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Another SUV conversion #4 in the shop

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  • Another SUV conversion #4 in the shop

    I have yet another SUV conversion in the shop. We have the engine and wiring harness but not much more than that as of now.
    I always suggest to use a donor ski that is complete. You 'd be surprised how many hoses, fittings, clamps, and bolts you will need from it. If you just started with an engine out of another ski you'd have a hefty bill in new or used hardware.

    Here is a list of parts that still need to be gathered up before the project really can get started. I am sure that I have left other needed parts needed but this is all that I can think of for right now.

    SUV parts needed

    GU5-U1481-00-00 CABLE, STEERING $292
    GU5-U153E-00-00 CABLE, NOZZLE CONTROL 3, trim $214
    (4 needed) 63M-44517-01-5B MOUNT RUBBER, engine mounts $71 each

    Parts needed from a 04 - 05 FX HO

    90445-20002-00 HOSE (L=1250)
    90445-14M06-00 HOSE (L630)
    6B6-1475E-00-00 PIPE 2
    6B6-1475F-00-00 PIPE 3
    90450-99M06-00 HOSE CLAMP ASSY
    90460-90M11-00 CLAMP, HOSE

    F1S-67550-00-00 WATER LOCK COMP.

    60E-E243A-00-00 HOSE 1
    60E-12581-00-00 JOINT, HOSE 1
    90467-200A0-00 CLIP

    60E-13907-01-00 FUEL PUMP COMP.
    90445-25003-00 HOSE
    F1B-U7711-01-00 TANK, FUEL
    6B6-26311-00-00 CABLE, THROTTLE 1

    F1S-6820A-10-00 METER ASSY $771

    (4 needed) 90119-089UT-00 BOLT, WITH WASHER
    6B6-8552A-00-00 HOUSING
    60E-81921-00-00 GASKET, TERMINAL $63
    60E-8552E-00-00 COVER, CASE $52
    (18 needed) 97780-60430-00 SCREW, TAPPING
    90480-01012-00 GROMMET
    60E-84742-00-00 SEAT, BASE
    66V-8132W-00-00 CAP
    66V-81844-00-00 GASKET
    6B6-8591A-10-00 ENGINE CONTROL UNIT ASSY $1,363
    (4 needed) 97780-60530-00 SCREW, TAPPING
    (4 needed) 90201-06M05-00 WASHER, PLATE
    (4 needed) 6A0-82317-00-00 DAMPER, IGNITION COIL
    (4 needed) 624-42542-00-00 COLLAR
    90464-99003-00 CLAMP
    68V-81960-00-00 RECTIFIER & REGULATOR ASSY $165
    (2 needed) 97780-60430-00 SCREW, TAPPING
    60E-87179-00-00 PLATE, COUPLOR
    97780-60516-00 SCREW, TAPPING
    60E-81916-00-00 COVER, TERMINAL
    60E-82533-00-00 GASKET
    (4 needed) 98680-05520-00 SCREW, OVAL HEAD
    6B6-81940-00-00 STARTER RELAY ASSY $108
    (2 needed) 90159-06008-00 SCREW, WITH WASHER
    60E-82117-00-00 WIRE LEAD $75
    60E-82117-10-00 WIRE, LEAD $76
    66V-82119-00-00 COVER, LEAD WIRE
    60E-82117-20-00 WIRE, LEAD $86
    66V-82119-00-00 COVER, LEAD WIRE
    60E-81950-00-00 RELAY ASSY $159
    97780-60520-00 SCREW, TAPPING
    60E-8259E-00-00 SWITCH ASSY $164
    97780-60520-00 SCREW, TAPPING

    6B6-14420-00-00 AIR, CLEANER ASSY 2 $140
    (2 needed) 90159-05006-00 SCREW, WITH WASHER
    6B6-14451-00-00 ELEMENT, AIR CLEANER

    60E-24300-01-00 FUEL PIPE JOINT
    60E-24474-00-00 Fuel COVER

    (4 needed) 6B6-82310-00-00 IGNITION COIL ASSY $170 each
    (4 needed) 95814-06016-00 BOLT, FLANGE

    60E-12580-00-00 JOINT ASSY
    90446-24M79-00 HOSE (L230)
    682-84385-01-00 CAP, 1
    60E-12443-00-00 STAY
    EU0-61652-00-00 NUT
    90445-21804-00 HOSE
    60E-12584-00-00 JOINT, HOSE 3
    60E-1243E-00-00 HOSE 2
    90447-22001-00 HOSE, WITH SPRING
    90447-28002-00 HOSE, WITH SPRING
    60E-12552-00-00 HOSE 8

    F1B-6224E-00-00 BODY, DRAIN 3
    F1B-67525-00-00 PACKING
    F1B-62241-00-00 DRAIN, COCKPIT
    F1B-6224E-00-00 BODY, DRAIN 3
    F1B-67525-00-00 PACKING
    F1B-62241-00-00 DRAIN, COCKPIT
    F1B-U8360-01-00 BILGE PUMP ASSY
    F1B-U7626-00-00 HOSE 1
    F1S-67620-00-00 HOSE JOINT
    F1B-U7629-00-00 HOSE, DRAIN 2
    F1B-U7628-00-00 HOSE, DRAIN 3
    GH7-6753B-00-00 PILOT, WATER
    90430-16910-00 GASKET
    GP7-61652-00-00 NUT
    F1B-U7844-01-00 HOSE

    61X-45332-03-94 HOUSING, BEARING $186
    66E-45813-10-94 FLANGE, COUPLING $84
    90201-278T0-00 WASHER, PLATE
    60E-51323-00-00 SHAFT, COUPLOR $275

