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Seems like you have checked and replaced pretty much everything already....only one comment....not sure what pipe you are running but 18 psi pop off is very low......Stock is around 45..ish.....mid to upper twenties normally bang on for most mods......others can chime in could be running way...

I am angling towards fuel starvation....how old is/are external fuel filters....replace it anyway....did you clean embedded filters in carbs....can you verify that excess fuel is returning to tank via return pipe..(decent flow) ..one one way check valve on gas tank working properly.

Highly unlikely that is the cause....its only just exposed the wiring....however.....if the exposed part was chaffing on the red lead or battery positive.....then you just got lucky you found this before things got ugly.......if the chaffing was caused by exhaust, motor rubbing on lead...

Also.....buy OEM relay from JM. AM ones are junk

One possibility is that your starter motor is pulling way too much current.....either binding on its bearings or your motor is too tight.....rusted cylinders, etc.....that causes the relay to overheat.......remove starter and test it.....also rotate motor with plugs out....check for smoothness.

With the mods you have, a bigger than stock low speed jet and a lower than stock pop off should have been done at that point.......If not ....these are the two variables that could also be causing your issue.

If your original starter got toasted due to an internal short ( thats why you bought an new one) then its highly likely that the solenoid lugs have welded the internal link due to the huge current that flowed through it, creating your problem....measure the resistance on the solenoid terminals...

I bought a 50CAL surf hull and pump, dropped in my DASA900, etc I also have a -4 SF carbon badass TPE1100 and a Rickter FR1 BB781....so have a diverse opinion on some AM options.. in short my best ride ever is the SFreak, FW and any surf condition, the hull is bomb proof and unbelievably...

How does the CDI get its pulse signal for 2004 and up. Purely for my understanding. I Left the Kawi world after all the electrical failures

Check the pulser coil on the stator.....its the single biggest reason these Kawi's lose spark....cant remember the exact ohmage reading it should be but if it open circuit its toast (a few hundred ohms like 350 or therabouts)...I used to have mine rewound with a slightly thicker SWG wire and a...

just use a dremel fitted with a cutting wheel and cut off 5 mm off each end rod and if needed cut off another few mm on the ball mount end pieces...should have more than enough thread left to adjust steering properly....had to do this mod more than a few times.

roger that...I do recall those connectors clearly....my switch was definately the one pictured in post #1 apologies

I had the same switch but I got it from AJS...I think they are actually from the very first Kawa 440 start/stop switches......quality is really good, but it lost its toggle function after about a year...(you have to hold it in to keep the contact closed) so pretty useless now and its very...

I will need to double the order details on my JM invoices to give you exact answers guys.....not touching my Freak.its ..still the best hull and motor I ever owned tks to Tem and McDog....give me a day or so please.....trying to dial in the 50cal so it feels more like my Freak.....grinded the...

Thank you.....makes sense.....I think I have a 9/15 on my SF with a 148torrent and 1105tpe....runs like a r*ped ape

I bought a krash 50kal hull which had the pump included.....dropped in my DASA900 bpioe, etc, and it feels way over-propped......engine can’t pull into the upper range except on flat sections.....looking for instant hit and rev-ability for surf riding, hard turns, white water mounting...

I use a chain wrench to turn the coupler and I hold the mid shaft in position with an old driveshaft that I lock down in my press......leaves a few grip marks on the outer shell of the coupler, but its better than breaking it......heat helps

tks guys much appreciated will see how things go without a spring for now then.

Does the KRASH 50CAL RTR trim system work with or without a spring to hold the nozzle firmly down.....mine came with nothing in place, but I have yet to ride it after just completing my build....any pics would help...tks