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1996 XP 800 Big Problems

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bam3352

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Hey Guys,

I've been having a problem with this ski for a little under a year now. I bought it 3 years ago and it ran flawlessly until one day I ran it pretty low on fuel. Upon refueling it would not start and it would just backfire. I have checked all the common things that cause backfiring....the RV timing, debris in mag, broken pick-up. I've replaced all the fuel lines and have compression tested the motor. It has approximately 165-170 psi in each cylinder.

The above situation happened last summer. I have not had much time to work on the ski as I am still in school and really only have about 6 weeks where I'm home each summer. I just got home a couple weeks ago and just finished sorting out a rebuild on an old blaster that now runs great. I moved on to trying to get this ski going again. The one thing I had not tried was the rectifier test of disconnecting the red wire to it. I put everything back together and did this. I tried to start the ski. It turned over for about 30 seconds and then it backfired louder than I have ever heard it. It broke the plastic through hull exhaust piece in the back of the boat.

Does anyone have any other ideas of what the deal with this thing is. I don't want to pull the whole motor out if I don't have to, but I understand I may have to do that.

Any help would be greatly appreciated.
 
165-170 psi is really high for a stock engine. Have you added anything aftermarket on it? Ideal is 150 for your engine. Other causes of back firing are Intake leak/crankshaft seal failure, malfunction of rev limiter, and timing off. Check the fly wheel key to see if it has been sheared it could be the timing is off.
 
Forgot to mention, it has an R&D rec head with weisco pistons. It was not bored or anything like that. Like I said, if fired hard through the exhaust. Would a normal backfired be able to break that plastic thru-hull fitting? The boat ran perfectly for almost two-years before this problem.
 
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