    65A-R1326-00-00 CAP
    66V-51318-00-94 NOZZEL
    (3 needed) 90119-069UB-00 BOLT, WITH WASHER
    66V-R1313-01-00 NOZZLE,DEFLECTOR
    (2 needed) 90119-089UE-00 BOLT, WITH WASHER
    (2 needed)90387-08M06-00 COLLAR
    66G-51190-00-94 RING,TRIM
    GH3-U146E-00-00 STUD, JOINT BALL
    (2 needed) 90201-068M4-00 WASHER, PLATE
    9538R-06700-00 NUT
    (2 needed) 90119-089UE-00 BOLT, WITH WASHER
    (2 needed) 90387-08M06-00 COLLAR
    66V-51312-01-94 HOUSING, IMPELLER
    2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
    I do custom Yamaha SUV conversions http://yamahasuvconversion.com
    http://www.gonejetskifishing.com 904-701-4FUN
  • #2

    Re: Another SUV conversion in the shop

    Here are some pictures of the Yamaha SUV that we have to work with for this SUV conversion.

    Attached Files
    2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
    I do custom Yamaha SUV conversions http://yamahasuvconversion.com
    http://www.gonejetskifishing.com 904-701-4FUN

    Comment

    • #3

      Re: Another SUV conversion in the shop

      And I thought I had a jigsaw puzzle... lol

      Comment

      • #4

        Re: Another SUV conversion in the shop

        I hope that this demonstrates why I say that you need a good running donor ski to start a SUV conversion.
        The owner did go out and buy another 2005 FX HO donor and delivered it to the shop today. It looks to be complete but the engine is in parts. It has a broken rod on # 1 cylinder. I will have many parts left over from this conversion that will be up for sale.

        I did order the new steering cable, trim cable, and engine mounts today along with a new impeller housing.

        Now I have all the needed parts to start the SUV conversion. I have 3 complete engines, one in parts and all other nessary components do get the job finished.

        I will post up some pictures soon.
        2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
        I do custom Yamaha SUV conversions http://yamahasuvconversion.com
        http://www.gonejetskifishing.com 904-701-4FUN

        Comment

        • #5

          Re: Another SUV conversion #4 in the shop

          Here is the SUV


          Here is the donor.


          I have all the parts pulled off the donor and the hull with title is for sale.
          Attached Files
          2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
          I do custom Yamaha SUV conversions http://yamahasuvconversion.com
          http://www.gonejetskifishing.com 904-701-4FUN

          Comment

          • #6

            Re: Another SUV conversion #4 in the shop

            The steering and trim cables arrived today. I have the SUV hull stripped and I am ready to start the fiberglass work.

            Attached Files
            2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
            I do custom Yamaha SUV conversions http://yamahasuvconversion.com
            http://www.gonejetskifishing.com 904-701-4FUN

            Comment

            • #7

              Re: Another SUV conversion #4 in the shop

              Hello I have installed the new steering cable and the trim cable. The hand control or the grip for the trim was deteriorated to the point that it would not hold the cable ends. I was able to use the grip off the FX 1100 as a replacement.I have the complete whole stripped-down. I have the multifunction display from the FX installed. I have moved the engine mounts and have the glass work finished. I want to get most of this project done over this holiday weekend.
              Click image for larger version

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              Attached Files
              2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
              I do custom Yamaha SUV conversions http://yamahasuvconversion.com
              http://www.gonejetskifishing.com 904-701-4FUN

              Comment

              • #8

                Re: Another SUV conversion #4 in the shop

                I got the fuel tank installed and hooked up. I got a through hole Fitting's back in the tunnel area installed. I got the intermediate shaft assembly installed and also got the pump put together and installed and reinstalled the ride plate. I got the ECU and wiring harness installed. I got holes drilled through the bulkhead. I reinstalled the handlebars and cowing on the top side.
                Attached Files
                2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
                I do custom Yamaha SUV conversions http://yamahasuvconversion.com
                http://www.gonejetskifishing.com 904-701-4FUN

                Comment

                • #9

                  Re: Another SUV conversion #4 in the shop

                  The engine is sitting in the hull and I am now aligning the coupling.

                  Attached Files
                  2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
                  I do custom Yamaha SUV conversions http://yamahasuvconversion.com
                  http://www.gonejetskifishing.com 904-701-4FUN

                  Comment

                  • #10

                    Re: Another SUV conversion #4 in the shop

                    The engine is aligned and wired up. All the hoses are hooked up and now all that is left to do is hooking up the exhaust. It is time for me to turn on the plasma cutter and welder and finish this conversion. I did fire up the engine and it started right up and shows 96 hours on the clock.
                    2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
                    I do custom Yamaha SUV conversions http://yamahasuvconversion.com
                    http://www.gonejetskifishing.com 904-701-4FUN

                    Comment

                    • #11

                      Re: Another SUV conversion #4 in the shop

                      This Yamaha SUV 1200 conversion is now complete. Here is the first half of the test ride, water test.

                      2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
                      I do custom Yamaha SUV conversions http://yamahasuvconversion.com
                      http://www.gonejetskifishing.com 904-701-4FUN

                      Comment

                      • #12

                        Re: Another SUV conversion #4 in the shop

                        Here is the second half of the SUV conversion test ride back to the boat ramp.

                        2003 SUV conversion, 2005 FX HO engine, 30 gallon fuel tank, Lowrance HDS 7 GEN III
                        I do custom Yamaha SUV conversions http://yamahasuvconversion.com
                        http://www.gonejetskifishing.com 904-701-4FUN

                        Comment

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