New build 1100 Kawi Motor Middle Piston meld afer short time
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  1. #1
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    New build 1100 Kawi Motor Middle Piston meld afer short time

    hi,

    My new Build motor which i rode yesterday first time in my SXR melted the middle Piston after 45 Minutes of ridetime, but fuel tank was empty at this time to so maybe it got lean thats why ??

    82.50 Pistons
    ADA Head 160 PSI
    Mikuni SBN 44īs
    Dry Pipe mods
    Filters
    Chokes removed
    Dual cooling
    50:1 mixture 95 octance fuel with Klotz TCW3 Oil

    My Jetting is

    120 low 1.5 out
    110 hi 1.5 out
    95 gram Spring with 2.0 N/S around 25 Psi pop off Pressure


    middle rpm to top rpm i needs a short time like a light switch...so maybe pop off is to high...

    Can you help me here what i need to change and what did u tink melted the middle piston ? possible because of the empty tank ? it dies same time
    THANKS ALL OF U
    Ski smokes at idle doesnt smoke at wot or cruising
    Last edited by Felix #86; 06-15-2022 at 05:37 AM.

  2. #2
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    Re: New build 1100 Kawi Motor Middle Piston meld afer short time

    PS: i run the 1100 Intake Crossover Manifold, i dont know if that care in something ?

  3. #3
    Top Dog JC-SuperJet's Avatar
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    Re: New build 1100 Kawi Motor Middle Piston meld afer short time

    What is your Elevation above Sea Level?

    For Sea Level Altitude, the Main Jet should be #130 at around 1.5 Turns for a Non-Ported Engine.

    Pop-Off doesn't effect the Engine past 1/4 Throttle. The Top End is Lean; go to bigger #130 Main Jets.

    Read the Mikuni SBN Manual again.

    Make sure the Spark Plugs are the correct Heat Range. ADA requires NGK 9 Series Heat Rating. And ensure they are the correct Length: HS or ES?

    Go to 40:1 Pre-Mix Fuel. 50:1 is not enough for the high RPMS above 7000.

  4. #4
    Top Dog JC-SuperJet's Avatar
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    Re: New build 1100 Kawi Motor Middle Piston meld afer short time

    Also, do those 44 Mikuni Carbs have a Return Restrictor built-into them? Or an External Return Restrictor?

    If no Restrictors, needs a #100 Jet in the Return Line to Restrict/Regulate the Fuel Pressure correctly.

  5. #5
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    Re: New build 1100 Kawi Motor Middle Piston meld afer short time

    i used with OEM 1100 ZXI Plugs they are NGK BR9ES i dont know how long they are. i dont have any restrictor in the Return line. so you mean i put an #100jet in the return line to get more Fuel Pressure ?

    i dont know if they have an internal one ??? How can i see that ? i just connect the return line to the Fitting at the Carb Rack...
    Last edited by Felix #86; 06-15-2022 at 07:31 AM.

  6. #6
    Top Dog JC-SuperJet's Avatar
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    Re: New build 1100 Kawi Motor Middle Piston meld afer short time

    Normally Mikuni Carbs come with a .60 mm Hole drilled into the Return Circuit. A 0.60 Orifice is same as a #60 Jet...

    If you have #60 Returns, then that means that the Fuel Pressure will be a little higher and the Engine might run a little richer, which is safe.

    I'm assuming that each Carb has its own dedicated Fuel Supply Line directly from the Fuel Tank.

    If No Restrictors, then the Fuel Pressure will be too low and the Engine will starve for Fuel at High RPMs.

    The Return Restrictor forces more Fuel into the Carbs instead of dumping the Fuel back into the Fuel Tank.

    Again, read the Mikuni SBN Manual ; )
    Last edited by JC-SuperJet; 06-15-2022 at 07:47 AM.

  7. #7
    Top Dog JC-SuperJet's Avatar
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    Re: New build 1100 Kawi Motor Middle Piston meld afer short time

    Also, learn the NGK Spark Plug Nomenclature so you know what the Heat Range and Length of the Spark Plugs are...

    Attachment 575293

  8. #8
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    Re: New build 1100 Kawi Motor Middle Piston meld afer short time

    no i use an carb rack from an GP1200 NPV with an Adapter plate to the Manifold, one in line from the Fuel Valve ( On+Reserve)
    i think there is no restrictor, i just ordert an blowsion one and will fit an 100 Main Jet.

    How can i check if my carbs does have an fuel restrictor ?
    Last edited by Felix #86; 06-15-2022 at 11:31 AM.

  9. #9
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    Re: New build 1100 Kawi Motor Middle Piston meld afer short time

    PS: I cant open your Link. Can you please confirm that i am using the correct spark plugs =?? Thank you so much
    Last edited by Felix #86; 06-15-2022 at 11:31 AM.

  10. #10
    Top Dog JC-SuperJet's Avatar
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    Re: New build 1100 Kawi Motor Middle Piston meld afer short time

    "NGK BR9ES spark plug. Fits all ADA Racing billet watercraft"

    https://www.adaracing.com/bgk-br9es-spark-plug

    If you have Yamaha OEM GP1200 Carbs then it already comes with Return Restrictor Orifices.

    Do you have a total of 3 Pulse Lines going to the Crankcase? The KAW 1100 Crankcase only comes with 2 Pulse Fittings. Did you install a 3rd Pulse Fitting for the GP1200 Middle Carb Pump?

    How is the Middle Carb receiving Fuel? Fuel Return leftovers from the Front and Rear Carbs? Works for the KAW 1100 Stock Carbs but not sure that's enough for the Yamaha Stock Carbs...

    What did you do with the Middle Carb Pulse Fitting? Is it connected to the Crankcase or capped off?
    Last edited by JC-SuperJet; 06-15-2022 at 12:39 PM.

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