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1996 XP Start button wiring and DESS Post issues

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shattered00

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Hello Ladies and Gents,

I have moved on from the VTS problem for now (couldn't post a video in the last thread I made, but will take still shots to display what I am trying to describe similar to a picture flip book).

I figured I needed to make sure the ski would even start before I mess with anything else and put it all back together. My friend has been instrumental in my making it this far along with the members of this forum, so thank you once again.

Here is the problem currently. I replaced the fuses in the E-box as well as the solenoid. There were signs of water intrusion at some point and someone else had definitely done work on the ski (both the MPEM and E-box were opened when I purchased the ski a year ago and the ski had sat for around 3 years before that. I cleaned off the surface rust from the contacts and used dielectric grease where it was needed. The start button contacts had previously been cleaned and there is a new start button. It makes a distinct click noise when the start button is depressed. I did not change the fuses or anything else in the MPEM box but plan to.

I then hooked up the battery and the cables and experienced the following when trying to start the ski (note that I did not have the fuel selector set to on which ended up being a good thing since it actually starting would have probably been bad):

1) Two beeps when putting the key onto the DESS Post
2) Pressed start button and heard very faint noise from starter (very, very faint click one time)
3) Rolled my thumb around the start button pressing harder and the ski began to turn over
4) I removed my finger from the button and the ski continued to try and crank
5) I removed the key from the DESS Post and it did not kill the ski
6) I had to remove the negative terminal to kill the ski which took forever since I was not prepared for it which took about 20 seconds hence why I was glad I didn't have fuel selector on

Reading through previous threads on here, it seems that I have two likely problems and my friend agrees. I wanted to verify if there is likely anything else I should check or if anyone else has experienced this outcome?

1) Replace the DESS Post
2) Find where the start button wires go and determine if the wires are frayed or connected properly into the MPEM box

Could there be anything else I should look for? Thank you very much for any input.
 
I have seen where a low or bad battery can cause this and also make the solenoid stick closed and keep cranking. I would load test your battery and be 100% sure it is good.
 
Here are the things I have done so far. I was told by someone else that the aftermarket solenoids are about as good as the aftermarket starters (not good) and to try using an OEM solenoid which I have ordered. I will report back as to whether this worked or not.

Below are things that I have done thus far while I await the OEM solenoid (none worked obviously):

-Bypassed the start button with a Deutsch DT on one end and mechanical start button on the other in case there was chafing in the handle bar column.
-Installed new aftermarket solenoid
-Load tested battery and it is good to go
-Swapped the starter for OEM one (definitely tries to crank better)
-Verified all fuses were correct and good in both MPEM and coil / solenoid box.
-Cleaned all connections and ground points in the starting and charging system
-Unplugged and re-plugged ALL connectors using dielectric grease
-Traced all wires to inspect for damage
-Installed a new DESS post
-Installed a second aftermarket solenoid and verified that wiring is correct as per diagram, internet research and by referencing my other 96 XP
-Lastly, swapped out the MPEM & DESS key from my other, working 96 XP with same result

If there are any other suggestions to try, please let me know. Thanks everyone!
 
I've had an aftermarket solenoid stick straight out of the box the exact same way. Sounds simply like a solenoid to me. Did you check that the 2 plug connector that plugs in to the solenoid gets 12 volts when pressing the start button? Did you jump the solenoid and verify it cranks no problem then?

The mpem won't let you engage the starter if it knows the ski is running so it wouldn't be button related. If the solenoid is still endlessly cranking then I would try unplugging the 2 plug connector from the solenoid while it's cranking by itself and see if it stops. If it doesn't, then that once again tells you it's the solenoid.
 
The OEM solenoid was put in and the ski tried to crank and stop appropriately! Thanks for the info. No more Chinese solenoids for me. I also replaced the start button since the old one was corroded and it worked good too. The ski is not getting fuel to the carbs just like my 95 now though. Surely it can't be two bad fuel senders, but I am not sure how long they typically last.
 
The fuel senders don’t go bad. All it is is a plastic tube running into the fuel. Make sure your hoses are on the correct nipple.
 
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