2004 XPdi starter issue

[justy_123]

Hey guys.
Have a 2004 XPdi. Brought it about a week ago. It has a starter problem.

If I leave the ski for more than a day, the first time I hit the starter button the starter will not engage the engine. However, if I press the starter switch again the starter engages and the engine starts and will start as many times as needed unless of course I leave the ski for a day.

I'm new to jet skis. Could it be the starter clutch starting to wear? Or could it be something else?

Really appreciate your help. Cheers Justin

 

[justy_123]

I forgot to say that when the starter doesn't engage the engine the stater motor still spins

 

[Dennis]

Starter motor

Sounds like the starter bendix (drive, clutch) is sticking on the first try. It probably has some debris on it. You have to remove the front engine cover and flywheel in order to access it ( it is separate from the starter). I would just keep using it the way it is for awhile and see if it doesn't fix itself. I say this assuming that it is not making a grinding sound when it is not engaging.
DAWG

 

[justy_123]

Cheers mate. Yeh it doesnt grind when it doesnt engage. Ill see how it goes. Hopefully it will free up.

 

[ski-d00]

check your solenoid, I've seen them where sometimes they click and work fine, sometimes they click but don't send voltage to the starter, very hit and miss whether it starts or not. had one where if you pressed it 10 or more times it would finally work and normally worked fine the rest of the day.

 

[Chester]

You should go ahead and replace the reduction gear/bendix. Generally, as things fail, they only get worse and you could get stranded.

Chester

 

[justy_123]

Hasn't fixed itself



Taken the Xp out a few times after first starting this thread and the starter motor is still doing the same thing. Hasn't let me down as yet tho. Even after doing 15 hrs on it in the last couple of months. As long as I don't leave the Jet Ski more than 2 days she will start first press.

Dennis, after listening to the starter motor more closely, I think the starter motor is making a grinding noise when it doesn't turn the engine over.

Any ideas what this could be? Solenoid? Bad connections?

Thanks guys for your help. I really want to get this issue sorted out. But I don't wanna pull the jet ski apart for no reason.

 

[ski-d00]

what exactly do you hear when you press the start button when it doesn't start? a click? nothing? the starter turning but not engaging? grinding?

need more info... but the starting system is very simple.

 

[Dennis]

Noise

It's time to replace starter bendix as suggested by Chester. Your problems could multiply if you don't. You'll have to pull the front engine cover and flywheel in order to replace it. Make sure the teeth on the flywheel are in good condition before you reinstall it.

DAWG

 

[justy_123]

Think ill do the bendix drive

Think it will be best to do the bendix drive. Can't be doing anything good like it is. :agree:

When it doesn't engage the engine it does sound like a grinder. Sounds kinda slow. Not really making a spinning noise. Could be only partially mating with ring gear?

Do I need to pull the starter motor off to get to this bendix drive or does the starter have to come off as well?

Cheers guys :cheers:

 

[Chester]

No need to pull the starter. You have to pull the pipe, the flywheel cover and the flywheel to get at the reduction gear (bendix). Don't separate the pipe, pull it all in one piece.

Chester

 

[justy_123]

Thanks mate. Will have a go at it this week i reckon.

Anyone have any experience with after market bendix drives? Are they any good? There's 951cc bendix drives on Ebay for $42 US. Sounds too cheap!

As for the pipe removal. Where's the easiest place to disconnect the exhaust from the engine? There's 4 bolts holding the exhaust on to the exhaust header but there's one bolt at the bottom that looks real hard to get to.