97 XP Starting Issue

[thomas0202]

Just finished swapping a new motor into my 97 XP. I've had it running in the ski a few times just to test before aligning and putting the pump back in. Got it all back together and go to start it and the starter bendix clutch strips out. Ski did not come with an OEM unit and I could not find one online so I ended up with a cheap eBay starter. I know not the best idea but its what I could get my hands on. Install it and the ski cranked over great. Turn the fuel on and bam she wont turn over. Just clunks and the engine just jolts back and forth. Thought the battery might be weak so I charged it and then it spun it over and fired up. Ran it for 30 seconds or so and then shut it off. Go later on to start it back up and its back to clunking. Tried my lawn mower battery which is almost brand new. Same thing. Reached down and rotated the crank to where it was on compression and the ski will start everytime. Which is great, but absolutely impractical for riding on water.

What would be the best place to start looking? It stumps me with the fact that I can rotate the motor by hand a little and have it crank over no problem. Both positive and negative cables check out on resistance. Haven't done a voltage drop test yet but plan to tomorrow. Was wondering if there was anything else I should check out. Thanks for the help!

 

[mikidymac]

The beauty of aftermarket starters and bendixes....... You can search ebay for oem ones or try places like Westside Powersports for tested used OEM ones. And yes, only OEm.

 

[IDoSeaDoo]

Rebuilding an OEM is much muuuuuuuch better than buying a junk chinese starter. I have a box of old OE starter parts jut for that purpose. But don't overlook the cables. The cable ends get frayed if they haven't been zip-tied properly. I've had those ends completely come off before, necessitating some clever tricks to get back home

 

[thomas0202]

Hate to admit this, but my family has an old 95 XP that has been in pieces for years. Took its starter off and cleaned it up the other day. It is clocked differently than the 787 starter, but I mounted it up and the ski spins over almost every time. I've got a brush kit on the way so hopefully it'll be good to go after that. For the times it won't fire over immediately it'll do the same spin 1/4 turn and stop. Sometimes it'll overcome the compression and spin and other I do have to help it over. I guess now I look more into the cables/battery or do I get the new brushes in and see then?

 

[mikidymac]

It’s the brushes if it gets stuck in spots.