The Mystery of the 1996 Sea Doo GSX Starting....

[ravens9273]

I have a 1996 Sea Doo GSX with the 787 engine.
This jet ski will not start. It is as if trying to start a ski with a low battery.

The engine in the Ski is new and has yet to be on the water.
The rectifier has been replaced
The electrical box has been replaced.
Starter has been replaced with an OEM starter
Stator has been replaced with OEM stator.
Today I also put in a new battery.

I have done all these things in steps hoping the next would correct the problem and still seems to not have enough juice to start.

When I first attach Dess key I get two beeps. The first try to crank seems for a few seconds like it may work then it does not. After that I only get clicking. If I unplug Dess key for several minutes the process repeats.
If I unplug Dess key for a few seconds etc.. It will only click.
I have no idea what is going on with this ski.

 

[glsmohio]

I had a problem like this but my ski didnt have dess. It ended up being the starter solenoid. Have you changed that?

 

[ravens9273]

yes the solenoid was changed with electrical box

 

[Coastiejoe]

Put a meter on the battery terminals, crank the ski. What is the voltage after it cranks for about 4 seconds.

 

[CReynoldsMIZ]

sounds like you might have a bad connection or bad positive or ground wires. lots of possibilities

 

[ravens9273]

What should I connect the negative ground wire directly to? Maybe this will help

 

[CReynoldsMIZ]

there should be a tab on the starter to connect the ground wire to

 

[racerxxx]

What should I connect the negative ground wire directly to? Maybe this will help

there should be a tab on the starter to connect the ground wire to

Correct, I like to take a flat file and clean the ear on the starter and then use the star washer to dig into the aluminum as the factory did.

 

[ravens9273]

when ground was connected to the tab on the starter it was sparking and smoking

 

[Sportster-2001-951C-Stock]

I use q-tips to clean my ears. Yep, fresh paint on a spot-face must be removed.

 

[Coastiejoe]

when ground was connected to the tab on the starter it was sparking and smoking

Are you sure you are not putting it onto the Hot/Positive terminal? That would explain the sparks...

 

[racerxxx]

That's your problem right there, if be willing to bet. Probably not totally tight.

Sent from my SGH-T889 using Tapatalk

 

[braindead89]

you say this is a rebuilt motor? I know my thoughts may be off from everyone elses but have you pulled the plugs and tried to turn it over with the starter?

 

[ravens9273]

OK... Have been working on this all day today.
Have tried 3 starters to date
tried 3 electrical boxes
New Battery
New Stator
Changed MPEM
Changed DESS Post
Changed wires
Fixed ground wire

Still the same.
I am not an expert with the electrical issues. I have changed everything possible around the electronics of this jet ski. I had a donor ski that had no issues with electronics.
I am home now and after looking things up I believe the two red wires (one going to battery and other to starter) were reversed from the electrical box. This is how it was when I got it and I just kept following the pattern.
Could that create such problems? Also would this also fry any other parts?
I will try reversing them tomorrow. Some how I am still not confident this will solve the problem and I hope I have not destroyed the list of parts above.

 

[soccerdad]

If you pull the plugs, can you turn it over with your hand? I am thinking it may be a locked up pump.

 

[ravens9273]

Engine turns without spark plugs. This also had the conversion done so no oil pump.

 

[Coastiejoe]

Ok,,, if any of this is wrong, please correct it... And provide the results.

1). If you jump the solenoid it cranks as it should. Consistently and continuously? Yes
2). With the lanyard on, it cranks ok for a moment, then stops, then only clicks? Yes
3). After #2 happens, what happens if you IMMEDIATELY jump the solenoid?

 

[ravens9273]

Links to videos of trying to start it today

https://youtu.be/Yhkjg8FLYDc
http://youtu.be/ey_ouz6DZnA

 

[ravens9273]

How to jump the solenoid? Have not done this yet

 

[Coastiejoe]

How to jump the solenoid? Have not done this yet

There are two larger terminals on the Solenoid. Jump across the terminal with a larger screwdriver or pliers.. It will likely spark a little, but the engine should crank.

Humor me,,, post a picture of the solenoid, I would like to see something...

 

[ravens9273]

Today has gone from bad to worse. Zero power now. No beeps and no trying to turn over. I cannot test anything. Fresh recharged batteries. Changed electrical boxes again and even mpem and it is dead

 

[soccerdad]

Is that small ground wire on the battery hooked up? They break off easily or are easy to forget. Try jumping across the two top posts on the solenoid. The two big ones seen here. Use a screwdriver or big wrench as costie says above.

 

[ravens9273]

I tried jumping solenoid and nothing. The ground wire is attached as well

 

[ravens9273]

Ok i jumped solenoid again and it tried to crank. I changed solenoid with a good one and still dead

 

[soccerdad]

Well that is sort of progress! At least it does something and it cranks! This has got to be something basic. you have changed so much I think something must have been left disconnected or loose. Start at the DESS post, then work your way though every connection to make sure they are correct. For it to run, you only need the harness to the rear electrical box, the harness to the motor, the dess post, the beeper and the start button. So really check those. And also all the little grounds in the front box if you actually disconnected the MPEM. And look at all the pins on the connector going into the rear electrical box.