650/X-2 Plug Reading; 2 cyl/plugs, 1 carb. What happened?

[KawiKid]

Hey guys,
still on the first tank of premix that came with the ski. it smokes a lot...I mean like my HX starting up after fogging, a lot...
I decided last night to take a look at the plugs after running. The PTO plug (the first 3 pics) is DARK with a bit of damp carbon on it.. (looks like hard chunks in the pic, but its really not) and the MAG plug is more of a mocha brownish color (The last 2 pics) which im told is ok?

question is:
this is a SINGLE CARB 38mm setup. How are both plugs different if its a single carb setup? On dual carbs, I know each carb gets tuned for each plug, but how does this happen on a single carb? and how do you adjust it if one plug looks good and the other is extremely dark (rich?)?
How do I adjust this?
Thanks guys!

 

[KawiKid]

I understand that, if this was a DUAL carb setup, and the PTO plug was rich/wet/carboned-up, you'd adjust the PTO carb and if the MAG plug was fine, you'd leave the MAG carb the way it is. How do you do this on a single carb when the PTO plug needs attention and the MAG is ok?

 

[KawiKid]

Bump. any ideas anyone?

 

[OCD Solutions]

Nothing like getting to know a new ski.

What's the history on the ski? Since this is the first tank, I would want to know if it was stored previously and had oil in the cylinders that could explain the uneven coloration.?.?.?

Maybe try a fresh set of plugs to make sure you can replicate the issue.

After that, check reeds and compression.

 

[Tyler Zane]

I dont really have an answer for you, ive been waiting to hear what others thought. These are just idea so take them with a grain of salt.

Maybe peek at the reeds. If one side was didn't seal properly i could see it affecting the burn because of the difference in delivery up the transfer ports.

Maybe there is a difference in ignition...

Did you check compression?

Maybe its just nature of the beast on a single carb, i dont have much experience with single carbs.

 

[KawiKid]

Hey guys,
Both are excellent responses. I had gone to action Kawasaki and mentioned it to Johnny Havell and the techs there, and as you guys said, they mentioned the reeds. one could be broken/worn/not seated properly? This is my first Kawi and I had previously dealt with RV (Seadoo) motors with no reeds.... so I'd have to inspect and learn.
However, as you said, try new plugs...so, I swapped out the plugs with a fresh set on Tuesday, and you wouldn't believe this...
although the mag plug was lighter, I had looked over the wires and made sure they were separated all the way back, I noticed where the mag wire went into the coil, there was some rust colored epoxy on top of the coil, and I noticed that when I barely touched the mag wire, it was basically separated from the coil. so a tiny little tug on it pulled the entire wire OFF! it appears that the PO put these new MSD wires and sheething and boots on, but as I now know the oem cdi's have the wires potted into the cdi and aren't swappable. Looks like the PO cut the OEM plug wires a little above the cdi and did a crappy splice job and just went sick with the epoxy, hoping it would stay. it clearly didn't. this also probably explains why I felt like it wasn't getting a full, crisp rev at times either. so, I start digging into the ebox to get this cdi out. once out, that second wire (PTO) wasn't in there much better than the first. So what I did was got a "quality used" oem cdi from ebay, and sent it to Jetski Solutions to get the refreshing service on it. In the meantime, I did repair the broken one "the correct way" which is to remove all of the potting down to the two metal spikes, make a fresh clean cut in the plug wires, epoxy them back in, then repot it. im not going to install this one, as the turnaround time from jetski solutions is only a few days, and I only have one new gasket on order (the gasket is $3, but the shipping is like $8!) So, I will keep my repaired one as a backup/spare, which will keep me on the water if this ever happens again.

So, do you guys think this hacked cdi could've caused the two different plug readings? I would have thought that the faulty wire going to the mag would've made that plug more fouled bc of intermittent/unsteady spark...but maybe that plug was lighter because it wasn't getting constant spark?

I'm hoping once they are both getting equal spark, the plugs will even out.. What do you guys think?

(here are some pics)

 

[Tyler Zane]

That's your ignition coil in the pics. The leads from the coil go to the cdi.

Jetski solutions was the right way to go. They do excellent work.

The intermittent spark will definitely affect the burn on a plug, because there isn't a burn. The clean unburnt fuel wipes away carbon from the crown and plug. The plug was likely wet when you pulled it and smelled like fuel. Good find, I expect you to see overall gains in throttle response.

If definitely do some more peeking around for more patched up stuff from the last guy that owned it. Good luck with the repair and brapp on!

 

[KawiKid]

@tzane yea I guess I was calling the ignition coil the cdi...I thought it was one in the same, as when I bought the replacement, (the black Mitsubishi box with the plug wires coming out) it was listed as a "cdi"...either way, you telling me that the intermittent/non existent spark would make that plug lighter/unburnt makes me feel like I will get to the bottom of this. I have a feeling i'll get an even burn once installed. yes, the plug wasn't completely soaked, but yes a bit wet and gas smelling until I wiped it with a rag..

