99 GSX Limited starter problem

[Jay146992]

I am really starting to hate my jet ski 1999 GSX limited with 80 hours. First the oil tank starts leaking and wasted about $50 worth of oil, then it would stall whenever I give it gas, then the wear ring came out while running and ruined the impeller and now something is wrong with the starter. I have had to replaced the oil tank, have both carbs rebuilt & pump, have a new wear ring and impeller put in. Also had to get a new battery. I had to do all of this stuff within a month of buying it.

Now when I hit the start button I can hear the starter motor running but it's not turning the flywheel. I'm thinking the gear broke? Any suggestions? Is it an easy fix?

 

[Dr Honda]

All I can say is to remove the starter, and see what's wrong. It could be a simple stuck gear. BUT... with all the other issues... I'm going to say it's something to do with the last owner neglecting the ski.

I know it sux... but you can't get mad at a 13 year old ski needing stuff.

 

[Jay146992]

So I removed the starter and tested it. It works fine. I stuck my finger in the hole where the starter gear goes into the engine and I felt a gear and it spins freely? not sure if it's suppose to but I also noticed the gear I was feeling was missing a few teeth and there are metal shavings in the hole. So what do I need to do to fix this? I already have the exhaust and carbs off.

 

[Kuzma823]

Sounds like your bendix gear is gone. The starter on the 947 engines goes into a bendix gear inside the front of the engine, when the starter engages it spins the a gear on the unit which pushes a smaller gear on the unit forward to engage the fly wheel and start the motor. The gears will spin freely with out the starter installed because there is nothing holding it back. The gears and throwout assembly sit on a shaft and normally only stay in contact with the splines of the starter. The other gear is only in contact with the flywheel when the starter is engaged and the throwout bearing pushes the gear out, when the starter is no longer under power the gear retracts in and away from the flywheel.. I know this because I have a 1998 GSXL that seems to have been abused by a previous owner too :rant: and had to replace mine last year. I believe you can replace the gear by going through the MAG cover on the front of the engine and it is held in place by a plate and two bolts (might be best to remove the starter first as well).

FYI, mine went bad because the gear rusted and would no longer move freely to engage and disengage the flywheel. If you find you have rust as well, verify all your seals are in good condition and that your starter is correctly secured as well.

 

[Jay146992]

Thanks for the info! Where is the mag cover at? I looked at the engine and it looks like the only way in is to remove the big cover. I can't see anything that comes off with two bolts.

 

[Kuzma823]

Unfortunately that big cover is the mag cover (short for magneto cover), if you remove that cover you should have access to the flywheel, magneto, bendix gear, etc. If I remember correctly there should be 10-13 small bolts around the perimeter of the cover, along with a wiring plug, oil lines, and one more large bolt that connects the engine to a front support bracket. I dont recall if the wiring has to be disconnected but that should be easy either way. Hopefully there is enough slack in the oil lines that you can move the cover without disconnecting the lines, the other option would be to remove the two small bolts holding the oil pump on to the cover. Removing the pump isnt ideal but I would do that before disconnecting the oil lines and having to purge them later.

Next, I would remove the large engine support bolt, lift up the front of the engine slightly and wedge something under the engine big enough to take the load off of the Mag-cover support, I used a spare piece of wood that I cut to the correct size. Make sure whatever you use is completely under the engine block and not putting any pressure on the mag cover. Then simply remove the 10-13 bolts holding the cover to the engine. You should now have access to the bracket and two bolts that hold in the bendix gear. You may need to remove the flywheel too but I dont think its necessary on this engine. Just put back together by reversing the directions above and dont forget to check all the o-rings for wear, replacing as needed.

I hope this helps and good luck. Btw, I am doing this all by memory so if your setup isnt exactly as I describe dont worry, my directions are probably slighlty off.

 

[SabrToothSqrl]

if it's in good shape and the red/black GSX, let me know if/when it's for sale... that's a fun ski I wouldn't mind having for a few seasons.

what Kuzma823 is describing is accurate, however on the 951 GSX you will have to remove the pipe to do that... on the 98-02 XP you do not have to... (although when pulling a flywheel, it might just be easier)

You might just want to pull the whole engine out with a GSX, that 951 is packed TIGHT in there... and to replace the bendix you will have to remove the flywheel as well... sorry for the bad news... but yea, it is 13 years old. If you are pulling the engine, you could always send it out for a fresh one... $1k - 1500 later, but it would be essentially a brand new motor.

 

[Jay146992]

Well, I took half of it apart and just said screw it and took it to the dealer. I'm not going to try and fix it then mess something up and make things worse. And I've never worked on a jet ski before so I really have no clue what I'm doing.