Kawasaki 650sx - Engine Rebuild - Port & Polish

1988 Kawasaki 650sx 2-Stroke Engine dissassembly, porting & polishing, and reassembly.
The hull & paint:
• Kawasaki 650sx - Hull ...

[@tylersgarage12]

I enjoyed the video, good camera angles, detailed narration and background beats.

[@NastyMoto]

Really digging the 650sx videos!

[@sweetschoolbus]

Excellent! I'll keep 'em coming

[@carolgreen1967]

The eternal optimist!

[@cj3waker]

awesome vid, rebuilding my x2 right now because I'm and idiot and didn't do it over the winter. I'd gladly take you up on a woodruff key, mine is completely buggered

[@sweetschoolbus]

I feel your pain. I'm just now getting to the paint job that I intended to have complete before Spring ;-) I'll send you a message so I can mail you a woodruff key.

[@davidwilliams2174]

Thanks for the great video. Picked up a 91’ JS650SX (same model my wife bought new back then). Had to put a new top end in going 1 size over. Trying to find an actual service manual not just the supplement so I can try to put all the hacked lines especially the ground wires I found bolted to the intake but not connected on the other ends! Anyone have some pics of yours 650SX ground wires (not battery) they could share? Enjoy your stand up!

[@bradytew]

Very helpful video! Picked up an '89 650sx last Fall and it runs good, but needs a port & polish job. May also upgrade to 44mm carb and intake manifold. I'd love to see a video of how your sx runs now. Thanks again!

[@sweetschoolbus]

Excellent! I've got some hull work ahead of me (and a splatter-paint job), then it's time to drop the engine back in! I'll keep you posted on the the progress and eventual outcome of the work. Thanks!

[@bradytew]

@@sweetschoolbus Perfect! Thanks!

[@BobTheBreaker9]

Hello, what service manual did you use? I am looking to get one on ebay but they all seem small.

[@sweetschoolbus]

Hello, Bob. I bought a Clymer manual to help guide me through the work on my '88 650sx. haynes.com/en-us/kawasaki-jet-ski/js300300sx/1976-1991

[@JetSkiBuyFixPlaySellChannel]

Did you have the cylinders bored and go up a size on the pistons???

[@sweetschoolbus]

No, just smoothed out the intake and exhaust passageways. Otherwise no increase in displacement.

[@JetSkiBuyFixPlaySellChannel]

@sweetschoolbus it's pretty important for good compression especially on two strokes when you have scored pistons and cylinders. At 06:55 you can see a scored piston.

[@sweetschoolbus]

@@JetSkiBuyFixPlaySellChannel oh, shit. Yeah, you might be right. I'll look into that. Thanks 🙏

[@lovivelaverdure1290]

Aren’t you smashing sideways on your crank bearings? Aren’t these not at all designed for side stress? With a sledge hammer? Is that ok?

[@sweetschoolbus]

Not ideal, I suppose, but fortunately the crank itself has some mass so it likely isn't relying too much on the bearings to withstand the hammering. Also, I'm not necessarily hitting it with much force. The "shock" is more what I'm after to dislodge it from the tapered end. Tensioning with the puller, then whacking with the hammer.