2002 sportster issues

[TrashPanda]

My 2002 sportster single engine is having issues. It will run fine for a bit ( 20 min or so). Then it will stall out. When restarted it will rev up (3500 to 5000 Rpm) but not come up on plane. It just makes noise and feels like cavitation. I can limp it home at half throttle and low speed. If throttle is put to half or more cavitation will return. The plugs seem like the rear plug is wet. New plugs will not fix it. I have not checked the rave valves yet. I do have a mechanic going out to look at it next weekend. Any advice on what to check would be appreciated. Oh on a side thought the water outlet tube thing ( spray nozzle) above the impeller on the back has never had a good spray, just a trickle is that normal?

 

[Raven888]

Sounds to me like there is something blocking the impeller and cooling water intake. The engine is overheating and shutting off. The cavitation is caused by the blockage of the impeller.

 

[TrashPanda]

Thanks for your reply. Yes you were right about a blockage. I had 3 rocks stuck in the intake grate. I have removed them and had a licensed mechanic friend of mine come and take a look and try to solve some of my other issues. Well my starter died will only click and not whirl engine. It will whirl when bench tested but sounds dry and it is only a hundred bucks for a new one. My buddy also found that both of my coils are coroded. One way worse than the other. So another couple hundred bucks for that fix The coils would explain why it would operate properly for a bit then crap out n blow black smoke. I’ll keep this thread posted on what happens with the boat.

 

[TrashPanda]

Finally got a real diagnosis. Blown motor connecting rod blew up and made shrapnel all inside one cylinder destroying the piston, jug, head and for good measure it had to destroy some of the bottom end as well. It destroyed the reed valve and the case just above the reed valve.

 

[Raven888]

Yikes! Lots of collateral damage because it continued to be run with the blown rod. A full rebuild would have been in order anyways. It sounds like a new motor now (or a new boat). Bummer!