1995 XP electrical

[matempl]

So I took my skis on our weeklong houseboat trip. On the second day the buzzer started going off on the 95 xp
I didn’t think the buzzer worked. After checking what I could I couldn’t see a reason. Ski ran great and no lights were on. Didn’t seem hot at all. I unplugged it. Day three the multifunction gauge started acting weird. Bat light would come on along with low fuel light sometimes dim other times bright. The bar graph on fuel gauge would have random bars shaded. Also when you push the start button with the key out all 4 lights come on like normal but then the bat and fuel light stay lit for over 10 min. The vts gauge stays active as long as those lights are on. I decided not to keep using it. Now at home and I tested the charging system and static voltage is 12.3. Running voltage at 5k is almost 16v. So we have a problem. Any thoughts?

 

[mwat65]

Sounds like metal particles on the stator. They cause all kinds of crazy electrical problems.

 

[matempl]

Metal particles on stator?
So do I pull the cover and blow it out? Does that indicate a bad stator?

 

[mwat65]

Yes pull the cover and flywheel clean the metal particles off the stator and flywheel. The shavings usually come from your starter.

 

[matempl]

So how difficult is it to get the flywheel off with the engine in the hull. Looks like I should have a holding tool. I have a dampener puller but would I be better off buying the correct holder and puller? And where can I get them?

 

[mikidymac]

Use a piece of rope down the front spark plug hole to lock the crank then remove the nut. Don't thread the puller bolts in too far or you will damage the stator.

 

[matempl]

So I replaced the rectifier per Nick at Westside. That seems to take care of the charging problems. The lights on the multifunction gauge are still on. Nick said to look for corrosion. I checked every connection incl grounds in the ebox. Nothing. When the gauge comes on with the key out for 33 secs all 4 lights come on for the first couple of seconds then the temp light goes out the fuel and batt light stay on bright and oil light is dim. What about a bad gauge?

 

[matempl]

My 96 gti uses the same gauge and on the 33 sec power up the only light that stays on is fuel. But its almost out of fuel.

 

[matempl]

Bad gauge. Put the gauge from the gti on and problem solved.