First Sea Doo

[Golfman]

New here looks like a great resource . Just bought a 1996 xp 800 that looks to be in good shape but has some electrical problems bought it not running .
The starter is spinner but not engaging so that's first , with the battery installed the 15 amp fuse at the solinoid is getting hot and the wires going into the stator cover is getting hot . The stator and trigger coil both check ok. The battery light is also on.
Does anyone have advice? Looking on line the cdi and mpem are very expensive so hoping its something else.
Thanks .
John

 

[GGuillot]

The starter is spinner but not engaging so that's first , with the battery installed the 15 amp fuse at the solinoid is getting hot and the wires going into the stator cover is getting hot . The stator and trigger coil both check ok. The battery light is also on.

If it's an aftermarket starter, I'd seek out an OEM, used or whatever you can find. A rebuilt OEM starter is better than a new aftermarket any day.

You say you checked the stator? If the wires at the stator are getting hot definitely a short somewhere, could have a short at the stator or a shorted rectifier or a weak ground. I'd run down all the ground points on the ski. If you haven't yet, may want to download the service manual to ck the wiring schematics. SeaDoo Manuals - FREE PDF Download!

Check the battery with a multi meter, should see about 12.6+ volts fully charged, the low battery indicator on these skis is usually around 12.4 volts or less.

 

[POPPS]

If it's an aftermarket starter, I'd seek out an OEM, used or whatever you can find. A rebuilt OEM starter is better than a new aftermarket any day.

You say you checked the stator? If the wires at the stator are getting hot definitely a short somewhere, could have a short at the stator or a shorted rectifier or a weak ground. I'd run down all the ground points on the ski. If you haven't yet, may want to download the service manual to ck the wiring schematics. SeaDoo Manuals - FREE PDF Download!

Check the battery with a multi meter, should see about 12.6+ volts fully charged, the low battery indicator on these skis is usually around 12.4 volts or less.

You can buy a new OEM bendix for that starter, ,,,make sure you count the number of teeth, they can vary by 1 tooth,.,,while you are in the starter, get an OEM brush kit and replace the brushes,,,now you will not have to get an after market starter.
Measure the resistance between the 3 yellow wires of the stator,,,should be between .1 and 1.0 ohms,,,and check for grounding between each yellow wire and engine ground,,to confirm that you do not have a short in the stator windings,,,even then,,,I've seen Startors testing perfect,,,but a piece of the starter bendix was broken off and was magnetized to the flywheel and shorting out the stator briefly and consequently blowing a fuse.

 

[Golfman]

Thanks so much guys I've ordered a starter and a rectifier and will fix the ground from the battery to the coil as its very frayed. The rectifier casing was cracked and I don't know how to static test it .
Thanks for the manual link.