Skip to main content
Topic: Triple's Kawasaki Wave Runner Rebuild (Read 9862 times) previous topic - next topic
0 Members and 1 Guest are viewing this topic.

Triple's Kawasaki Wave Runner Rebuild

Alright so most of you know that I just recently picked up a Wave Runner on Craigslist. It's a 1996 Kawasaki 750 Xi Super Sport. I picked it up for $500, and even came with a trailer. These were the pictures on the Craigslist ad.



From the sellers description, it had lost compression in one cylinder after the engine overheated while he was out on the lake. He tested both cylinders when he got the ski back to his house, finding out that one of the cylinders couldn't hold any more than 30 psi. I was thinking either the rings melted and chewed up the piston crown and head, or the head warped and blew the head gasket.  So, we went and picked it up, and I started wrenching right away. First of all, you can see which cylinder overheated just by looking at the head....


First thing I did (before I disassembled the cylinder head bolts) was test the compression myself to see what I was working with. Cylinder #1 has 154 psi, Cylinder #2 has 22 psi. So I popped the head off to take a look at what's inside.....


This is the cylinder that has only 22 psi of compression....




As you can see, it's got some scoring. I also noticed that both pistons have play inside the cylinders, so that right there told me it's going to need boring to the next size with all new pistons and rings, along with top end bearings.


Now I told myself that I needed to find out what was causing the engine to run that hot. A BIG problem with these Ski's is the stock oil-injection system (just like blasters, huh...). The pumps are known to fail and are very unreliable. So I proceeded to take the carburetors off to find the oil injection lines, and guess what I find? The line running to the carburetor with the blown cylinder is broken off, barely hanging on. That explains the blue sludgey oil sitting at the bottom of the hull, and most likely the blown cylinder.


So that's where I am right now. I just picked this thing up last night, and I've been busy at work so I have had about 2 hours into this thing so far. Other than the engine issue, this thing is in great shape. The hull doesn't leak, all the electrical works, has spark on both plugs, etc etc. There's some decent scratches on the underside of the hull, but nothing severe. I may repair it later on, but it'll hold for now. It has an SMC hull, which means I cannot use fiberglass to repair it. I've been reading up on repairing SMC hulls and I need to pick up some special resin.



Re: Triple's Kawasaki Wave Runner Rebuild

Reply #1
Sweet PWC Brotha ! , Glad you dug into it and found the Problem so Fast . Looks like that thing will have a nice new Top End Soon !. Looking forward to the Progress , Always wanted one to play with but The Funds were never there for One .

Re: Triple's Kawasaki Wave Runner Rebuild

Reply #2
Nice buy and very cheap i am sure you will have it back up and running in no time :)
You've Just Been Smoked By A 2 Stroke!


Re: Triple's Kawasaki Wave Runner Rebuild

Reply #4
Those iron liners or nicasil? If Nic I highly suggest Millinium Technoligy in Minnasota, they are also a Weisco dealer. One stop shop. They also can do any repair welding if necessary. Be aware this won't be cheap  :o , probably about $500 for replate and pistons.
 
http://www.mt-llc.com/index.php

Re: Triple's Kawasaki Wave Runner Rebuild

Reply #5
[quote author=Larry's Shee link=topic=516.msg1#msg1 date=1366374237]
Those iron liners or nicasil? If Nic I highly suggest Millinium Technoligy in Minnasota, they are also a Weisco dealer. One stop shop. They also can do any repair welding if necessary. Be aware this won't be cheap  :o , probably about $500 for replate and pistons.
 
http://www.mt-llc.com/index.php
[/quote]

Nope, these are iron sleeves. A simple bore to the next available size is all that is needed. Before I contacted the seller, I researched about what material the sleeves were made of, knowing that  Nikasil sleeves would be expensive to repair. Luckily, this ski engine has iron sleeves.

 

Re: Triple's Kawasaki Wave Runner Rebuild

Reply #6
Looks like a good deal!
'04 Yamaha Blaster
'14 Honda trx330r
'01 Honda cr125r
member #25

Re: Triple's Kawasaki Wave Runner Rebuild

Reply #7
After doing tons of research, a very common problem with these 2 stroke skis is their crank seals. Luckily, this engine has the seals accessible without having to take the entire bottom end apart. I need to take the flywheel and stator off, and the coupling that attaches to the drive shaft. I would order them now but my last 2 paychecks just bounced yesterday thanks to my wonderful boss. I'll be giving my 2 week notice on Monday because Ive had it with his shit. I started a new job last week.

