96 XP blowing 5 amp fuse ONLY when i hit the start button

[tonydynomite]

Hi all & thanks for the help in advance.

I recently purchased a 96 Sea doo XP. The boat needed a new battery and when Installed I noticed that the MPEM was bad. ( kept Blowing the 5amp fuse right away ) I purchased a new MPEM, installed it & now whenever I try to start the ski it blows the 5amp fuse. If I replace the fuse and dont hit the start button, I get my gages lit up and VTS will go up and down. As soon as I hit the start button I get a very quick Flash from the battery Light then Pop... Does anybody have any ideas? I have read so many threads on bad MPEMs but nothing that fits this particular issue.

Thanks!
Tony

 

[Matt Braley]

Sounds like one of the gauges could have a short in it. have you tried unplugging them? You can unplug the 4-pin connector coming out of the grey box(just make sure it's not the 4 wire plug from the rear E-box).

 

[mwat65]

Metal particles from your starter can bridge your stator contacts causing this to happen, but first try unplugging your vts and see if it still blows. Hopefully you have a short . Are you sure the mpem you bought is good ? Check and clean your stator plug.

 

[tonydynomite]

Metal particles from your starter can bridge your stator contacts causing this to happen, but first try unplugging your vts and see if it still blows. Hopefully you have a short . Are you sure the mpem you bought is good ? Check and clean your stator plug.

Hey MWAT65, I tried unplugging the VTS, still blows when I try to start. I'll have to check the starter. My Old MPEG was blowing the 5amp fuse as soon as it would plug in. So im not 100% sure that this one is good, I just know the diode is not smoked like the old one.

 

[tonydynomite]

Sounds like one of the gauges could have a short in it. have you tried unplugging them? You can unplug the 4-pin connector coming out of the grey box(just make sure it's not the 4 wire plug from the rear E-box).

Hey Matt, Thanks for chiming in. I just tried that, still blowing the fuse. One thing I forgot to mention is that there is no beeps coming from the Ski. Not sure if that has anything to do with it but just thought I should throw that Info out there

 

[mwat65]

The 720s are bad for metal particles on the stator. I’ve only seen it a couple times on a 800 but it does happen.

 

[Digdog]

Try unplugging the wires to your solenoid (not the main positive wires) and see if it does it then

 

[tonydynomite]

Try unplugging the wires to your solenoid (not the main positive wires) and see if it does it then

Thanks DigDog,

When I did that, the fuse did not blow. I took off the plug on the bottom of the solenoid with the yellow and black wire.

 

[Digdog]

Thanks DigDog,

When I did that, the fuse did not blow. I took off the plug on the bottom of the solenoid with the yellow and black wire.

I would change your solenoid, sounds like it came apart inside. While it's out test the starter by jumping the two large positive leads, the solenoid could have failed because the amperage load was to big because of a failing starter, bad battery or something like that, solenoids seem to be a problem on doos. If you can load test the battery, check it for water level. Check all of the ground connections also.

 

[tonydynomite]

I would change your solenoid, sounds like it came apart inside. While it's out test the starter by jumping the two large positive leads, the solenoid could have failed because the amperage load was to big because of a failing starter, bad battery or something like that, solenoids seem to be a problem on doos. If you can load test the battery, check it for water level. Check all of the ground connections also.

Sounds good!
I just ordered a new one, should be here by Tuesday. When I first got the ski it had a bad battery in it. I put a jumper box on it to try and start, thats what caused my first MPEM to blow. Perhaps I blew the solenoid too. Battery is brand new, and I just doubled checked all my grounds, they all seem good. Im going to pull it out now and test the starter.

Thanks for the help! I'll let you know if I get it up and running with the new solenoid

 

[Matt Braley]

Good call on the fried solenoid

 

[tonydynomite]

I would change your solenoid, sounds like it came apart inside. While it's out test the starter by jumping the two large positive leads, the solenoid could have failed because the amperage load was to big because of a failing starter, bad battery or something like that, solenoids seem to be a problem on doos. If you can load test the battery, check it for water level. Check all of the ground connections also.

It was indeed the solenoid! I cant thank you enough. I was going crazy with the electrical on this ski!

It finally turns over now. Still wont start, pretty sure the carbs needs to be cleaned as it has been sitting for over a year. But carbs are much easier to deal with than electrical.

Thanks again all for the help!

 

[Mekanix]

That's one for the memory bank