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  1. #1
    PWCToday Newbie
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    95 WaveRaider 1100 - Blown #1 Piston x 2

    Bottom Line Up Front: I need help figuring out why Piston #1 on my ski keeps exploding!!!!


    Ok...here's the situation...

    Pre-rebuild Jet ski configuration: Original carbs w/o the "idle bog" TSB...1.5 N/s...oil injection pump....mikuni dual output fuel pump
    1) 1-month ago, jet ski started running "bad". Found an oil line had slipped of the pump. Unfortunately the ski had been ridden for 30 min or so in this condition. Connected oil line, and it ran "ok" for another hour or so.

    2) After an hour, while at full throttle...then engine died completely while riding it pretty hard. Was able to restart it, however top speed was now 40mph (not the usual 60+).

    3) Pulled the cylinders....piston #1 had blown. Thought it was due to damage induced by lack of oil because the top of the cylinder looked awfully clean....told evidence of running lean.

    So I cleaned everything up...replaced the piston...and rebuilt the carbs. I also installed the block-off plate and filled the tank w/ premix + break-in oil. ~ 40psi pop-off



    I took the ski out to break-in the new setup......here is what happened....
    1) 10 minute idle to warm up...no issues

    2) 30 minute 0-20% throttle...no issues. Cool down for 30min.

    3) 30 minute 0-50% throttle...no issues. Cool down for 30 min.

    4) in the 30 minute 0-90% throttle....after about 15 minutes...started running really "bad" and heard something wrong with the engine. Engine died...tried to restart...but something was blocking the crankshaft from fully spinning (my guess is the rings lodged in an opening)!

    5) Pulled the head off....once again piston #1 is blown. Once again...Looked like it had been running very lean.

    Does anybody have any ideas of what the real problem could be?
    Is the #1 Carb getting starved for fuel/oil? #2 and #3 look fine!

    Do I need to do the "drill out the return" and add a restrictor to the return fuel line to solve the problem, assuming I don't have too much of a mess now in cylinder #1? If so, what size? Do I need to change pilot & high speed jets?

    Should I just thrown in the towel...and sell my baby?!

    Ugh!!!!!

    Any help would be greatly appreciated!!!!

  2. #2
    PWCToday Regular
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    Re: 95 WaveRaider 1100 - Blown #1 Piston x 2

    Blown as in a shattered piston? Or a cracked ring on the piston?
    1995 Kawasaki 750ss-Sold

    1999 Kawasaki Ultra 150, shredmaster ride plate, extended nozzle, tripple pisser kit....

  3. #3
    Top Dog orangefinger's Avatar
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    Re: 95 WaveRaider 1100 - Blown #1 Piston x 2

    these are notorious to have blown crank seals in rear
    KELLYHIEKE.ROCKS NEW WEBSITE CHECK IT OUT - FEMALE AMATEUR FREESTYLE

    HURRICANE ECLIPSE TPE 900CC P&P Performance

    94 Blaster "KAW 1100cc"

    650 SC

  4. #4
    PWCToday.com Is My Home Away From Home freekstyle's Avatar
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    Re: 95 WaveRaider 1100 - Blown #1 Piston x 2

    Post up pics of the pistons. May have a rod or crank bearing coming apart.

  5. #5
    PWCToday Newbie
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    Re: 95 WaveRaider 1100 - Blown #1 Piston x 2

    Quote Originally Posted by freekstyle View Post
    Post up pics of the pistons. May have a rod or crank bearing coming apart.
    Here are some pics from the first time the #1 piston blew up. Rings melted into the piston itself. There wasn't any noticeable damage to the rod once I got it all cleaned up. The head was pretty banged up.

    If the problem was a front or rear seal....would I be able to figure that out without cracking the case?

    I sincerely appreciate your input! Thoughts?

    IMG_8869.JPG IMG_8872.JPG IMG_8873.JPG IMG_8880.JPG IMG_8881.JPG 55348392449__A532506F-68F8-49E9-80EA-0A1B507CFF22 (1).JPG
    Last edited by x83762; 07-31-2018 at 01:25 PM.

  6. #6
    Top Dog orangefinger's Avatar
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    Re: 95 WaveRaider 1100 - Blown #1 Piston x 2

    i would recommend at this point to pull complete engine , split cases , inspect for debris & clean and defiantly replace the crank seals ...

    dump oil injection , go to pre mix, check jetting ,clean carbs rebuild etc and double check head gaskets , if i can recall jetting was staggered ...mmh..compression too ...mmh getting old
    KELLYHIEKE.ROCKS NEW WEBSITE CHECK IT OUT - FEMALE AMATEUR FREESTYLE

    HURRICANE ECLIPSE TPE 900CC P&P Performance

    94 Blaster "KAW 1100cc"

    650 SC

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