2002 Seadoo GTX DI Won't Start

[DoAnything!]

• Good Afternoon, Let me start by saying that I am self taught at working on this ski with all of your guy's help over the last year and of course with youtube videos .
  I bought a 2002 seadoo gtx DI after owning several 1997 seadoo gtx's. I rebuilt the top end (1 over, values shave down to the right size at the machine shop). It fired up on the hose, and alarm went off after several minutes then went away. I dropped it in the water and she ran great for 10 minutes then died and would not start back up. towed back in. Took her home, tested the rectifier and it was skyrocketing to 18 to 20 volts on idle. Changed the rectifier and ran it on the hose. 14.50 on idle 14.48 at 3000 rpm... Into the water she went.. ran for 10 minutes and she died. Towed back in. took her back home and tested the battery. Bad cell. Bought a new battery and tested it on the hose. 14.48 at idle, 14. 39 at 3000 rpm... back to the water. Ran it for 15 minutes just off the doc with wire clips to the battery and clipped to a volt meter.. put it in neutral and held it at 3500 rpm 14.39 at 3500 rpm 14.55 at idle... after 15 minutes, meter off and off I went. road for 10 minutes at 3500 to 5700 between here and there and then she shut down, though this time it was not an instant shut down like the first two time. It was as if she was running out of fuel. when I tried to restart it acted as if it had a weak battery and would not start. Towed in. When I got home the battery was at 12.55. I charge the battery and unlike before, now it will not start. It turns over and acts as if its not getting fuel or spark. One last note... each of the other time it stopped running, as soon as I got home and charged the battery she would start and run on the hose. This time she does not start. Just acts like she wants to but does not have fuel reaching her or no spark. I don't know what to test first in a logical order and I don't want to start taking parts off my other 2002 gtx di for testing at random. And each time I put the key in two beeps ..all good..Would greatly appreciate some help.

 

[mikidymac]

Check compression. You might have an engine seizing.

 

[DoAnything!]

Check compression. You might have an engine seizing.

Thank you for the reply... engine was just rebuilt and oil pump was primed and I checked for right amount of oil ratio but you are right anything is possible.. I'll check that a bit after 1pm today and post results..

 

[DoAnything!]

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  DoAnything!
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  Junior MemberJoin: 1 day agoPosts: 4
  about 23 hours ago · #1
  
  2002 Seadoo GTX Di Wont Start
  
  Good Afternoon, Let me start by saying that I am self taught at working on this ski with all of your guy's help over the last year and of course with youtube videos .
  I bought a 2002 seadoo gtx DI after owning several 1997 seadoo gtx's. I rebuilt the top end (1 over, values shave down to the right size at the machine shop). It fired up on the hose, and alarm went off after several minutes then went away. I dropped it in the water and she ran great for 10 minutes then died and would not start back up. towed back in. Took her home, tested the rectifier and it was skyrocketing to 18 to 20 volts on idle. Changed the rectifier and ran it on the hose. 14.50 on idle 14.48 at 3000 rpm... Into the water she went.. ran for 10 minutes and she died. Towed back in. took her back home and tested the battery. Bad cell. Bought a new battery and tested it on the hose. 14.48 at idle, 14. 39 at 3000 rpm... back to the water. Ran it for 15 minutes just off the doc with wire clips to the battery and clipped to a volt meter.. put it in neutral and held it at 3500 rpm 14.39 at 3500 rpm 14.55 at idle... after 15 minutes, meter off and off I went. road for 10 minutes at 3500 to 5700 between here and there and then she shut down, those this time it was not an instant shut down like the first two time. It was as if she was running out of fuel. when I tried to restart it acted as if it had a weak battery and would not start. Towed in. When I got home the battery was at 12.55. I charge the battery and unlike before, not it will not start. It turns over and acts as if its not getting fuel or spark. One last note... each of the other time it stopped running, as soon as I got home and charged the battery she would start and run on the hose. This time she does not start. Just acts like she wants to but does not have fuel reaching her or no spark. I don't know what to test first in a logical order and I don't want to start taking parts off my other 2002 gtx di for testing at random. Would greatly appreciate some help.
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  rodsatheart
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  Super ModeratorJoin: Oct 2014Mentions: 1Posts: 4843Mena, Ar.
  
  
  
  about 14 hours ago · #2
  
  
  Pull a plug and check for spark. If spark, pull the flame arrestor and put some premix down the throttle body and see if it fires. If it does, then you have a fuel issue.
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  DoAnything!
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  Junior MemberJoin: 1 day agoPosts: 4
  about 9 hours ago · #3
  
  
  Thank you Rodsatheart.. That's a great start. I'll do today... little after 1pm and I'll post result..
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  DoAnything!
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  Junior MemberJoin: 1 day agoPosts: 4
  8 minutes ago · #4
  
  
  Okay so I did compression test.. 150 on both sides...I replace the spark plugs for some new ones gapped correctly tested for spark and there was Spark. Drop some premix into the arrestor put the spark plug back in hit the button and though the battery seemed weak it fired up and stayed running. I shut her down and when I went to starter again she had a weak battery and would not start. I repeated the step putting a little fuel inside the arrestor started her up and even with the weak battery she started and continue to run . I turned her off and try to starter and again she's got too much of a weak battery I'm guessing to push fuel to get her started so I have my battery charger on the battery. so I won't be sure until the batteries fully ( put a voltmeter on the battery and it was at 12.45) if this again was a case of the jet ski running on battery power until it died. If so I'm back to square one which is I've changed the rectifier and this is a new battery that I purchased it's brand new never used and when I'm idling at 3500 RPM with a voltmeter on it it showing within the limits at 14.48 to 14.5 1... I have not kept the voltmeter on the battery when running the jet ski at 5000 RPMs or higher and I'm wondering if at that point the rectifier though new isn't working properly or could this be a bad stator just throwing ideas out there don't know

 

[jhjesse]

Check the fuel pressure. Should be a combined 107psi.
Check air compressor pressure. Should be 27psi
Pull the fuel pump and change the internal fuel filters on the pump.
Change the external fuel filter canister.
Recheck fuel pressure.
Have the injectors cleaned.

