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  1. #1
    PWCToday Newbie
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    1992 Kawasaki 750ss problems and stumped on finding the issue

    I bought a '92 750ss last year off craigslist that had been sitting for at least 5 years (it was kept inside/under cover but not winterized).

    The top end was bad so I bored the cylinders and replaced pistons. We have good compression now.

    I finally got the jet ski running and it would run well for about 10 minutes and then just totally cut out and die. I could then restart it and limp it home (perhaps it was overheating but the engine did not feel very hot and felt more like an electrical issue).

    I replaced the stator (it was out of spec) as I thought that may have been causing the engine to die when the wires heated up.

    Once I did that I couldn't get it to spark and after investigating the coil, that was also bad, so I replaced that and I now have spark.

    I got the ski up and running again but it had about half the power and just ran rough. It seemed as though it could be a timing- Simply no power and I couldn't get it up to speed at all. I thought maybe I had switched the spark plug cables by accident so I switched those and it didn't make any difference with how it ran (can swap the cables and no difference).

    I pulled the stator and double checked everything was ok there and it was.

    It's also really tough to start. I have to removed the spark plugs, clean them, and then hook it up to a battery charger, and the only way it starts up is if I spray starter fluid directly into the carburetor. Then it's tough to start again. Seems like a flooded engine (or weak spark and drowns out the spark plugs right away with any fuel in it).

    So I'm simply stumped. I feel like I've cleaned or replaced everything on this ski and still can't get it running right (replaced the voltage regulator too and the carbs are clean).

    The battery is weak and I thought this may be an issue. It only sits at around 11.5 volts (and that's after its been sitting on a charger).

    So I'm stumped. Could it be the battery causing a weak spark? Could I have messed up the timing somehow when I replaced the stator? Could it be a carb jetting issue? That's where I'm at with ideas.

    Any help is appreciated!

  2. #2
    PWCToday.com Is My Home Away From Home freekstyle's Avatar
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    Re: 1992 Kawasaki 750ss problems and stumped on finding the issue

    Pistons in backwards?

  3. #3
    PWCToday Newbie
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    Re: 1992 Kawasaki 750ss problems and stumped on finding the issue

    No, I made sure that was all set up correctly upon installation.

  4. #4
    PWCToday.com Is My Home Away From Home Chester's Avatar
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    Re: 1992 Kawasaki 750ss problems and stumped on finding the issue

    Did you pressure test the engine? Did you replace the crank seals?

    Chester
    Speed is very expensive. How fast do you want to spend?

    Stand up:
    98 SXi-Pro

    Couches:

    96 XP
    86 X2

  5. #5
    Top Dog bandit88's Avatar
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    Re: 1992 Kawasaki 750ss problems and stumped on finding the issue

    When you replaced the electronics, did you use OEM or aftermarket? Have the carbs been rebuilt?
    -92 X2 - PJS 800 conversion
    -95 750SXI
    -86 440 undergoing 750 conversion

  6. #6
    PWCToday Newbie
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    Re: 1992 Kawasaki 750ss problems and stumped on finding the issue

    If it run on starting fluid, your running out of gas. Pull the return line off the carb and crank it over. It should have fuel running out. If it does clean the carb, if it dont, check crank impulse line and fuel pump


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  7. #7
    PWCToday.com Is My Home Away From Home
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    Re: 1992 Kawasaki 750ss problems and stumped on finding the issue

    Test the compression again.
    Riding mostly Lake Austin

    1984 JS440
    1989 650sx
    1991 X2
    1992 750sx
    1995 900zxi (qty 2)
    1995 X2

    Quote Originally Posted by cujo View Post
    God intended PWC to be two strokes, as well as dirt bikes, snowmobiles, and chain saws....

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