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1996 XP Battery Voltage Drop

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etemplet

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Been having issues with the 1996 XP and decided to troubleshoot as it was doing strange things. Seemed to start only when I let go of the start button. It also gave me some sputtering for a few minutes the other day then cleared up Ski is restored so I've done pretty much everything Here is the skinny. Battery voltage drop at the terminals goes from 12.7 to 11.6 when cranking. I get a dim light on my spark plug tester. When I let go of the starter button and the ski starts the spark plugs tester glow is noticeably brighter. I pulled the starter and rebuilt it but the starter never had an issue. Spun the engine very well. This did not resolve anything.

I connected an additional battery using jumper cables and still only dim glow on the plug wires and no start. I'm thinking it is the coil but I'll verify the battery is good tomorrow. When the ski does start I'm getting a voltage increase so I figure the rectifier and charging system is working to some extent. Strange strange to me.

How much battery voltage drop is acceptable?
 
Sorry you’re having issues with the 96 again... I think that voltage drop is in the acceptable range. You’re going to get a slightly weaker spark while you are cranking, as the battery voltage has dropped while the starter is pulling amps. I would expect that to get stronger as you release the switch and starter stops drawing current... You should have plenty of spark to fire it off though.

I thought I remembered that you went through all the grounds in this ski. Is that correct? I suspect the coil as well, but the grounds are easy enough to go through and check...
 
The voltage should never drop below 12v. Anything under 11v and the MPEM might not even fire. If the starter is good something else is drawing amps like bad cables, connections or battery.
 
Thanks for the response. I'm not sure I did the grounds inside the gray box up front but everything else go attention. It's weird for sure. I actually thought it was funny how the ski has been acting. The ski started and I rode it a bit each test day, so far 3 times out. I'm just finishing up on ski getting it all spot on. This is where i get really anal. :D I thought I read somewhere that under 12 volts and the skis would not start. I just wanted to make sure. I'm gonna change the coil tomorrow and see what happens. I think I'll do a voltage check at the coil first. Thanks for the input.
 
I did a voltage drop test on the positive cable from the battery to the starter while cranking and it was strange. I replaced the brushes and cleaned up the starter but it could have a bad stator. It is definitely something in that little area.
 
Well the voltage drop debacle thew me off the correct path. I knew I read that less than 12 volts was bad so I began to try to solve that issue and thought it was related to the ski's behavior. I am not one for EVER pulling parts off good running skis to test anything. I just won't do it. However, I had one of these units on another XP that needs an engine. I didn't trust it but figured I'd give it a try. I cleaned it up so that if it worked I wouldn't have to do anything else. Well...... that sum bish fired up so fast... even before I could hit the start button almost. And it fired up repeatedly. :) I decided to do a voltage drop test on the battery while cranking. Since this whole system is different the cables are all are different. Voltage dropped to 11.57. Ski fired right up... every time. It was THE COIL obviously preventing start up. I'll move all this back to my XP Thread. Thanks for listening and as always... APPRECIATE the help !!!
 
Thanks for the response. I'm not sure I did the grounds inside the gray box up front but everything else go attention. It's weird for sure. I actually thought it was funny how the ski has been acting. The ski started and I rode it a bit each test day, so far 3 times out. I'm just finishing up on ski getting it all spot on. This is where i get really anal. :D I thought I read somewhere that under 12 volts and the skis would not start. I just wanted to make sure. I'm gonna change the coil tomorrow and see what happens. I think I'll do a voltage check at the coil first. Thanks for the input.

The CDI begins to malfunction around 10V, if less then this at battery terminals while cranking you probably have no spark. It'd have to be a badass battery to maintain 12V while producing 200A, those lilliputian boxes aren't up to that.

How to Properly Check the Juice in Your Car Battery
 
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The best I got was 11.7 volts but generally 11.56volts it could hold. sure had me chasing my tail. I swapped the box out.... I'm sure it was the coil. :D Good info brother.. Thanks you as always !!
 
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