93 SPX with starter issues (I think)

[kmack]

Here is the scenario:
1-1/2 weeks ago we had both of our Seadoo's on the water and they were running fine. Ran the SPX for about 2 hours without any problems. Shut it down and let stay tied up to our pontoon while we relaxed and used the GSX to pull the kids on a tube.

About an hour later I went to start the SPX. It cranked fine but the engine was cold. I choked it and it continued to turn over. After about 3 tries on the starter, the battery started to sound weak, then it quit turning over completely. The only thing you could hear was a clicking sound (like a relay) coming from the grey box.

We parked it (thinking dead battery).

We we got home, I tried it again after sitting on the charger for an hour. Nothing but a click. I took the plugs out to release the compression and it would turn over, but slowly.

Looked at the battery again and it was low on water. Filled it back up and put it on the charger. It was holding a charge after a day so I put it back in the SPX. Nothing but a click again.

So.....thinking I can't slavage the battery now, I pulled the good battery from the GSX, which I know starts, and put it in the SPX (same model battery). Only got the click. Pulled the plugs. Only got the click. Doesn't do anything. I can turn the drive shaft by hand so I know it's not locked up.

Now I'm thinking starter. But the starter is under the exhaust (PITA!!). Question is, how do I get it out, how do I test it, and does anybody have any other suggestions? I'm trying to get it fixed before the weekend as the weather on Sunday is going to be great.

(I guess this is what I get for teasing you Northern guys about the warm weather down here in Texas)

 

[Bills86e]

A good light & mirror, a ratchet set with long extensions & swivel. two bolts on nose
and one near rear. Get them out and rotate alittle to get cable nut off. Bill

Wecome to the world of wrenching. Once out examine it & load test it. It may need cleaning & brushes, or replaced.

 

[Dr Honda]

:agree:


Clean it, and put in new brushes, and it will probably be fine.

 

[kmack]

Would it be easier to pull the exhaust out first? It looks like it would, but I'm not completely sure.

Is the starter easy to rebuild? I've never rebuilt one before. Sounds easy and I can pretty much figure anything out. Just sometimes I figure it out after I broke something....

 

[Bills86e]

You just need plenty of light, a mirror, Its done all the time with patience.

 

[kmack]

Ok, so now that I have the starter out, how does it come apart? The only bolts I can see are the two on the back that hold the rear mounting plate on. I took the nuts off of those to get the plate off, but I can't see how everything comes apart further.

What next?

 

[kmack]

I think I figured it out....at least it would seem that way since the starter is on my work bench in pieces!

It looks like the brushes are shot. Where can I get some new ones? It also looks like the inside of the starter needs to be cleaned really bad. Any suggestions as to what I should use?

 

[Dr Honda]

To clean it... just use some soap and water. Any cleaning solvents will dissolve the coating on the wires.

You can buy brushes at your local dealer.

 

[kmack]

Final version...

Ok, so I got a new set of brushes for the starter. Cleaned up the internals of the starter. I just used a clean rag and some shop air to get all the black dust out. Put it together last night after I painted the starter housing. The old paint was pretty ugly.

So I hooked some wires to it before I put it in to make sure everything went back together correctly and it darn near jumped out of my hand! (I guess it works!)

I finally got it back into the ski and it cranks SO much better!!!:hurray: Actually seems to turn over a lot faster than it did before.

A bit of advise for those looking to try this. A little vaseline on the back side of the gasket will help save you from losing it under the engine. Not fun to try and get back.
Also, put the bottom bolt place before you slide the starter into place (use a long extension to hold it there while you move it into position). I tried the top bolt first and then the bottom one, but with an extension in the way of my mirror, I couldn't see the hole for the bolt. Plus I dropped it 3 times and it wasn't fun trying to get back. Once, I had to use a big magnet under the hull to slide it to a place I could grab it. Then I took the starter back out, put the bottom bolt in, held onto the extension with the starter as I slid it into place and it worked first time.

Anyway, the starter is back in, and it cranks over great. I didn't start it last night because it was after 10pm when I finished (and the neighbors would have been pissed). I'll start it this afternoon to make sure everything is good.

Also, during the course of all this, I somehow managed to salvage the old battery! It's been holding a great charge throughout this entire ordeal. That saved me about $50!!!:hurray::hurray:

 

[Bills86e]

Good Wrenching. Well done! Good Luck, Party ON!