hey no sure if you will see this in time but i have a race tomorrow and cant get my 1991 750 X2 to start.. If i drop my positive lead from my starter straight to my battery it will turn over. I have already replaced my solenoid and regulator inside the elctrical box. But im at a loss for what else to try.. Hitting my start button i get no click no noise whatsoever.

[@EricksonMachinePerformance]

At that point it's most likely the start stop switch

[@bradleyburnett4470]

@@EricksonMachinePerformance i had a feeling it might be, ill look around for a new one. Thank you very much for the fast reply. Ill keep up on this channel now that ive found it. 👍

[@shawnspears3237]

What brand gaskets are you using?

[@EricksonMachinePerformance]

Mainly Wsm

[@joselitoperez2484]

Very informative specially about the lapping of the flywheel before torquing. Just one question is all the specifications apply to 650 SC model.

[@EricksonMachinePerformance]

Thank you. And yes this is the same as the sc

[@7808y]

Did i miss where he mounted the stator

[@leviashley687]

Where do you get your pistons, rings, bearings and seals?

[@EricksonMachinePerformance]

Most I have in stock. I'm a dealer for basically every major brand. Feel free to email me

[@leviashley687]

@@EricksonMachinePerformance thanks for the tip. It would definitely email you when I have a chance to pull the engine apart.

[@andres71181ase]

Good afternoon, I have one of those machines with a problem. maybe you can give me a hand

[@mikebingay8061]

i tried a head gasket and it still stalls after 2 minutes then starts right up after i dry the spark plugs

[@EricksonMachinePerformance]

email me your phone # [e-mail]

[@mikebingay8061]

my 650sx runs for 2 minutes then stalls and i pull the plugs and water is on the plugs, why?

[@hamblinshogs]

CH gasket shit the bed

[@larrylucas7611]

I need help with my Kawasaki 900 trim anybody else I know anything about this

[@omarsola205]

this vid has more adds then bolts on that engine. good video tho

[@khanhduy1921]

How much does an engine cost?

[@EricksonMachinePerformance]

Email me what your looking for [e-mail]