Personal Watercraft Illustrated

I went a re-read a few highlights from project Copperhead's article (May 2008). I had not looked at it since last year, but I didn't think I was that wrong....

The article basically says that after the 250X sucked in a gallon of fresh water Kevin "rushed" the ski over to Circuit Jet Sports...where it was torn down (and found to be full of rust). Rust doesn't happen that fast.

Yes, Copperhead. There was substantial damage to the engine, as we hydrauliced the engine, that is, the water compressed in the cylinder chambers, which distorted three valves, shifted two valve guides, and played basic hell with the valvetrain.
The magazine said: "no valves were snapped, bent or splintered-evidencing that none of the valve guides would need replacing."

The stalling of the reciprocating assembly also hazed two bearings.
"The crank , bearings, and connecting rods were in pristine shape..."

And you should've seen the supercharger. While many PWC-enthusiasts are really "gear heads," I've had a lot of experience with Roots-style blowers. The twin rotors had binded thanks to the added internal pressure (due to the water injested via a "cold air induction" system), and had locked and ground the pressed-seal bearings into pulp.
The article mentioned having the supercharger case polished by California Polishing, but NOTHING about a rebuild.
 

Rustymuscle

Editor-in-Chief, The Watercraft Journal
Location
Nashville, TN
Aaron, you're 100% right in quoting the rebuild article. Here's the problem, our primary evaluation of the damage was wrong.

The damage was far worse. If you'll notice, the next thing we tried to do with Copperhead was participate in the 2008 Mark Hahn Memorial. We didn't even complete a lap...

The Ultra was given back to Kawasaki a week later. Their in-house service department tore the ski down to the ground and found all the damage, giving me a full report.

Although beautifully polished, our supercharger was cooked. Although the bottom end spun by hand, the bearings had been oblonged and held out for less than 20 minutes.

You'll notice we replaced the valves during the first build. I still have them in a shoebox and they still have the marring from being shifted at 7,000rpm.

Basically, in my opinion - and in the eyes of many others - Copperhead was a failure of a magazine project ski of this magnatude.

There have been ideas of resurrecting the name and trying another Ultra, but it's not looking like that's going to happen any time soon.

Barracuda (our RXT-X) has been only half as troublesome, and has required no where near the same amount of TLC. I'll be racing it a couple times in the near future and see if I blow anything else up.
 
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