96 xp 3k rpm limit, 5mph max

[jdgherasim]

hello everyone, i got a chance to take out my new to me 96 xp out on the lake today. Rebuilt carbs with mikuni parts, popoff 32psi on both, no leaking seats or anything. i’m having a weird issue, the ski won’t go past 3k (i’m guessing as I don’t have an rpm gauge), but definitely around 3k rpm. it sounds like a rev limiter, i sit around 7ish mph wide open. i unplugged the red wire off the rectifier with no change, i actually got worse performance after unplugging. only 2 times the ski freed up and let me go wide open up to 40 mph, once i came back to an idle I couldn’t go past 3k again. 150 psi in both cylinders.new battery. fresh gaskets all around for exhaust and carbs. any ideas? i can idle around but it will kill itself every so often. new rectifier on the way just in case, the ski will rev past 3k on the trailer, thanks!

 

[jdgherasim]

to correct what i said about 7ish mph wide open, i don’t mean it’ll rev out and sit at 7mph, i can’t pick up speed at all no matter what. basically had to idle it back to the launch ramp.

 

[jdgherasim]

this video i found is the exact thing my ski is doing

 

[burtshaver2021]

I couldn’t say for sure but thought I would put in my 2 cents. A few things that you could try. Check the rave valves, I have a 97 GSX, when I first got it wouldn’t usually go above 4500 rpm and if it did, it wasn’t for long. On land, put a voltmeter on the battery while revving the machine to 5000 rpm, see what the voltage at battery is, can’t remember the the exact number, but if it’s high, say 15 or above roughly then a bad regulator/rectifier. Tried clipping back the plug wires a 1/4”? Check the colour of the plugs, Have you tried running it on reserve setting? If none of this helps or indicates a problem, I would recheck the carbs, I would have to look into the Mikuni manual to see what part of carb controls up to 1/4 throttle but double check the jets for dirt, those 2 or 3 tiny holes that go to the throat of the carb. Try putting 4 Ibs if pressure to pulse fitting on carb and see if it holds. Double check high and low screw settings. Your sure it was genuine Mikuni? Where did you purchase it from?

 

[burtshaver2021]

What carb settings? Also you mentioned new exhaust gaskets, ride around with seat off and see if that makes a difference, I’m thinking possible exhaust leak, choking it? Just some ideas

 

[jdgherasim]

What carb settings? Also you mentioned new exhaust gaskets, ride around with seat off and see if that makes a difference, I’m thinking possible exhaust leak, choking it? Just some ideas

could very well be an exhaust leak, theres no water leak but there is a slight smell of oily exhaust gases inside the hull then i take the seat off and a little smoke

 

[Stevie96xp]

Kind sounds like you got an exhaust leak ride it with the seat see what she does. Also check the raves

 

[Doug Overkill]

Sounds to me to be electrical safety circuit related. There is a switch on the forward - neutral - reverse that prevents the ski from starting when not in nuetral. This switch also Rev limits it to 3000rpm. Will it start in forward? If so Switch or wiring is bad.

 

[Stevie96xp]

The

Sounds to me to be electrical safety circuit related. There is a switch on the forward - neutral - reverse that prevents the ski from starting when not in nuetral. This switch also Rev limits it to 3000rpm. Will it start in forward? If so Switch or wiring is bad.

xp has no reverse

 

[WhiskeyD]

Definitely sounds like a bad voltage regular. Unplugging it shouldn't make the ski run worse either. I'm thinking its something electrical going on.

 

[2-Smoke]

I am experiencing this exact issue with my 96 XP right now. Have you had any luck fixing it?

 

[Stevie96xp]

I am experiencing this exact issue with my 96 XP right now. Have you had any luck fixing it?

Did you try unplugging the ret wire coming from the voltage regulator

 

[2-Smoke]

Did you try unplugging the ret wire coming from the voltage regulator

Yes, I actually swapped out the whole unit with a known good one, and the issue still returned.

 

[Stevie96xp]

Ok

Yes, I actually swapped out the whole unit with a known good one, and the issue still returned.

ok you say it revs over 3 k out of the water I would check your carbs again. Make sure there all good and check all your lines in the fuel system