96 XP Hydrostatic Lockup

[jcsign]

I have a 1996 XP that was running fine until my kids went for a swim and could not get back on due to waves. The watercraft tipped on its side several times over the course of a half hour, but never rolled over. After they got on the engine would not crank. I removed the plugs and it cranked but water with oil kept shooting out of the cylinders. It will crank with one plug in but not 2. If I put my thumb over the removed plug hole I can stop it from cranking. Thus, I thought the starter was weak from water intrusion so I replaced it. Same symptom, water/oil still shoots out the cylinders with the plugs removed. Also water shoots out the exhaust when cranking. It is on a trailer in my basement.

I have the intake housing removed and there is not any water on the inside. Where is it coming from? The exhaust side? How do I get all the water pumped out? It makes a mess of the bilge/hull pumping out the cylinders and keeps wearing the battery down.

Any suggestions would be a help. The machine ran great until that dreaded summer day 4 months ago.

 

[rookie101]

4 Months ago!!!!!!



The water is sitting in the bottom of the engine around the crank shaft! You have to remember that the exhaust is water cooled on a your machine. When it was tipped on it's side and the exhaust became higher than the rest of the motor, all the water that was sitting in it poured in to the engine.

What you have to immediately do anytime this happens is to remove the plugs and roll the ski on it's side so that the exhaust is the lowest point of the engine. Now crank the engine until water stops shooting out of the cylinders. Once you get it dried out you need to run the ski for a half hour or so to evaporate any remaining moisture trapped in the engine and prevent corrosion.

What worries me is the ski has sat so long in this condition that it may be to late. Get it running as soon as possible (or try) and do a compression test.


Aaron

 

[jcsign]

Rookie101-Thanks

Thank you for your explaination. Makes sense. However, since the ski is inside on a trailer I am unable to turn it on its side. Any ideas of what to disconnect to remove the water out of the exhaust and crankcase? I can crank it at pump water/oil out of spark plug holes. I am thinking of boring out the center electrode of 2 old spark plugs and connecting a hose on them. That way the water/oil will pump out away from the bilge into a bucket along side of the ski. Don't know yet if that will work.

Like you said...hope it is not too late. Corrosion in the lower end could be disasterous in the future.

 

[rookie101]

The only way I know of to get the water out is to crank the engine over with the ski on it's side. Trying to crank the motor over with the ski sitting upright could take a month to get all the water out, and burn out a few starters.

If I were you I would call a couple of you bigger friends over and lift the ski off the trailer, or just very carefully tilt the trailer and ski on it's side as a unit. If you try it with the ski still on the trailer make sure it is well secured, and the folding jack (if equipped) is folded with the trailer sitting on the tongue. Be very careful if you try it that way, and don't blame me if you drop the ski on your toe.:rofl:

If anyone with a ski like yours knows a shortcut to get the water out they may chime in, but I think your stuck with having to get it on it's side.

Aaron

 

[PWCdoc]

You said it'll turn over with one plug in? If so, you can get it running as it sits. You'll need some premixed fuel. Jumper cables on the battery to keep it from running down too much, full throttle 100% of the time, turn fuel off at first, no choke. The idea is to run as much air thru until enough of the water is out of one of the cylinders. You'll need several sets of plugs as well. When you can get it to turn over with both plugs in you are close to having it running. Dowse fuel into the throat of the carbs and try to start. You can even get it to start on one cylinder too if possible. It'll be noisy but it can be done. Back and forth on the plugs, fuel, full throttle. When it fires up run it with the one plug still removed for a few secs...5 secs should be sufficient. Then put a good plug in that hole and remove the other and repeat. Then, 2 good plugs and get it running. Since you're not at the lake get it running on the hose for a standard flush sequence time period. You can do this with the seat on to help keep from making too much of a mess on the ceiling....but I recommend taking it outside since it's going to want to make a mess anyway.

 

[rookie101]

Do what PWCdoc is suggesting. He works on these for a living, so will have lots of first hand experience with this sort of issue.


