94 gtx blows 15 amp fuse

[oldwill]

Hi everyone
Do not post much but use this site for so much info. I have 4 jet skis and have maintained them all with help from this site. I finally have run into a problem I can not figure out.

Problem; 94 GTX will blow the 15 amp fuse only after I idle through the no wake zone ( 45 seconds) and then 20 seconds of full throttle. Fuse will then blow, the ski will still run but sluggish and about at half speed.

Set up; After replacing the fuse the ski will start and at idle will draw 13.8 volts. I can rev up to 4000rpm and will stay steady at 13.8 volts. Battery is at 12.6 volts. I can hook the ski to a hose and run for 3 or 4 minutes and everything is fine. I jiggle every wire I can to see if there is a short and no change. I have checked, rechecked every wire in the gray box and all seems good. I have checked all the grounds and all seems to be good. I even moved the battery ground from the motor mount to the starter bolt.

What I have already done; Replaced the stator and nothing changed, will blow fuse under the same conditions. replace the rectifier, will blow the fuse under the same conditions. Replaced the MPEM and will blow the fuse under the same conditions.

If I had hair I would pull it out. Not sure what to look next or what to do. Anybody have any ideas?

Thanks for reading a rather long post
Old will

 

[Mickirig1]

Try unplugging your gauges. Under front hatch. Loose wires may be worn and grounding somewhere. Sure you have wires on stator out of the way? I had one that would ground out because wires hit fly wheel teeth. You have to make sure retainer bracket for wires is in place. Wires need to be pushed into Chanel above fly wheel before they exit the case. Clearances are very tight in there. Key point is it does when running and getting jarring motions. Tells me something is hitting a ground.

 

[oldwill]

Thanks for the reply. When I replaced the stator I was real careful about the wires so I think I am good there. I will unplug all the gauges and give that a try. Not sure if this is an issue, but just curious. If the stator touches or rubs against the flywheel will this caused this problem?

 

[Mickirig1]

Might think about looking at the wires between stator and MPEM. Mine are jammed between gas tank and Styrofoam. Could have insulation rubbed off wires. Maybe unplug temp sensor. It may be dead grounding on jars and bumps.

 

[oldwill]

Thanks again for the info. I will try unplugging the temp sensor and see what happens. I will let you know what happens as I am taking the skis out on Monday for some fun and hopefully no issues.