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Discussion Starter #1
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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Discussion Starter #3
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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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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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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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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Discussion Starter #8
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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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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Discussion Starter #10
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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Not familiar with seadoo's, but there is nothing like that on yours. Just the water supply to the engine, and the bilge pump discharge tubes. If you wanted you could pull the pump and check the supply port and impeller clearance. Need to make sure the gaskets are installed correctly. Did you check the cooling passages in the head ?
 

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Discussion Starter #12
I blew compressed air through the water jackets on both the EM and head. During the first tear down that did not include removing the Head Cover I may have installed the gaskets wrong because I read in the shop manual there is a stamp stating UP. I’ll check this time for the stamp..

Out of curiosity, how did sand find it’s way to the area behind the stator motor cover?

Could sand enter the oil pump?

T
 

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Discussion Starter #13
1997 Kawi 1100 STX Oil Pump

Quick question for a serious matter.

My husbands dad was working on his Jet Ski to resolve an over heating problem so my hubby and I could use it next week before he ships off to Iraq for another tour. Both of them had to help a friend whose house burned down last week so they are unavailable to help me.

My neighbor tried to help me this afternoon and removed the oil pump from the Kawi trying to help me solve the overheating problem, but he only removes parts and does not know how to put them back together.

I am an Arizona gal so know my way around tools and after evaluating the problem it looked simple until I noticed the pump would not align onto the stator cover plate so I could attach it.

It is dark now but I did notice there is a small 1" metal rod on the oil pump that turns and I am presuming it needs to be aligned into the gap in the flywheel?

To ensure I got this right, can I presume if the oil pump meets the stator cover and bolts down with no space between the cover and the shaft, that the rod did in fact slide into the Flywheel?

Come on guys, give the blonde babe a hand...Thank you.

JuneBug
 

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Discussion Starter #14
1997 Kawi 1100 STX Exhaust Pipe Gaskets

I was cleaning my Kawi to resolve an overheating issue and now that I am reassembling the exhaust pipe to the exhaust manifold I noticed the Service Manual instructs to ensure the two gaskets are installed correctly. Unfortunately there is no "UP| mark as stated in the service manual. There is, however, on one side a recession (swimming pool) going around the entire gasket and on the opposite side a bulge. I am presuming one of those indicators is the upside, but which one?

Anyone know?


Thanks
 

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Sorry to hear about the friends house. That sucks.
You are correct. The drive tang on the pump inserts into the slot on the drive adapter in the stator cover.
What specific gaskets are you talking about ? A picture of them would help. Also, the head gasket also has a arrow on it that needs to be pointing to the front of the engine along with the "up" being oriented correctly.
Because there is no filter in the water supply line from the factory, sand can get sucked up through the jet pump. You can get inline sand filters, but it needs to be high quality. No, sand cannot get in the oil pump unless it is intentionally added to the oil tank or supply line.
 

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Out of curiosity, how did sand find it’s way to the area behind the stator motor cover?


T
Was there sand in the stator area or just behind the small cooling cover ?
Again, make sure the fitting and passage on the jet pump is clean, make sure the supply line in not soft or kinked. I'm assuming that you check to make sure the inlet fitting on the bottom of the exhaust manifold was clean ? Has anyone actually touched the engine after it was run on the water to see if it was actually hot, or are we just going off the over heat light on the dash ? Since sand was found all through the system, I highly recommend taking the temp sensor apart and cleaning all the corrosion and sand from it. It's a bugger, and it has to be done carefully because you will not be able to completely remove it from the ski. I put a piece of 2x8 or 2x12 across the engine compartment opening as a make shift bench to work on so the hull does not get damaged.
 

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Discussion Starter #17
The sand was found behind the front cover that mounts to the Stator Motor. (The oil pump mounts to the cover) Not a lot if sand, maybe 15 per-cent of the entire area, but is was caked on the back of the cover, easy to clean. There was no sand in either of the two brass elbows that attach to the cover.
 

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If you have everything clear, and all gaskets are installed correctly, you should be good. Back it into the water, fire it off and let it idle for a bit on the trailer while feeling the head. If it stays cool you should be good. If it gets to hot to touch, it's getting hot. If it stays cool to warm to the touch but the light goes off, the sensor is prob restricted. Under throttle the pisser should have a good hard stream of water coming from it, and it should just be warm under normal riding.
 
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