1996 GSX SOLENOID SOUNDS LIKE THE RUSTY TIN MAN IN THE WIZARD/OZ

[grusnak1001]

* NOTE* This has been an intermittent issue which is getting worse. When pressing the start button nothing happens most of the time (except the buzzing/hissing sound coming from the solenoid). I thought it was a bad solenoid, but the brand new OEM solenoid I installed does the same thing. When I put a screwdriver across the solenoid posts the starter engages (even without pressing the start button.) so I've eliminated the starter as the problem. The battery is fully charged putting out 12.5 volts. Seems to me that the issue is coming from one of the cables coming from the battery or possibly one of the little wires connecting one of the fuses to the solenoid. I tried using jumper cables to bypass the battery cables but they were to big & bulky to grab on to anything. I am open to ALL ideas. Please help.

 

[mikidymac]

First thing to do is check and clean all your grounds.

The other thing to do is make sure you get two beeps when you install the lanyard.

The start/stop button doesn't go directly to the starter solenoid, it goe into the MPEM and the MPEM decides to send power to the solenoid to close it and turn the starter.

Most issues on these are ground issues.

Wiring diagram is here... https://seadoomanuals.net/download/pdf/service/manuals/1996/1996-seadoo-gsx-gtx-sup-manual.pdf

 

[grusnak1001]

My seadoo has many issues. My instrument panel does not work and it hasn't beeped in years. As far as the grounds (wires connected to the starter) I cannot get to them (I'm 68 years old). I'm thinking of connecting a cable from the negative post on battery directly to the engine. As for the positive cable do you have any suggestions?

 

[artr]

I think Miki is right that grounds can be the cause of a lot of problems. Since you have shorted across the original start solenoid and got the starter to crank and changed the start solenoid for a new OEM one and get the same results as before, I would suggest you check two ground connections that can cause a lot of problems on your ski. The first is the small black wire that attaches directly to the negative battery post along with the large black cable. Make sure that small black wire is connected to the battery and is supplying a good ground to the bolt that holds down the base of the ignition coil. The second ground wire to check is the ground wire going to the base of the start solenoid (small black wire). This ground comes from that same bolt that holds down the ignition coil that is near the start solenoid and has a number of black ground wires attached to it. Remove the bolt and clean it up as well as all the ring connectors on the ends of all the ground wires that attach to that bolt (use a wire brush or emery paper and wipe off with rubbing alchohol). Reassemble and see if those connections resolve the issue.

 

[grusnak1001]

artr..First of all, thank you for your detailed explanation. Even I could understand what you were saying. I won't get to it until Saturday but I do have to check out one thing you said in particular. The second ground wire you mentioned going from the bolt that holds down the coil...I don't recall seeing that. ( I'm just going from memory) That will be the first thing I check out. I just ordered from eBay a set of cables that were parted out from an old ski. My thought is if I don't get any solutions from y'all, I will do my best to replace the red cable going from the battery to the solenoid and
replace black cable from battery to bolt on engine. No way I can get to the starter. (bad back-bad eyes). What do you think of that strategy? ONE MORE THING...The little wire going from the e-box to the neg battery post may not be in the best shape. I was never sure what it does. How important is it?

 

[artr]

As far as your strategy of replacing red and black cables to the solenoid and engine I think it is not necessary. You already proved that the red and black cables going from the battery to the solenoid and the solenoid and battery to the starter work fine because when you shorted across the solenoid the starter cranked without any issues. Don't change those yet, you may introduce a new problem.
The little black wire from the negative battery post to the bolt on the base of the coil is critical. If not connected then no spark and no crank when pressing the start button. If a poor connection the no/poor spark and possible cranking issues.

As a side note the large black cable the goes from the battery to a bolt on the engine is actually going to one of the two bolts that hold the front of the starter to the engine. It is therefore providing ground to the engine and starter.

 

[grusnak1001]

Crossing my fingers & hope you are right. I should be able to check out that little wire this weekend & report results. Thank you

 

[mikidymac]

Artr is correct. You have already verified that the main positive and ground cables from the battery are good because it cranks when you jump the high voltage solenoid lugs.

If your ski has the small ground wire from the electrical box to the negative battery terminal like the 1996 XP then that is probably your issue. People forget that wire when connecting the battery and it behaves exactly like yours.

If that little ground is good then you are going to have to check the grounds in the electrical box.

 

[grusnak1001]

Thanks for your input miki. I can't wait to check out that little bugger! We'll keep you posted.

 

[grusnak1001]

Better, but not perfect. That little black wire going to the neg battery post was frayed so I cut off about an inch to get a good solid connection. The wire under the insulation was blackish, like gunmetal. Any idea what that's all about? I put a new connector on. I turned over & started the first 4 times, then it wouldn't engage until the 3rd try. After that, it would start most of the time, but when it failed to connect, I would still hear the hum/hiss/buzz (what ever you call it).
I'm not sure if it's just luck, or if I KINDA fixed the problem. It definitely was an improvement though. (Lets find out what were doing right..and do more of it) HA-HA. Any ideas where I go from here?

 

[artr]

The wire under the insulation is corroded, probably due to moisture. You need to cut away more to get to shiney copper to make a good connection. If the wire becomes too short you could solder on an extension wire or just replace the whole wire. If the existing wire is not flexible it is probably corroded in other areas and should be replaced.

 

[grusnak1001]

I suspected that artr. I will try to cut away more while adding an extension. In the event the corrosion goes all the way to the box, how would I go about replacing the wire? I see it entering the box but i don't know where it ends up.

 

[artr]

Miki had earlier gave you a link to a manual that contains an electrical schematic of your machine. At seadoomanuals.net you can get the schematics and the shop manual your ski. You should invest some time familiarizing yourself with those resources to help you diagnose problems that will arise with these older machines.
To answer your question, the small black wire from the battery negative post goes to the bolt that holds down the base of the ignition coil. Take another look at my post to you from yesterday. It talks about this black ground wire and also cleaning up that bolt on the base of the ignition coil and all the wire connectors that attach to it.