1996 gtx mpem Faults

[Paul 1996]

I was riding my ski, whe i noticed the 12v low on the dash ( never seen before) and the speedo and rev counter were giving erratic readings ( mechanically it was going fine). Rode back to the jetty, turned it off. Checked all plugs, nothing loose. Went to restart, no spark. Took my mates ski for a ride. About an hour later, the ski wouldnt event turn over or register the lanyard. Battery fully charged.

Go home and tested the mpem. The black to Grey/white test should be 9-11 K ohms, im getting 31K ohms. Any ideas what caused this, as i want fix the problem before i replace the mpem and blow it again.

What does the grey/ white wire do? Can I fool it / bypass it?

 

[Dr Honda]

The white gray wire is going to your lanyard. It’s the data line to read the chip. I wouldn’t worry about that one. I would figure out why you were getting a 12v low warring. Even though you say the battery is charged… I would look for broken, or corroded wires between the battery, the solenoid, and the MPEM. You may have lost a ground, and the system just isn’t getting power.

 

[Bills86e]

No Spark

Check, clean & dielectric grease the fuses & holders, And All electrical connections.
Battery cables can corrode internally, so if one gets HOT, more likely than not its
the culpret. Is water in rear Ebox? there is fuses in there too! Water in there can split a coil open. See if you get the signal there and work your way back to where
you get power.
Make sure you hooked up the small black wire coming out of the coil box to the negative side of the battery, and the magneto plug is plugged in.

 

[Paul 1996]

Thanks for the help guys, will check the basics and be back in touch

 

[Paul 1996]

Think ive found the problem ( or part of ), stator is grounding out to earth. Ill replace before i do any more fault finding.

When i replace the stator, how do i know which wire on the stator connects to which of the three yellow wires to the Magnetto plug, does it matter?

 

[Bills86e]

Simply make a drawing, note the orientation of each color coded wire and note the
plug catch. You will need a DETENT PIN REMOVER when you pull the center "tooth"
to push out the pins in the plug, to be able to get the wires thru the housing hole.

Radio Shack Part # 274-223 for .093 pins.

 

[Paul 1996]

I might have had the three phases out of orientation, hence why the stator died the second time. I repaired first time and worked a treat ( rewound one post ) but forgot to resin coat it, so the vibration go to the copper and wore through the schlack coating, when Ive repaired it the second time I must have got the connections wrong.

So Ill have a go at rewinding from scratch. Ill take photos, as this is an easy fix for someone with patience.

Beats paying $300 dollars on a new one, after all, when you ride old 2 stroke stuff, I can really justify spending big bucks on it, Different story on a late model 4 stroke turbo...............

 

[Paul 1996]

Hi Bill,

Im not sure if my drawing is correct re the connections to each of the yellow wires as i just hooked them up in any old fashion to start. I assume they would run in sequence from left to right, connecting to bottom to top in yellow wire order ( or something like this)

Can any one confirm,

 

[Bills86e]

When the male & female plugs up, each wire color should be iin-line with each other.

 

[Paul 1996]

im starting from scratch, the male plug into the magneto female housing plug is ok. Its the end of the three wires from inside the mag housing, what order do they get connected to my three windings on my stator.

 

[Bills86e]

coil wire routeing

Maybe someone who has one apart can upload a pic. You might find on ebay, or
look in classified section someone may be selling a stator coil and have the pic.

Your service manual also has the DIAGRAM, its near the rear pages.