Aaron:cheers:

 

[jcsign]

Thanks Guys!!!

I will give it a try this weekend. I talked to the SeaDoo dealer mechanic today and he said to remove one plug at a time and just keep cranking until the water keeps coming out. He said he has done many of these and it will take 12 or more sequences of this to get the water out. I will try what PWCdoc suggests since it is easier that trying to turn the ski on its side. I just wish it wasn't winter and 20 degrees outside. I'll let you know if I have any success.

 

[timmyboy76]

20*....

I will give it a try this weekend. I talked to the SeaDoo dealer mechanic today and he said to remove one plug at a time and just keep cranking until the water keeps coming out. He said he has done many of these and it will take 12 or more sequences of this to get the water out. I will try what PWCdoc suggests since it is easier that trying to turn the ski on its side. I just wish it wasn't winter and 20 degrees outside. I'll let you know if I have any success.

lets hope, water aint frozen. That be a bummer..

 

[jcsign]

Crankcase Drain???

I was just curious if the 787 engine has a drain plug or vent/breather hose located on the lower section of the lower crankcase. Just a wish I suppose not because that would be too logical for a 'watercraft'.

The more I think about it, after 4 months I am paranoid of what damage may have occured )or will occur) to the crank/rod/piston pin bearings. It is fresh water, not salt water. That is one plus. Also, it is stored inside so no ice concerns. Even if I get it running, has anyone experienced water in the engine and if it eventually damaged the bearings? I do not think I will ever be comfortable riding it if I get it running. I will always worried the engine will blow up at any minute.

Thanks for all your help!
-Jeff-

 

[timmyboy76]

for water drainage, should beable to disconnect the outlet water hose, (that supplies the "tell-tail" and exhaust),from the case, and that would drain it..

 

[PWCdoc]

No, the only manufaturer that ever had a drain for just the thing you are dealing with is Kawasaki. There is no drain on your motor. And you state that all this happened 4 months ago? If so, you need to go ahead and plan for a complete rebuild as the sleeves will be rusting and the crank bearings will be suffering the same fate. Hate to tell you....but it's going to happen sooner rather than later.

 

[jcsign]

Running Again!!!

Well I finally got around to working on the ski again and had success. The procedure I used was as follows:
- Removed one spark plug and cranked with fresh battery for about 10 seconds, pumping out water. Did this approximately 5-6 times.
- Reinstalled plug and removed other plug. Did the same thing until minimal amount of water was pumped out.
- I installed one new plug in the cylinder that appeared to have the least amount of water pumping out (PTO cylinder). Left other plug out. Opened throttle and choke to full, installed fresh battery, and sprayed small amount of starting fluid into carb intake (air box was removed).
- Cranked engine and got a single fire. Water shot out of exhaust pipe.
- Replaced plug with another new plug and cranked with the same conditions. Got a couple of fires. Much more water poured out of the exhaust pipe.
- I was out of new plugs so I dried them in front of a space heater. I repeated the steps (full choke, throttle, good battery and starting fluid) about 5 times until it fired several cycles.
- Now I thought it would crank with both plugs in so I put 2 dried plugs in and cranked again. It fired briefly. I then removed both plugs, dried them and put them back in. Next, I cranked it while feathering the throttle to get it to fire. It took 3 times doing this with dry plugs before it continued to run.
- Several gallons of water was discharged out of the exhaust and onto my basement floor.

I believe the entire exhaust system was full of water and that is why it would not originally crank with both plugs in. Like sticking a potato in a tailpipe. Yes, the water flowed into the cylinders. Not a good thing. The question is how much got past the rings into the lower crankcase. At this point I am happy for now that it is running. I plan to keep my fingers crossed and see if it holds together in Spring when it is back in the water. If not, a major engine teardown will be in order.

I just wanted to take the time to explain what I did to get it running again if anyone has the same situation some day. It is a tedious and timely process but it worked. I also wanted to thank everyone for your feedback in the past. This is a great forum. Thanx!!!