SXR SXR-800 Mystery

Trixter

Trixter

Location
Toronto, Ontario
Hi all,

I have an 04 SXR with some issues, hope you guys can help.

It was winterized at the end of last season. (before that it worked great!)

It sat in my garage under a tarp until May of this year.

On the first start, idle was fine and strong, maybe a bit high.

when i applied some throttle, the engine pretty much stayed at idle and sounded like crap. Every time i apply throttle it does the same.

I checked the spark plugs and the wires. everything is good, giving a strong spark.

i cleaned the carb filters on the fuel pump side, they were good. seems to be getting enough fuel.

I've done some research around this and other jetski forums and some guys think the culprit may be a temp sensor throwing a limp mode. I'm not sure where the temp sensor is (besides the one on the firewall next to the CDI, which is clean and dry).

would the Temp sensor cause such a problem?

how do i fix the timing if it's a timing issue?

any other ideas ( on an idling ski that seems like it hits limp upon throttle application)?

Any input is appreciated
 
Trixter

Trixter

Location
Toronto, Ontario
djkorn1 said:
Carbs are gummed up from fogging oil? Pull em off and tear em down and clean em up? Make sure jets aren't blocked.
Click to expand...

I only looked at one of the jets in one of the carbs. It was free and clear of debris.

i will clean 'em up but doesn't fuel take years to gum up?

I did put in some fuel stabilizer prior to the winter.
 
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Trixter

Trixter

Location
Toronto, Ontario
If the timing was shot, would it idle fine? or would it have idling problems as well?

because as it sits now, idle is fine, just throttle application poops out.
 
Trixter

Trixter

Location
Toronto, Ontario
Just finished cleaning the carbs (including the filters). there was very little gunk in there, that didn't fix the issue. The carb screws have not been touched, they are set according to the Dry Pipe setup. The jetting is clean on both carbs.

I checked the fuel pick-up inside the fuel tank, clean. i replaced ALL the fuel lines to the carbs and the return lines. The rest of the fuel filters are clean and supply fuel to the carbs (i can see the fuel flowing and i can see it returning to the tank).

I checked all the wires, they all are good and grounded.

I checked the temp sensor at the firewall, its clean and connected (although i have no way of checking if its still working). The temp sensor that was on the stock headpipe has been bypassed, as per the Dry Pipe instructions.

There is nothing caught in the jet pump, its clean.

The reeds look great, no damage.

The throttle cable moves just fine, butterfly valves open fully and completely.

The flywheel and magneto have not been touched.

I'm not sure about the timing though. If the timing was off, would the ski idle, wouldn't it idle very badly?
 
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rollin5150

rollin5150

Location
Idaho
Are your plugs fouled? I really don't think that it is a timing issue. Nothing should have changed since you winterized it. If timing was off, it would back fire or have a rough idle
 
Cannibal

Cannibal

Tasty Human
Location
Summit Lake, WA
Did it ever backfire on you while cranking? Might have sheered the woodruff key.

I had a 750 engine that would idle absolutely fine, but had not power at all, wouldn't rev, woodie key fell out the back when I installed the flywheel. Rookie mistake. The timing was so retarded that it started and idled great, but spark was happening way too early to make any power.
 
Trixter

Trixter

Location
Toronto, Ontario
Rollin5150, I think you are right, it doesn't sound like a timing issue, idle is perfectly fine.

Thumper, I don't block off the exhaust during the off season (maybe i should). My place is rat free, besides, the water box has been taken out of the ski and cleaned over the winter.
 
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Trixter

Trixter

Location
Toronto, Ontario
Flapjack said:
Did it ever backfire on you while cranking? Might have sheered the woodruff key.

I had a 750 engine that would idle absolutely fine, but had not power at all, wouldn't rev, woodie key fell out the back when I installed the flywheel. Rookie mistake. The timing was so retarded that it started and idled great, but spark was happening way too early to make any power.
Click to expand...

The ski did backfire VERY loudly the first time it started this season, it was out of the water I thought maybe i did one too many primes and the fuel blew.

It also backfires occasionally while cranking. Black smoke come out, then resumes to white/blue-ish smoke.

You may be right about this 'woodruff key' (never heard of it, probably b/c i've never touched a flywheel before).

but that begs the question..... how easy is it to shear the key off? what is it made of? toothpicks? How easy is it to replace? do i need a bank loan to afford it?
 
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Cannibal

Cannibal

Tasty Human
Location
Summit Lake, WA
I have not heard one way or another if Kawi upgraded the woodruff key on the SXR or not. It has been an issue with 650s and 750s. The key is only 3mm thick. I believe Yamaha uses a thicker one and doesn't really have this problem.

Let me take a look at mine and remind myself how the timing marks work. Might be a quick check you can rule out.
 
Cannibal

Cannibal

Tasty Human
Location
Summit Lake, WA
So I installed a dial indicator in the rear cyl and dialed it to TDC. Inside the timing inspection port, there is a dot, about 1/8" in diameter that was past the center of the opening just a little bit (about .015 on the dial indicator past TDC from being centered).

If you don't have a dial indicator, remove both plugs, roll the engine over (i stick my hand down to the coupler and spin it) until you see the rear cyl nearing TDC. Now take a screwdriver and insert it into the plug hole. You want the cyl to be pretty much at TDC, so when you roll the engine over, it doesn't bind up on a crooked screwdriver and damage something. Now just work the coupler a little until you find the top where the screwdriver isn't raising or lowering. Get a flash light and remove your inspection plug and take a look.

Here's a pic of mine I just took. The left side of the pic is toward the gas tank and the right is closest the head.

SXR down the hole.jpg

Steve

Disclaimer: I'm more familiar with 650 engines and they have a better mark on the flywheel. I'm new to the SXR, so don't take my word as gospel. Just trying to help out.
 
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OCD Solutions

OCD Solutions

Original, Clean and Dependable Solutions
Location
Rentz, GA
I forgot the Kawi's had that handy inspection port. should be able to spot any water intrusion from there too right?

I'm still thinking about the plugged exhaust idea. We had a squirrel pack an entire bag of dry dogfood into the air cleaner of one of our vehicles before. It would run but just barely. Got a pretty good chuckle once we uncovered the cause. If it was restricted then you should be able to feel it at the exhaust outlet. Even at an idle the exhaust should be fairly strong. If it's just a wisper, you may have an issue.
 
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Cannibal

Cannibal

Tasty Human
Location
Summit Lake, WA
You can't see much in that hole, but if there were water in there, you could find out while it's running, it should fling it out and the flywheel would be wet.

Ya, rodents will pack away crap like no tomorrow. Don't rule that out.

I had a car come in one time with the heater core packed full of dog food. Imagine hopping in your car on a 95* degree humid North Carolina day just to have hot moist dog food smell blow right in your face.
 
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