I decided I'm going to take he engine out. It'll just make things easier and take up a lot less time. I'll be using up my entire day tomorrow to work on this thing so I'm going to try I get a lot done and take a lot of pictures.

Re: Triple's Kawasaki Wave Runner Rebuild

Reply #8
Look farward to the pics  :)
You've Just Been Smoked By A 2 Stroke!

Re: Triple's Kawasaki Wave Runner Rebuild

Reply #9
Been there, done that with paycheck. Don't know if I would give notice, you didn't get notice you weren'y getting paid.
 
JMHO, your results may, and will vary.

Re: Triple's Kawasaki Wave Runner Rebuild

Reply #10
[quote author=Larry's Shee link=topic=516.msg6586#msg6586 date=1366504034]
Been there, done that with paycheck. Don't know if I would give notice, you didn't get notice you weren'y getting paid.
 
JMHO, your results may, and will vary.
[/quote]

This is the 3rd time I've had paychecks bounce. If it was a one time deal I would understand, but 3 is enough for me. I'm getting paid more at my new job and it doesn't  involve culinary.

Re: Triple's Kawasaki Wave Runner Rebuild

Reply #11
Well I've just be doing simple stuff with the Kawi lately. Cleaning, re-furbishing, replacing, etc. Ordered some West System Epoxy with Fiberglass Mat to repair the hull. Got the area all sanded down and it's ready for the repair. Should be stronger than it was ever with this West System stuff, gets great reviews and its made for the water. Got most of the bottom sanded down, ready for paint. In the process of finding the best epoxy paint for the bottom of the hull, since it's exposed to water the entire time in the water.

Took off the flywheel and the impeller coupling off the engine, had a couple little hiccups. When I pulled the flywheel off, the key must of been STUCK into the crank, so I sheared it right off when I pulled the flywheel. No biggie, an OEM Woodruff key is $7 shipped. Also, when I pulled the coupling off, (threaded), some of the material from the coupling stuck onto the threads on the crank. No biggie either, I chipped the material off the threads and then filed it down, threads look new now, so they should hold up fine.

Sending the top end off this week, most likely tomorrow (Monday).

Just basically been trying to get this thing in like-new condition. I decided I am NOT going to take the larger decals off. They are WAY too expensive to replace ($75 - $140 PER DECAL!, and there are 10 of them!). I'm just going to put some painters tape over them when I spray the epoxy paint.

Cleaned the carbs squeaky clean, replaced some rusty bolts that held the choke butterfly flaps in.

Cleaned the reeds, these things had dirt/sand all over them!

Just other random stuff like that. I need to order an oil injection blockoff plate ($10) and a crankcase drain blockoff plate ($10)

I'd post pics but there's really no point, I'll post pics when I get more done. So stay tuned!






Re: Triple's Kawasaki Wave Runner Rebuild

Reply #13
Engine is out, top end is at SCD's, and the hull repairs are almost done! I had to lay down fiberglass mat with Epoxy Resin and Hardener from West System. This stuff is a major pain in the ass. Sticky, gets all over, takes a while to dry. But after that, this stuff is STRONG! I'm pretty impressed at the strength of this stuff! Even after one layer of mat, strong as hell.

The biggest spot I needed to repair was on the bottom of the hull right in front of the intake grate. There was 2 large gouges that allowed water to soak into the fiberglass, making it weak. I had to cut the area out until I reached dry, strong fiberglass. That's what I did, and then I laid down 4 layers of mat, starting small and progressively getting larger. I got the area all patched up and I just mixed up some Peanut Butter Epoxy to re-shape it back to how it's supposed to be. Coming along very nicely and I'm very impressed with these West System products.

Heres what I started with, the bottom. You can see it's beat to shit, but luckily all those scratches only go through the paint, and don't affect the fiberglass at all.




After just some sanding of the paint, most of the scratches are gone


If you look closely you can see the area that was rotten. I cut more of it out after I took this picture





Another area that needed repair:



After 4 Layers of Mat


Just need to fill it in with Peanut Butter, sand it, and it's done. Ready for paint

Heres the bottom after mat, and freshly applied peanut butter




Still some work to do. Need to sand it and apply just a little bit more in one area. After its dry, sand it to shape, and its ready for paint.





Re: Triple's Kawasaki Wave Runner Rebuild

Reply #14
Great job doing the fiber glass repairs must of been hair pulling hate the stuff used it my self like you said gets every were and sticks to every thing it touches looking farward to seeing the next steps :)
You've Just Been Smoked By A 2 Stroke!