2007 Kawasaki Ultra Lx Engine
Thread: 2007 Ultra LX Engine Advice
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03-02-2016,09:57 AM #1
2007 Ultra LX Engine Advice
Bought a 07 Ultra LX really cheap from a friend and ski looks good but engine will need some work. I can do the work on it but could also use some advice. Goal is to get this back to good running condition and have for family and friends to ride.
Story on the ski: Cylinder psi 1,2,3,4 - 150, 130, 0, 100. I looked at the tops of the pistons with a boroscope & looked like it had some detonation on each of them. The story from my friend is that he got the ski in 2009, ran great until Spring 2014 where the overheat alarm kept going off. Would only go off in the water and not on the hose. He rebuilt the pump & still had overheat issues. He said the alarm would go off within 10mins of starting in the water. He brought it to a local shop to fix and he said when he picked it up (supposedly fixed) that it had the same overheat problem when he put it in the water but had a new issue of a "knock noise from the engine". He put it on the trailer Summer 2014 and hasn't messed with it since.
My thoughts are that it had/has an obstruction somewhere between the pump and engine since he said the alarm wouldn't go off on the hose. He did say that it was still pissing but I'm thinking it could've not had adequate flow. So the overheat issue is not the main problem now..... the internals in the engine are. I checked the oil and there was no signs of water mixed with the oil & oil was at the proper level on the dipstick. I have yet to dissasemble anything but would like to start this week/weekend. Should I pull the head & cylinders or just go ahead and pull the whole engine? I'm guessing that it either dropped a valve and that could be the knocking noise he was describing which is why it has 0 compression on #3 and/or the detonation killed the piston.
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03-02-2016,04:21 PM #2
pull the head and see what you find, no need to remove the engine just yet.
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+1 by:
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03-02-2016,05:09 PM #3
Can the head be removed without pulling the engine? The manual says to pull the engine.
Chester
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03-02-2016,08:06 PM #4
I pulled the head this afternoon. Cylinder #3 had an intake valve that came unsecured where the keeper holds the valve spring down at the top. The valve did not break in half or drop all the way, but it did touch the piston. The valve is still intact. The #3 piston has major pitting and looks like the top of the piston has melted away some around the edges of it. The cylinder bores don't appear to have any gouges except for one small spot at the very top of cylinder 3.... I don't even think the ring goes that high. I took pics of each piston, cylinder and valves on the head but probably won't be able to post the pics until tomorrow.
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03-03-2016,12:27 AM #5
i wouldnt have suggested if it cant be done!!
Originally Posted by Chester
Can the head be removed without pulling the engine? The manual says to pull the engine.
Chester
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03-03-2016,12:28 AM #6
replace the valve no matter dont re use it..
I pulled the head this afternoon. Cylinder #3 had an intake valve that came unsecured where the keeper holds the valve spring down at the top. The valve did not break in half or drop all the way, but it did touch the piston. The valve is still intact. The #3 piston has major pitting and looks like the top of the piston has melted away some around the edges of it. The cylinder bores don't appear to have any gouges except for one small spot at the very top of cylinder 3.... I don't even think the ring goes that high. I took pics of each piston, cylinder and valves on the head but probably won't be able to post the pics until tomorrow.
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03-03-2016,07:54 AM #7
Pics
Yes, I plan on replacing the intake valve that floated & also an exhaust valve next to it that appears to not have a good seat. Not sure if this head will be reusable because of the pitting from cylinder 3...? I'm thinking replace those 2 valves, if not replacing the entire head. Going to pull cylinder off and inspect pistons. Piston #3 will definitely be getting replaced and possibly resleeved. All other pistons will get new rings & new hone. Here are some pics of everything. Will number which cylinder each pic is for. All Cylinders
Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 4
Cylinder 3
Cylinder 3
Cylinder 3
Cylinder 3
Cylinder 3
Cylinder 3
Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 4
Floated Intake Valve
Head - Oil from valve cover made a mess
Valves on Cylinder 1
Valves on Cylinder 2
Valves on Cylinder 3
Valves on Cylinder 4
Valves on Cylinder 3 - Floated Valve (pushed out) & other valve that does not appear to be seating well.
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03-03-2016,11:54 AM #8
Thanks for your reply but I already figured it out. I had to pull the head off a customers Ultra 260X yesterday.i wouldnt have suggested if it cant be done!!
Can the head be removed without pulling the engine? The manual says to pull the engine.
Chester
Chester
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03-03-2016,01:07 PM #9
Ouch that's bad, multiple cylinder with smashed pistons! Did it ingest water? Leaking intercooler?
That's in rough shape.
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03-03-2016,01:43 PM #10
It does not have an intercooler on it. This ski is naturally aspirated.Ouch that's bad, multiple cylinder with smashed pistons! Did it ingest water? Leaking intercooler?
That's in rough shape.Two issues I know it had..... valve touchdown on piston #3. Prior to that, only problem was the ski overheating. I'm sure the overheating was the main cause cooking the pistons with the valve doing more damage on #3.
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