96 XP No Power

[Austrian Rotax]

Hi everyone, my 96 xp has been giving me nothing but trouble lately (this is one of many other issues ive had to repair on it) the machine started not revving to full rpm and pulsing on the throttle, disconnected red wire on rectifier and it ran perfect again so I bought an aftermarket rectifier and installed it and now after the installation the mpem was giving me the normal 2 beeps but a few seconds later it gave me 4 beeps and wont start, the machine was parked in good running condition it sat for two weeks in my garage mind you I never tested it immediately before I installed the new rectifier. I played with the start button, pressed it five times to give me the 4 beep code. I disconnected and reconnected the battery twice and now the machine has absoletely NO POWER.Now when I press the start button the mpem won't wake up just a few mins prior it would wake up when pressing start button twice. I checked all the fuses in the front box and they all tested good by multimetre, (two 5A and one 15A). I checked all the grounds and they are all tight, battery is sitting at 12.6V. My hands did disturb a lot of the wiring in the box but I couldn't find any bad connections. Thanks any help appreciated

 

[Coastiejoe]

If you did NOTHING but install an aftermarket rectifier, then disconnect it and see if the issue goes away.


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[Coastiejoe]

Also, check all the fuses as you or a bad (new can still be bad) rectifier may have popped one or more.


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[Austrian Rotax]

I tested all the fuses after the machine wouldn't power up anything at all, they all have continuity, I did this with the new rectifier installed. I even took a test light and probed the sockets the fuses go into and the test light showed power at the pins so fuses are getting power it appears.

 

[Austrian Rotax]

I am embarrassed to mention though that I did a pipe repair with jb weld earlier this season it has held up well but a few drops of jb weld dripped onto the deutsch stator connector and now I also did an awesome job welding the connectors together LOL but the machine has run a few times after this incident. And, I disconnected the battery while installing new rectifier. Its just I can't imagine a rectifier causing an issue like this, I know they are low quality but these junk rectifiers usually fail in other ways, but I will install the OEM one back in and see what happens. Thanks

 

[Austrian Rotax]

One more question I was probing around with my test light and on my 95 xp the spark plug grounding posts show ground but on my 96 xp I get no ground on the grounding posts any indication there?

 

[crundell73]

Are you blowing your mpem's or the 5amp fuse cause I just had that and had metal shavings in my fly wheel and it was shorting out my mpem's , I 'am still having other problems to get it out on the water but maybe look into that . I have a 97 787 motor .

 

[Austrian Rotax]

I am not blowing any fuses with the new rectifier connected all fuses good, I have tested the 5amp, 15 amp and 7.5 amp fuse in the front box they are all good. Also I have another question I probed all the wiring and the purple wire going into the mpem is supposed to be power if I remember correct and it has no power going to it also I opened up rear electrical box and tested the 25A and 7.5A fuses they tested good but the fuse holder for the 25A fuse didn't have power on either prong where as all the other fuse holders have power on at least one prong. Any ideas? Thanks

 

[Austrian Rotax]

Ive done some testing through service manuel procedures and here's the result as mentioned above already no power to purple wire which where there is supposed to be power. Also no power from the CDI power source from MPEM through holder relay. But there is power to the holder relay from the RE/BL wire. Also I reinstalled the OEM rectifier and no luck, doesn't make any sence to me I was careful installing the new one I had battery disconnected while installing the new rectifier. I realize my symptoms point to a fuse but no fuses are blown ive checked and rechecked all the fuses as stated above only dilemma I have is why my 25A fuse has no power even going to it.

 

[Austrian Rotax]

Ok guys heres a new one for the definition of four beeps after lanyard in, I fixed the issue of no power, bad ground in stator deutch connector, some hack backyard mechanic used a weather pack female pin instead of deutsch female pin very loose connection and the pin pulled loose after just a little tension on the stator wires, the pin wasn't even locked into place in the connector well at all. Its amazing this machine ran with such a loose and clumsy ground it has ALOT of play on the male pin coming out of stator. Just me working on the electrical box disturbed the stator connector enough to cause that ground to fail. I put the aftermarket rectifier back in and until I can get a new deutsch connector and pins I just held the ground wire to the male pin and the machine gave me two beeps and no more four beeps afterwards so It appears four beeps can also indicate bad ground for mpem. I should have tested the ground circuit but all the wiring in the ski looked great and all grounds were tight so I made an assumption, problems like these are why I hate used machines sometimes, never know what asshat worked on it before you and what they did.

 

[crundell73]

that is hard to find good job !