1500 shuts off

[bostonwhaler]

1998 1500 e

No boom on rear cylinder after new piston. Rings. cylinder etc.
Tested coil . stator ect plugged all back in changed rear plugs from 8 to 6 have boom
And will run for a couple of minutes but suddenly dies
Like hitting kill swich.
Hit starter same thing shuts off after a minute or 2
Any ideas?

[id-man]

Welcome to the forum. If you know how to change a whole piston you're already way past my knowledge base but there are some on here who should be much more useful. I just wanted to bump and say really you changed a piston? I'm impressed! Don't be surprised if you get asked for details on that procedure :)

[cactusjack]

Long Stick Goes Boom - Krokus

[ringadingh]

Squirt some gas in the throttle body when it starts to die, that will determine if its electrical or fuel related problem.
Also check the safety switches on the clutch lever & sidestand.

[dshelly]

With a name of a boat for a user name it's no wonder you can't keep it running. Take it out of the water....

[bostonwhaler]

Piston was trashed due to running lean
took motor back out and apart today thought maybe cam timing was off
No luck dead on
Plenty of fuel. Pull rear plugs and they are soaked
don't really have time to squirt fuel to bike it just ramdomly shuts off
no stumble just puff done
1 st start ran on front only pull plug wires off rear no change
after testing electronics started again same thing
after staring at it for a while hit start button bang both cylinders have boom
Idled approx 5 min went dead
and so here I am scratching the forehead
bypassed clutch switch neutral and side stand no change
Was thinking this kawasaki would be just as reliable as my Boston whaler

[ringadingh]

It certainly sounds like an electrical problem somewhere, check all the wiring connecters, sometimes they are dirty or corroded, or you may have a broken wire somewhere in the harness. Have you checked the spark plug wires & caps? They do go bad after a while and your bike is a 98.

[bostonwhaler]

Found the culprit
Flywheel banging against pickups
Keep in mind I picked this bike up to rebuild at some time in its life the
Flywheel bolt had to of come loose and whom ever just stuck it back in and
Tightened it down. Well on the washer there are specific splines that must
align.
Unbelievable the bolt is bent and has some considerable wear.
I can't believe it even started.
and of course the splines are jacked but repairable
looks like new pick ups and while I'm there stator

[bostonwhaler]

My brothers (aka Nasty Dave Shell) drag bike had this same symptom once at Scribner NE divisional race
Shut off going through traps
Would restart die a couple of times then click click
Twisted camshshaft
rebuilt bike made 1st round, electronics failed red lit
Didn't win but didn't go home bike made its quickest pass ever

[mick56]

Originally Posted by bostonwhaler

Piston was trashed due to running lean
took motor back out and apart today thought maybe cam timing was off
No luck dead on
Plenty of fuel. Pull rear plugs and they are soaked
don't really have time to squirt fuel to bike it just ramdomly shuts off
no stumble just puff done
1 st start ran on front only pull plug wires off rear no change
after testing electronics started again same thing
after staring at it for a while hit start button bang both cylinders have boom
Idled approx 5 min went dead
and so here I am scratching the forehead
bypassed clutch switch neutral and side stand no change
Was thinking this kawasaki would be just as reliable as my Boston whaler

Hello mate, what were the symptom's when you're bike blew a piston, i recently discovered my air screw on the carb was missing, this coincided with it farting about on low rev's, at the same time i reckon the exhaust note changed and the rear cylinder pipe went black, probably because it was running hot, i have just fitted a K&N filter and am wondering if the increased engine noise that it is making is due to the sound being more easily heard through it, or is it piston damage ? I rode the bike for about 100 miles total in short 10-20 mile trip's since the carb screw fell out, i hope i have'nt done what you did, i am thinking a compression test is a good way to see if i have, i would like to hear you're view's on it.

[bostonwhaler]

the guy I bought it from stated that he was riding down road when engine let go
rear piston melted sending oil to top of piston thus blowing oil out from side of engine via spark plug
loosing the air screw would make the bike run really fat (rich) potentially dumping allot of fuel into cylinder washing the oil off the walls of the cylinder thus destroying the piston rings and cylinder wall.
hot pipes turn blue in color.
pull rear plugs check for aluminum deposits on plug this would be indicative of a melting piston
do a compression and leak down test if all good
drain the oil should smell like fuel
change oil and filter
install new spark plugs
does bike have aftermarket pipes?

[bostonwhaler]

anyone have a set of pulsar pick ups for 1998 1500E?
discontinued by Kawasaki

[mick56]

Originally Posted by bostonwhaler

the guy I bought it from stated that he was riding down road when engine let go
rear piston melted sending oil to top of piston thus blowing oil out from side of engine via spark plug
loosing the air screw would make the bike run really fat (rich) potentially dumping allot of fuel into cylinder washing the oil off the walls of the cylinder thus destroying the piston rings and cylinder wall.
hot pipes turn blue in color.
pull rear plugs check for aluminum deposits on plug this would be indicative of a melting piston
do a compression and leak down test if all good
drain the oil should smell like fuel
change oil and filter
install new spark plugs
does bike have aftermarket pipes?

Well i learnt something there, i thought that the screw being gone would allow more air in,but thinking about it my bike has been using noticeably more fuel.Yes i do have after market pipes, is that relevant ? i dont know what they are but they are 2 on one side and loud as f--k, top (rear cylinder) one is shorter, can you explain the leak down test please.Thank's for you're help mate

[bostonwhaler]

Cylinder to be tested top dead center compression stroke
leak down test tool or similar tool
while holding flywheel bolt do not let go flywheel will want to turn
add air to cylinder slowly via spark plug hole
listen for excaping through
carb-- intake valves
exhaust--exhaust valves
oil fill hole-- rings
if your bike is not smoking, burning a unusual amount of oil, oil fouling spark plugs, blowing oil into air filter, starts fairly easy go ride
If any thing you are probably lean on fuel that'll melt her down

[bostonwhaler]

May be a hick in the sticks but i have a 93 Vulcan 88 that threw a rod for unknown reason
9000 miles all stock
The pick up coils appear to be the same as the 98 other than length of wire
stator same except for connector maybe out put?
some research to be done