 

[DoAnything!]

Great I'll do that in that order tomorrow am... thank you... do you think that fuel pressure can also cause the ski to act like a weak battery when I try to start her even though the battery is fully charged? Because that is throwing me off...

 

[DoAnything!]

Please tell me what this means! Ok bought another new battery, cleaned injectors and started ski.. it fired right up.. put the hose on her, and she ran at 5000 rpms on and off for 10 minutes and she turned off.. in an attempt to check if I had lost spark I took off the mag side spark plug to check for spark.. when I hit the start switch she fired right up with no problems. I was shocked.. powered it off...hit the start button again without the mag side spark plug and again she fired right up..what is this? Please don't tell me that the Mac side piston is seizing after it gets hot?

 

[jhjesse]

Running it on the hose for 10 minutes at 5000rpms is probably not a good idea.
Water runs backwards from the usual in the water flow.
Your carbon seal is probably toast by now.

 

[mikidymac]

Not only bad for it but running on the hose tells you nothing other than it runs as there is no load on the engine.

In my opinion there is absolutely no reason to run on the hose unless you are flushing salt water or debris out of the cooling system. Even then it only needs to be for about a minute.

 

[DoAnything!]

Thank for the good advice.. I miss spoke.. I was revving it up to 5000 .. never the less, I did a compression test this morning cold.. and 120 on the pto side and 58 on the mag side. Dont know how or what I did to ruin a new top end.. everything new.. right bore.. values shaved to right size to insure clearance for the bigger pistons... primed the oil jump with a drill, checked oil flow to the inlets.. I'm at a loss..

 

[DoAnything!]

so I'm wondering what my next step is take the heads off pull the cylinder jugs and then what? In other words I don't know what caused the problem to begin with... replacing Rings or piston or getting the cylinder head redone or honed it's not an issue but I'll be back at square one not knowing what caused this problem to begin with

 

[mikidymac]

Did you have the injectors serviced and checked?
Did you check fuel pressure.

Running lean with not enough fuel is just as bad as not enough oil in a 2-stroke.

 

[DoAnything!]

the injectors were cleaned but fuel pressure was not checked nor did I check the air pressure from the compressor because both seem to be in working order. So what's my next step? do I have to pull off the head and Jug and start over on the top top-end or is making sure that it's getting proper fuel and oil mixture the way to go to try to save it

 

[mikidymac]

At 120 and 58 psi compression your engine is toast. The big issue is what is causing it.

 

[DoAnything!]

Tearing my engine down now I'll send some pics

 

[Barrys1976]

any updates?

 

[DoAnything!]

I destroyed a brand new top end rebuild ... that's the update..rings melted on the mag side.. pto side has the beginning of scourging...

 

[DoAnything!]

the thing that sucks is I don't know what caused this. I prime my oil pump with a drill make sure none of the oil lights were plugged. I guess the fuel pressure could have been under a hundred and seven cuz I never check that and I didn't check to see if 27 lb of pressure from the air compressor. I got the jugs back at the Machine Shop to get a board bought another top end kit I'll put it back together and figure it out before I EverStart her up. I guess not sure where to start if anyone has some suggestions that would be great.

 

[mikidymac]

That cylinder head looks like a corroded mess. Did you clean it and install a new gasket before you put it back together? If it was leaking water then you washed all the oil film off and that toasted that piston. The piston dome looks dry and clean so it was either washed off with steam or no fuel.

That cylinder had either a lack of fuel or oil. My guess is fuel since you checked the oil system.

 

[jhjesse]

Looks to me like that cylinder wasn’t bored with the proper clearance. Did you measure the cylinders before you assembled the top end?
Cylinder head as Mikey said looks like water was leaking as well.

 

[DoAnything!]

I took the jugs to be bored at a shop I didn't do it myself gave him the specs that came with the top end kit also they shaved some off the valves because it was one over on the Piston size and it called for it... the kit had brand new gaskets and I checked the torque specs on the book manual. I'm a novice at this so I could have made any of one or more mistakes but I thought I was pretty careful following what the book said. I ordered a new top end kit 1 .25 / and dropped off the piston and The Jug at the shop to get bored again I'll call tomorrow and make sure that they get the right measurements for the clearance.

 

[DoAnything!]

Did you have the injectors serviced and checked?
Did you check fuel pressure.

Running lean with not enough fuel is just as bad as not enough oil in a 2-stroke.

I did not check the fuel pressure. But I will this time around. I clean the injectors myself but I'm going to have them serviced this time around

 

[DoAnything!]

That cylinder head looks like a corroded mess. Did you clean it and install a new gasket before you put it back together? If it was leaking water then you washed all the oil film off and that toasted that piston. The piston dome looks dry and clean so it was either washed off with steam or no fuel.

That cylinder had either a lack of fuel or oil. My guess is fuel since you checked the oil system.

There was nothing corroded when I put those things on there is no corrosion on that that's just burnt crap on it right now everything was cleaned at the shop when they did the boring brand new gaskets brand new top end kit was nothing used in there that was 45 minutes of running that thing with no oil apparently and I guess it's people are saying water seeping in