SXR Water in carbs

[Bsullz36]

Hey guys I recently bought a 2006 sxr and am having some problems. The ski runs good then cuts out and dies. I’ve come to find out there’s water getting into the fuel system somewhere. After it cuts out I pulled the intake cover and you can clearly see water beaded up in the carb. I have already drained and cleaned out the tank multiple times. Rebuilt and cleaned the carbs. Checked all the fuel lines. Replaced the filler neck and cap and checked the tube from the filler neck into the tank for cracks. The fuel pickup is also clean and oring is in good shape. Today I strapped it down to the trailer and tested it under load in the water with the lid off. After about 5/10 minute running you could once again see water starting to bead up in the carb. The hull had a very tiny bit of water in it after but I did not see any leaks especially nothing spraying into the carbs. I am at a dead end. If anyone has any ideas that would be awesome.

 

[Bsullz36]

That makes sense I’ll have to check that out. Thanks!

 

[Bsullz36]

My guess is that Water Vapor is condensing inside the cool Intake System/Carbs.

Water Vapor may be coming from a leaking Head Gasket, a leaking/corroded Exhaust Cooling Passage or a Cracked Sleeve which allows water to enter the hot Cylinder, vapor thru the Ports to the Crankcase, then from the Crankcase past the Reed Valves into the Carburetor Throats where the Water Vapor condenses into the Beads you see on the Throttle Plates...

Remove the Cylinder Head to search for a blown Head Gasket.

Inspect the Sleeves for cracks. SXR 800s are notorious for developing Sleeve cracks.

Inspect the Exhaust Manifold for pinholes or cracks. SXR 800 Exhaust Manifolds have also shown this issue.

I’ve checked the cylinder and exhaust manifold for cracks but can’t find any. What’s next? Replace the base and head gasket and give it another go?

 

[Bsullz36]

Note that Kawasaki Gaskets have an "UP" orientation, meaning the side marked stamped UP must face Up. Pretty obvious, but many people install the Gaskets incorrectly.

 

[Bsullz36]

I don’t think the motors ever been opened up before. I can’t find anything.

 

[Bsullz36]

Those are just spots. No milky fluid and heads flat and no loose bolts.

 

[Bsullz36]

.

 

[Bsullz36]

While cleaning the base gasket off the bottom end I noticed a nice crack at the front of the motor behind the stator cover....

 

[Bsullz36]

So far that’s all I can find. Hopefully that’s my only problem.

 

[TheBuzzard]

I've ridden many an sxr to death and I never noticed water like that.
water on the throttle plates aint coming from no head gasket, cracked sleeve, exhaust manifold either.
it looks like water vapor condensation to me too.
I seriously doubt those water droplets are what is causing it to die out.
you said you ran it on the trailer in water for 5-10 minutes and saw the water. you didn't say it died out at that time.
if you had the hood off and could squirt gas in the carbs as it was dying out, you would know if it was fuel related.
a primer pumped as its dying has told me answers in the past on a few skis.
that crack looks like it needs a bead of clear silicone over it to me. not sure how it could have happened.
a leaky head gasket allows compression pressure into the water jacket and squirts air/water out the pisser instead of just water. easily recognizable.

 

[Bsullz36]

The water on the throttle plates is what’s causing it to cut out. Whip them off and it runs perfectly fine again. Once the droplets start to appear it runs like junk and cuts in and out and eventually will bog out and die.

 

[Bsullz36]

Did everything stated above. Put it all back together and same thing happened. Water in the carbs cut out and died.

 

[Bsullz36]

The whole electrical system is new including the stator. The only thing not new is the cdi.

 

[Bsullz36]

The electrical system was installed but a local kawi dealer so I’m assuming it’s all oem.

 

[Ross]

That is strange.
To summarize:
-Tank was emptied and all fuel lines cleaned. It really seems like you have water in your fuel somehow still though.
-If you have a primer, make sure it is not getting submerged because it could be letting water into your fuel lines.
-Electrical issue maybe, but that doesn’t explain the moisture on throttle plates.
-Maybe moisture has built up in the case and is somehow trapped? I don’t know if that’s possible.

 

[Bsullz36]

Ya all new fuel lines tank cleaned out multiple times new filler neck and cap. Carbs cleaned and rebuilt. All new gaskets for the exhaust and intake along with head and base gasket. Whole electrical system is new besides he cdi. I have a new exhaust system on its way and gonna try that also.

 

[Ross]

Ya all new fuel lines tank cleaned out multiple times new filler neck and cap. Carbs cleaned and rebuilt. All new gaskets for the exhaust and intake along with head and base gasket. Whole electrical system is new besides he cdi. I have a new exhaust system on its way and gonna try that also.

Okay, keep us posted. I haven’t run a stock sxr pipe in years, so I’m curious if that could be the cause of your issue.

 

[wmazz]

After about 5/10 minute running you could once again see water starting to bead up in the carb.

It is not likely the water is coming from the fuel. Water does not freely pass
through jets while the engine is running. (for lack of a better term) Water
density or viscosity? is greater than gasoline, so it tends to plug jets under
running conditions, and cause bad hesitations, drop a cylinder or stall.

Most likely you are just seeing humidity condensing on the throttle plates.

Hey guys I recently bought a 2006 sxr and am having some problems. The ski runs good then cuts out and dies. I’ve come to find out there’s water
getting into the fuel system somewhere. After it cuts out I pulled the intake cover and you can clearly see water beaded up in the carb.

Rebuilt and cleaned the carbs.

Did you ever find water inside the carb, after you removed the diaphragms?

Replaced the filler neck and cap and checked the tube from the filler neck into the tank for cracks.

The most common place for water to enter the fuel tank is the filler cap.
That is why, on a tune & service you should always inspect the cap and its
gasket. It is a common problem on all watercraft that someone will replace
the filler cap, and forget to purchase or reuse the filler cap gasket.

I have already drained and cleaned out the tank multiple times.

Draining the tank isn't enough, you must mop it dry with a rag.



When I looked at your cylinder pics, I did notice signs of water ingestion. What
kind of flame arrestor is being used, and is the drive line coupler's splash guard
still mounted to the engine?


Bill M.

 

[Bsullz36]

It is not likely the water is coming from the fuel. Water does not freely pass
through jets while the engine is running. (for lack of a better term) Water
density or viscosity? is greater than gasoline, so it tends to plug jets under
running conditions, and cause bad hesitations, drop a cylinder or stall.

Most likely you are just seeing humidity condensing on the throttle plates.




Did you ever find water inside the carb, after you removed the diaphragms?




The most common place for water to enter the fuel tank is the filler cap.
That is why, on a tune & service you should always inspect the cap and its
gasket. It is a common problem on all watercraft that someone will replace
the filler cap, and forget to purchase or reuse the filler cap gasket.




Draining the tank isn't enough, you must mop it dry with a rag.



When I looked at your cylinder pics, I did notice signs of water ingestion. What
kind of flame arrestor is being used, and is the drive line coupler's splash guard
still mounted to the engine?


Bill M.

Everything’s stock on the ski. It’s water condensation on the throttle plates. Once it dies out give it a pump of the primer and fires right back up no problem. The tank has been wiped dry and blown out. All new fuel lines filler neck cap gaskets you name it. I just got l another stock exhaust system that was on a running ski to see if theres a pinhole in there I missed.

 

[Bsullz36]

So I just put on the new exhaust and once again no good results. Continues to bog out from condensation on the throttle plates. I also came across a new stator that I put on and nothing.