I just got the gasket in today and john wrote back saying the used oem replacement I sent him tested perfect for the servicing..it'll be back here on Tuesday the latest, and I'll be able to get going!

Thanks for all the help!

actually, here's a video of BEFORE I found the bad wire. I was asking around if this was too smoky for a 40:1 premix because my one plug was darker. now I think I know why the one plug was darker (spark plug wire) but while I gave it a few quick revs, I noticed the last rev or so didn't seem crisp, as if it was getting intermittent spark.. so im hoping this wire service resolves the "un-crisp" throttle response.

 

[Tyler Zane]

It honestly doesn't sound like it running bad. the smoke is normal, I wouldn't consider it excessive. I wouldn't judge how it runs out of the water (not under load). report back, I'm curious the hear the results.

 

[KawiKid]

I will! I've heard great things about jetski solutions repairs, so I'm curious to see if ill notice the difference.

 

[KawiKid]

so I was redoing that metal plate that holds the Ebox in.. So I pulled the the metal plate out, and I noticed something that was troubling. On the back wall under where that plate is, (firewall?) there's a perfectly round abrasion (almost a hole) about the size of a quarter, where if you touch it, it feels like you can EASILY put your thumb through it. It feels roughed up, almost like when you cut a piece of pvc with a Dremel. I looked on the back side of the plate and it doesn't show any heat damage. This "hole" looks almost as something was beginning to burn a perfect circle in it. I'm just afraid to put the Ebox back together, have a hole burn thru and the ski sink.
Was that a pre drilled hole that the PO may have filled? Or is that there for a purpose or do I have some overheating component issue going on? What do you think?
I'm thinking I can reinforce it and put some heat shield on it? Just troubling that I can basically push my finger thru it so it wouldn't take much more to burn thru. The weird thing is it's the same color of the repainted inside hull, so maybe it's been there for a while and the PO just ignored it?

Thoughts?
Thanks!

 

[Tyler Zane]

Its hard to tell from the pic but im pretty sure thats one of the holes in the bulk head where they pour the 2 part foam into the tray area. Dig at it a little with your fingernail. 550sx, js440, and even superjets have the same holes. Superjets have a sticker over the hole.. lol It looks like yours was painted over.

Anyways, its definitely not from a overheating component and isnt going to sink your ski. Continue with the install! Get that sob going!

 

[KawiKid]

@tzane yep, that's exactly what it feels like! Foam! That was painted over! Great! Whew.. Ok well if that's there for a reason then that's a relief!
John from Jetski solutions said tomorrow, Tuesday the latest and it gets here overnight. So I'm just sticking it out and doing some more cleaning up/detailing inside in the meantime.
I'll report back when I fire it up!
Thanks for all the help!

 

[KawiKid]

Alright, well I just got my plug wire assembly back from Jetski Solutions. I am SUPER impressed with the work, and the little bag of spare parts that came along with it. The bummer is it JUST came today (2day priority) and I'm leaving straight from work today to go to Daytona Beach until mid day Sunday. I'll hopefully have it installed and fired up by mid to late afternoon sunday and will report back.

I now noticed what another forum member wrote about not being able to bolt the plug wire assembly back into the ebox plate because it now has two bolt heads that protrude. I personally haven't tried it yet, but I think it should still work.. if not, I may just grind the heads down a little.
Here, take a look

 

[KawiKid]

Its hard to tell from the pic but im pretty sure thats one of the holes in the bulk head where they pour the 2 part foam into the tray area. Dig at it a little with your fingernail. 550sx, js440, and even superjets have the same holes. Superjets have a sticker over the hole.. lol It looks like yours was painted over.

Anyways, its definitely not from a overheating component and isnt going to sink your ski. Continue with the install! Get that sob going!

Was able to install the plug wire setup from JSS last night, but had to do a little modifying for my wire ends to match with the other ends on the spark plug wire assembly.
It was about 12:19 AM when I snapped everything back together, so starting it wasn't an option.
Before leaving for work today, I decided to test it.
FIRED UP NICE AND SOUNDED CRISP!

Cant wait to hit the water and see! Thanks for all the help, I'll report back after the ride

 

[KawiKid]

Hey guys, didn't want to start an entirely new thread for one question, so I figured I'd add it here.
I tried doing some research and really didn't come up with much, except people SAYING that they have a dry pipe...
So, My ski came with a "dry pipe".... I'm new to stand ups and their mods/parts.... What is the difference between a "dry pipe" and a "wet pipe"...and how is it done and which one is better? and is it better on a 650sx? do all stock skis come with "wet pipes"?

Thanks!