97 Kawi 1100 STX overheating - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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post #1 of 18 (permalink) Old 06-27-2019, 04:43 PM Thread Starter
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97 Kawi 1100 STX overheating

I just changed the starter relay, cranked the engine and heard a pop, but it started fine.

A few days later went for a ride and the temp gauge icon popped up, preventing the jet ski to exceed 10 mph.

Service manual does not address this problem, so here I am seeking advice from the big boys.
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post #2 of 18 (permalink) Old 06-27-2019, 08:50 PM
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How much water is coming out the pisser ?
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post #3 of 18 (permalink) Old 06-30-2019, 12:53 PM Thread Starter
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Steady flow. I attached a hose to the inlet and water flowed through the intake grate, but none through the jet pump.
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post #4 of 18 (permalink) Old 06-30-2019, 04:05 PM
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When on the water, water enters through the jet pump, preheats in the exhaust, goes to the engine. Im hopeing you had the ski running while on the hose. The pisser should only have a small stream when on the hose. Only turn the hose on just enough to make a small stream.
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post #5 of 18 (permalink) Old 07-01-2019, 10:28 AM Thread Starter
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Yep, engine was running, then water turned off before engine was turned off.
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post #6 of 18 (permalink) Old 07-01-2019, 09:12 PM
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Pull the line off the pump and blow some air through it. Carful though, it can push the water into the cooling system and act as if hose is on somewhat. Might pull the water lines off the stator cover and make sure the cover is not blocked.
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post #7 of 18 (permalink) Old 10-21-2019, 06:09 PM
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Time to take the Kawi out for a run, so, because of the overheating I experienced I presume water is not circulating through the engine?

1. Back-washed engine;

2. Checked the impeller for debris, none;

3, Blew air through hose going to pump, all clear;

4. Pulled exhaust pipe extension chamber muffler, blew air through brass fitting;

5. Removed exhaust pipe elbow,

6. Removed exhaust manifold, cleaned ports.

Reassembled and took to a nearby lake and engine overheated within minutes just like before. Of course, when the engine overheats, the engine goes into safe mode so can't accelerate.

Returned home and repeated the above process, but this time....

a. I removed the head cover and when I blew through the engine ports at least a couple tablespoons of wet sand blew out of the ports;

b. So, I removed the engine cooling cover and saw a build up of sand inside so I cleaned the cover and the two brass fittings.

I was told by an unreliable source that there are a couple holes behind the cooling cover that let water into the engine, but I see none.

Before I re-assemble, did I do everything possible to solve the the problem?
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post #8 of 18 (permalink) Old 10-21-2019, 09:37 PM Thread Starter
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1997 Kawi 1100 STX Overheating

An acquaintance told me that to resolve an overheating problem I had to remove the engine front oil cooling cover. It makes no sense, however, because my engine overheats as soon as I drop it in the lake I removed the cover and when I did I noticed there was depostis of wet sand inside, so I cleaned the inside and the two brass fittings.

I also removed the head cover and when I blew out the chambers a couple tablespoons of wet sand came flying out.

Any suggestions to help me find the reason for the overheating, or, did I cover everything?
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post #9 of 18 (permalink) Old 10-22-2019, 05:02 AM
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There are no hole in the stator cover that allow water into the engine. That cover is there to cool the oil drive coupler bearings. Sounds like it was run in to shallow of water. Min depth should be 12-18" at the pump before firing it off. Corrosion and sand can also build up in the temp sensor. It can be pulled apart and cleaned, but it's a bugger. Brass sensor screws into the housing, and it's tight.
When you removed the head, was the exhaust manifold off ? Did you use new gaskets ? While you had the head off, did you inspect the cyl bores for abnormal wear ?
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post #10 of 18 (permalink) Old 10-22-2019, 01:07 PM Thread Starter
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I've owned the Kawi's since new, so know not to beach them, however, on occasion when anchored in turbulent water they get beached. When t hat happens I clean out the are near the pump housing, but maybe, not all the sand gets washed out.

On that note I just read a Thread that there are breather holes in the pump that can get clogged with sand. The Thread referred to Sea Doo's, so maybe that does not apply to Kawi's?

In response to your question Rod, on the first tear-down like the recent I removed the exhaust manifold and cleaned all the ports. They were not scarred nor had abnormal wear. That said, I read in the shop manual that there is an "up" stamp stenciled on the gaskets to ensure they are fitted correctly. I was unaware of that, so did not check.

All water jackets and bores on the head appeared normal. There was a few tablespoons of sand flying out of the jackets when I blew air threw the holes. None of the jackets were clogged.

Did I waste my time cleaning out the brass elbows mounted on the stator motor cover as well as the area between the stator motor and cover? There was sand in that area which a purported mechanic said needed cleaning.

There are no Jet Ski mechanics here though a couple Doo mechancs who do not work on Kawi's so I am on this project by myself.

Before I assemble all the parts any advice will be appreciated.
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