I have a 96 XP that I can't get to turnover with the spark plugs installed. Motor runs fine with no spark plugs installed. It does not spew out any water, oil, gas etc from the cylinder so I don't think its hydrolocked. Simply putting fingers over the spark plug holes (which is not a good seal) stresses the motor. After installing the spark plugs the starter turns the engine over anywhere from 0 to about 4 times.
We already replaced the starter solenoid/relay and rebuilt the starter motor with new brushes and cleaned up the commutator. We ground down or wire brushed all electrical connections so they are shinny, including the starter motor case. Motor runs fine outside of the pwc. We took jumper wires directly to the terminals of the starter motor to avoid any internal bad cables, connections, etc. We checked resistance on each motor winding. This is a brand new battery that was charged for about 6 hours. We also tried a lawn & garden battery that was charged overnight. Tomorrow I'll try a full size boat battery that is also charging overnight.
To check engine or jet pump seizures or partial seizures I am turning the PTO flywheel by hand, but its hard to turn. What I want to know is the approximate force that the flywheel should turn with. Its hard to describe, but with the spark plugs installed I need to use both hands very tightly on the PTO and I can barely spin it. Without the spark plugs I can spin it with one hand. I would estimate I use the same amount of force to grab the PTO as I would with picking up a 15 lb weight by the finger tips. Once you apply that much force your fingers can grab onto the PTO tight enough to turn it. Turning it is not the difficult part, its getting the grip on the outside diameter of the disc. If there is an actual spec, I can attempt to measure it properly.
Please attempt to descibe the force you need to turn yours with.
Next thing is to buy a new starter even though we pretty much just re-built this one, however I'm not convinced this is the problem.
Thanks
We already replaced the starter solenoid/relay and rebuilt the starter motor with new brushes and cleaned up the commutator. We ground down or wire brushed all electrical connections so they are shinny, including the starter motor case. Motor runs fine outside of the pwc. We took jumper wires directly to the terminals of the starter motor to avoid any internal bad cables, connections, etc. We checked resistance on each motor winding. This is a brand new battery that was charged for about 6 hours. We also tried a lawn & garden battery that was charged overnight. Tomorrow I'll try a full size boat battery that is also charging overnight.
To check engine or jet pump seizures or partial seizures I am turning the PTO flywheel by hand, but its hard to turn. What I want to know is the approximate force that the flywheel should turn with. Its hard to describe, but with the spark plugs installed I need to use both hands very tightly on the PTO and I can barely spin it. Without the spark plugs I can spin it with one hand. I would estimate I use the same amount of force to grab the PTO as I would with picking up a 15 lb weight by the finger tips. Once you apply that much force your fingers can grab onto the PTO tight enough to turn it. Turning it is not the difficult part, its getting the grip on the outside diameter of the disc. If there is an actual spec, I can attempt to measure it properly.
Please attempt to descibe the force you need to turn yours with.
Next thing is to buy a new starter even though we pretty much just re-built this one, however I'm not convinced this is the problem.
Thanks
