1999 Sea Doo GTX RFI - Battery Not Charging

[LIBoater]

Quick additional question... the oil pump shaft looks especially flimsy... any special techniques for ensuring it aligns on the pump and/or shaft?... assume connect pump end first, but interested to hear if anyone’s had experience?... wouldn’t want to get all this way and screw up the oil delivery system at the final step... thanks

I put a dab of silicone grease on the pump spindle and it seemed to hold the shaft in place pretty well... cover went back on fairly easily I must say!

 

[LIBoater]

New stator fitted... hardest job was disconnecting and reconnecting the plug!... also managed to get a new o-ring, which was also pretty tricky to fit, but I managed to stick it in place with some grease... stator cover plate back on now, but ran out of light this evening... will return tomorrow to make sure all the bolts are tight, reinstall engine mount and water hoses, plug in stator, reconnect grounds and fire her up... fingers crossed this fixes it!... and before anyone comments, I KNOW the cable guard is on upside down in the photo... I fixed that before bolting the plate back on

 

[LIBoater]

So the frustration continues… new stator installed…. but STILL no charge going to the battery… if you look at the old stator it was clearly shot… is it possible that the old stator blew my new rectifier before I realized it was the stator that was the issue?… open to any suggestions as to how to check power output to the rectifier from the stator etc?… HELP! Thanks

 

[clegg]

I just went through a no charge issue on my 1997 GTI. I first tried a rectifier from Prime. The engine would not even respond to the start button so I returned that, put the exisiting rectifier on and the seadoo was starting again. I pulled the 4 pin connector from the stator to harness (to check stator resistance) and found a broken pin on one of the yellow wires. I repaired that and now the battery is charging

Check all grounds and connectors.

 

[LIBoater]

I’m losing the will to live on this one… I replaced the stator with a brand new unit (the old one was DEFINITELY shot, so it was the right thing to do), HOWEVER, still no charge when engine running and increasing revs… I had previously changed the rectifier but is it possible the bad stator fried the brand new rectifier?… i have ordered another rectifier but clutching at straws as to what to try next?

 

[clegg]

Check the output on the stator. If it's an aftermarket one, it could be faulty out of the box. As far as the replacement rectifier, it may not be good either.
It's a good idea to check the stator with a Multimeter to be sure it's producing voltage.
A repair manual will have the procedure for checking.

 

[POPPS]

Great advice guys,,,great job LIB,,,no need to pull the engine,,

 

[clegg]

I just found another no charging scenario on a GTI I just bought a couple of days ago. Of course the PO said everything was "fixed" and ready for the water.

I always check this junk because I know there still will be issues.

So I start this one with my meter connected to the battery cables. What do you know, not charging!
Before I even considered stator or rectifier, I looked in the ignition box in the back and the starter relay (solenoid) was not even screwed down, zero bolts. I also noticed a way too small gauge wire from that sol to the starter, I pulled on it and the wire pulled out of the crimp terminal.

Had a new correct size 6ga wire made up and put all of this back together. The AGM battery looked older so I put another battery in (had it in stock) and now it's charging.

Check everything , ignition box, wiring, connectors, battery etc before just assuming and wasting time and money on parts.

 

[LIBoater]

I just found another no charging scenario on a GTI I just bought a couple of days ago. Of course the PO said everything was "fixed" and ready for the water.

I always check this junk because I know there still will be issues.

So I start this one with my meter connected to the battery cables. What do you know, not charging!
Before I even considered stator or rectifier, I looked in the ignition box in the back and the starter relay (solenoid) was not even screwed down, zero bolts. I also noticed a way too small gauge wire from that sol to the starter, I pulled on it and the pulled out of the crimp terminal.

Had a new correct size 6ga wire made up and put all of this back together. The AGM battery looked older so I put another battery in (had it in stock) and now it's charging.

Check everything , ignition box, wiring, connectors, battery etc before just assuming and wasting time and money on parts.

My starter solenoid has just failed... based on your comment, I wonder if replacing that (arrived from Amazon today) will fix it?... here's hoping... will replace this weekend (headed to the boat soon) and will report back. Thanks all!

 

[SDAVIS478]

Well did you ever find the problem ?

 

[LIBoater]

Well did you ever find the problem ?

That’s a long story… short answer is “not yet”… I’ve had other issues, which include re-powering, so new engine is about to go back in the ski… the “failed” solenoid ended up not being the starter solenoid at all, but a seized jet pump stopping the engine turning over… however, while the new engine is on the bench I am going to triple check the new stator is still good… will also check all the wiring in the hull between stator and rectifier… if the stator and wiring al tests good, I will put the engine back in the ski and see if the battery charges, if not I’m assuming it must still be the rectifier (but I’ve changed that twice)… I remain baffled, but will update once I’ve completed the above - unless anyone has any other ideas I should try?… engine is out so I can easily access everything right now

 

[LIBoater]

Well did you ever find the problem ?

I believe the problem was down to wiring (congrats for the winning answer @clegg)… as part of the rebuild I moved the battery ground from the rear of the engine to the new starter and it’s clearly a much cleaner ground… I think that was the final issue, although I did replace the stator and rectifier as well!

 

[Hanan peters]

Just to be clear you moved the battery ground from the rear of the engine to the starter and it worked? I'm having the same problem on my 99 GTX. Found a 20A blown fuse to voltage rectifier. Replaced fuse and rectifier and still wont start. Put old rectifer on (oem original)...still no go. Now trying to turn over and getting a hi temp. Been hard to start this year when normally running like a dream. Maybe starter solenoid is the culprit?

 

[LIBoater]

Just to be clear you moved the battery ground from the rear of the engine to the starter and it worked? I'm having the same problem on my 99 GTX. Found a 20A blown fuse to voltage rectifier. Replaced fuse and rectifier and still wont start. Put old rectifer on (oem original)...still no go. Now trying to turn over and getting a hi temp. Been hard to start this year when normally running like a dream. Maybe starter solenoid is the culprit?

TBH I did so many things I’m not sure precisely which one worked, but I think having a solid ground definitely helps! Process of elimination: fuses, rectifier, battery health, stator, wiring (in no particular order)… I hope that helps?