Kawi 650 water in cylinder

[Coach]

Hi all,
I have a 91 X2. All stock with block off plates for the injection and case drain.

I noticed after riding it and it sat for a bit in storage that one of the spark plugs was rusty. So I am getting water into the cylinder. I did the basic head gasket change to see if I would get lucky with that being the issue. The cylinders, pistons and head all looked great with no obvious places where water might be getting in. I ran the ski and after checking the plugs they are milky, so I am still getting water into the chambers.
It seems that there are only a few places the water could be getting in. Either the head, head gasket, exhaust gasket (which was replaced recently as well but after this issue came up), the cylinder, or the cylinder gasket to the case. The water jackets do not go through the case correct?
Is there any other places that could be letting water into the cylinders? If those are the only places then it seems that a simple new top end (cylinders and head) would cover most places where water could be getting in except if the case was warped or something at the base of the cylinders.
Just wanted to run this by the forum to see if anyone had any ideas. Its probably due for a top end anyway but like to run though options before I start to throw parts at it.

Thanks!

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[WFO Speedracer]

There is one more place but there is a story here so wait till the end.

When I worked at the Kawi dealership we sold a new Kawasaki X2 , the customer kept saying it did not run right, compression , reeds all the normal stuff checked out so I took it and water tested it, he was correct in the water it went down to one cylinder. We pulled the head and checked it , replaced the head gasket, same thing, we replaced the exhaust gaskets , same thing .

Kawasaki field reps were of zero help so I had to figure it out on my own , I pulled the cylinder and left the head and exhaust manifold on it.

I capped off the line coming out of the head , filled the shop sink up with water and pressurized the fitting at the bottom of the exhaust manifold , what I found was a hole in the casting going from the cooing jacket straight into a transfer port , it was caused by a porosity in the casting .

Kawasaki replaced the cylinder , pistons and gaskets under warranty which solved the issue .

While none of that really matters here it does tell you how you can check yours out .

 

[Coach]

Right on. Thanks! This ski always had an issue with this I think. When you would run it, it would run fine. Then if you stopped and took a break for 5-10 min it would run on 1 cylinder for a few minutes till it cleared out. Then it was fine till you let it sit again. This ski then sat for a few years and we moved. Now we ride it in the ocean where you do not take any breaks, you ride till your exhausted then come in. So it I haven't noticed if its still there. The only reason I noticed it now is from checking the plugs and seeing that they were rusted. So maybe this is the same issue just noticing it now. The ski runs ok but I do not know when the last time it was rebuilt.
Maybe its time for new top end.
Thanks for the reply!

 

[WFO Speedracer]

One other thing Kawasaki cylinders are known for pulling up the deck slightly where the studs are put in at , it may be out enough that it is causing sealing issues on the head gasket , the fix is to deck the top of the cylinder to get it flat again .

 

[Coach]

Thanks. It would be nice to know where the issue is but I may just look into replacing the top end and just be done with it.
This issue is if there is water in the cylinder there is a good chance it also made it into the case, So now do I just rebuild the entire motor?
This is kind of a fun extra ski to have around but money spent on this is not money spent on my SJ.
Decisions decisions...

Thanks!

 

[WFO Speedracer]

Pretty much you disassemble the engine down to the bare cases , that way you can spin the bearings and make sure they are all good, put in a new set of crankshaft seals, have the cylinders bored and the cylinder deck checked then go from there.

 

[Scorn800]

Is it that back cylinder (close to tray) getting the water in it?
Make sure the exhaust gasket for the head pipe is installed correctly or it can leak water into back cylinder