Need help after top end rebuild, 97 GSX, won't turn over with the spark plugs tight.

[Flatchman]

Need some advise on my 1997 GSX. 2 years ago I did a compression test and found 135 and 45 lbs of pressure. Could not afford to do the top end rebuild last year, so I tackled it this winter. I sent the pistons and plugs to the machinist/mechanic and the report was water ingestion caused the failure. When I started to reassemble the top end I noticed a lot of oil in the crankcase, and I thought of how we cranked and cranked trying to get the ski to start. I tried to get some of the oil out, but decided it would help lubricate the freshened top end. I finished the reassembly and turned the motor over with the plugs out, using the starter and all was good. I put the plugs in and now the motor will not turn over. I read about hydrolocking, so I turned the motor over several times for 30-45 seconds, without the spark plugs, and let the starter cool. I got a little spray from the spark plug holes but not much. I have installed a new battery and checked all connections. I install the spark plugs recharge the battery.

Still when I press the start button I hear the starter engage and turn the motor until it hits compression, and then the starter releases, and tries again and again. I have never lifted off of the start button. I pulled the starter and cleaned the commutator and checked that the brushes are not burnt and are making good contact.

When I press the start button, the starter engages and bumps the motor, releases and bumps again. Over and over until I release the start button.

I don't think I have a hydro-lock problem. How do I test a starter under load? It was working fine until I rebuilt the top end. With a fresh battery and the spark plugs very loose, I can turn the motor over and tighten the plugs by hand, and the starter will continue to turn the motor over. Any suggestions? Thanks

PS. Your forum is great, and I have been reading and learning for years. Thanks for the great data source.

 

[Coastiejoe]

Most common issue with a not turning over situation is, bad battery, bad or poor connection wires, or bad starter.

It does sound like a starter issue based on your comments. But,,, it could easily be the battery or wires as it will act exactly the same. What is the voltage of the battery while trying to crank the engine. This will help isolate which direction to head.

I am after loaded volts. Get a meter on the terminals and let us know the volts while cranking.


Repairing and selling iPads, iPhones and Mini iPads.

 

[Minnetonka4me]

Joes info is spot on....

 

[Flatchman]

Thanks for the response. I charged the battery and got 13.1 VDC. I tried to measure the voltage while turning the engine over, but it would not, and only bumped and bumped against the compression point. This caused the voltmeter to bounce all over and I could not get a reading. I loosened the spark plugs, and the starter turned the engine over, and I measured 10.1 VDC as it turned over.

If the starter is bad, should I replace or rebuild? Thanks for your advise.

 

[Minnetonka4me]

If you have an extra ground wire to temporally hook up just to make sure your old ground wire isn't rotten on the inside... It would be a good quick test before you pull the starter. Also open the rear ebox and make sure the isn't any corrosion in there.

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[manolocross]

It sounds like a new battery might be the fix... How old is the battery your using and what brand and type. Have the battery load tested. When you did the top end did you have the rave valves machined down???


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[CReynoldsMIZ]

Either battery or starter. If you cleaned up the starter, and the brushes and connectors looked good. It sounds like the battery...

 

[Flatchman]

The battery is brand new, and I had the Raves machined

 

[Flatchman]

I have two GXS's, one working and one that I am fixing now. I can pull a known good wire from the other ski and test using a known good wire. The rear ebox looks like new.

 

[CReynoldsMIZ]

Here is basically all you need. A multi meter.

First, connect it to the battery. If when you hit the start button, the battery jumps down to like 10 or below, then you have a bad battery.

Then do the same, but put the tester on the positive lead of the starter. If it reads 12 volts, or full power from the battery, then you have a starter problem.

If you have full 12 volts or higher when testing at the battery, but get less than that at the starter post, then you probably have a wire connection problem.