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95 XP (717) - The SeaDoo gods Hate Me

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Tenacious D

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Ski:
95 XP with 717 engine, dual carbs

Background:
Took it to the lake Saturday. Started right up, and ran perfectly during several jaunts throughout the day (anywhere from 10 minutes to 30 or so). On Sunday, it started right up, and ran perfectly for app. 20 minutes, whether at idle, jogging or WOT. After initial run, we stopped to switch riders. Ski was hard to start (had to hold start button for app. 5-10 seconds), and when it finally turned over, it was severely bogged down even at WOT and wouldn't go more than 2-3mph, although the RPM's never seemed to fluctuate (i.e. once it got to it's 2-3mph range, they didn't increase whether the throttle was pushed to 1/4 or all the way to WOT). While the 95 XP doesn't have the "limp mode", that's the best way to describe it. While incredibly slow and with next to no power, the engine never seemed to threaten to die so long as the throttle was pushed. We always take our pontoon boat out with us, which we used to pull the ski behind until we anchored somewhere and I could take a look at it. Despite the fact that I had just put two brand new NGK BRES8 plugs on the ski on Friday night, I pulled each to see if they could offer some clue (and that was the easiest place to start). The port-side plug looked as expected, essentially new with a little black wetness on the end of the threads. The mag side plug, however, was covered - and the gap was occluded - with something that looked like carbon, but which was more of a brown than black color. See the attached detailed pics. I replaced the port side plug with the same one I had inspected (it looked fine) and put a new NGK BRES8 plug back in the mag side. The ski fired right up, and took off, running perfectly for about another 10 minutes. Just about the time I was beginning to rekindle some hope in the SeaDoo gods, again, they smote my foolish hopes. While I was going along at about 1/2 throttle, or 20-35mph, the ski suddenly died. It didn't "peter out" or sputter, it didn't knock or lose power or RPM's - it died, and without warning of any kind. No buzzers were sounding (yes, mine works), no lights were illuminated, it just went dead. It re-started, and ran without problems for another 200 yards or so and then same thing - died without warning. It took even longer to re-start it a third time (app. 10 instances of holding the start button for 5-7 seconds, each), and when it did start, it would only run in the same "bog mode" as I previously described, and even then, it died after about 20 yards. Satisfied that the problem extended well beyond my ability to diagnose or repair on the water, we simply towed it behind us for the rest of the day. I haven't touched it since we returned, as I have been too busy trying to control my heaving sobs and keeping the nearly overwhelming sense of dejection from further wounding my inner child (he's the one who talked me into buying the jet ski to begin with).

Known Problems: (in the event that it might help to better understand / solve my mystery)

1. The VTS motor, while it remains in place and connected, is trashed. The previous owner (whom I now hate) put the cover back on it wrong, and allowed water to turn the motor into, essentially, something that resembles a relic from the Titanic. As the VTS motor doesn't work, the jet is stuck in position, and it takes it a few seconds to "get up" on plane when starting out.

2. The RPM gauge doesn't work, and the needle never moves.

3. I have no idea as to where the "pee hole" is (on the ski, not myself), nor if water is flowing out of it. However, I have had no indication that my engine is overheating. I just don't know where it is, in case you ask me to check something on it (feel free to tell me, because I think that's one part a man should always be able to locate, if asked).

4. On one instance, I can recall removing the gas cap to hear a small hissing sound, but it hasn't done it since. Admittedly, my ski doesn't run long enough for me to need gas, or to build up any vacuum that I would notice.

In the three weeks since purchasing the ski from some random guy (and whom I now strongly suspect is evil incarnate), I have done the following repairs / fixes - all thanks to the wise members of this board.

1. I have rebuild the carbs with a genuine Mikuni kit, including
a. replaced the N/S (1.2) and
b. replaced the tiny carb filters
c. precisely adjusted their settings per the main "fuel issue" sticky, here

2. I have replaced the gaskets that attach the carbs to motor.
3. I have removed all gray fuel lines and replaced them with black automotive lines.
4. I have emptied, cleaned and replaced all of the gas in the tank - twice.
5. I have cleaned the spin-off fuel filter.
6. I have cleaned the gas selector switch.
7. I have added an in-line fuel filter.
8. I have clipped 1/4 off of the plug wires and re-booted them.
9. I have removed the old plugs, and installed new ones gapped to the specs of the manual - three times.
10. I have a battery that is less than one (1) month old, and which I have had tested under load at AutoZone
11. I have tested my compression in both cylinders, three separate times each - both measured 130, exactly, each time.

Is it a carbon ring? Is it my MPM? Is it the ground? Bad DESS?

I honestly have no idea as to where to even continue looking at this point, and will instead, trust that someone here can offer some insight into how best to solve my plight.

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It looks like rust, when you tow your ski are you pinching off the inlet hose?

Lou
 
It looks like rust, when you tow your ski are you pinching off the inlet hose?

Lou

SeaDoo's do not tow well, have tried numerous times behind our pontoon and it just doesn't work!! I agree with Lou, looks like water in the engine.
 
No, I'm sad to say that I do not pinch the inlet hose off, Lou.

Am I to assume that this is flooding the still (non-running engine, when being towed) engine with water when towing, and that's the cause of the problems?

Would that explain why the MAG plug is trashed but the PTO is fine?

Which inlet hose should be clamped when towing (location of it)?

How to explain that the 'ski runs well for a short time and only refuses to start after being stopped (to switch riders)?

Certainly not questioning the line of reasoning - I appreciate any advice I can get - just trying to understand it, and determine if this is the main culprit of all of my problems.
 
I know that when my 1997 Speedster with 717's was doing the same thing...starting and running for about 20-50 yards at a time...dies then wait for about 2-3 minutes then start up again...ended up being a bad rotary valve cover. It was fouling plugs and running weird...not sure if this is your problem but its worth a peek. The list of things you did is almost identical to what I tried before I got to the Rotary cover...
 
You should pinch off the hose coming from the pump to the motor, on the port side.

Lou
 
Thanks, Lou. If the plug is a result of water being in the engine, will it continue to cause this plug fouling, get worse or eventually clear the water and be fine?

Thanks, Chips. Can anyone offer an experienced perspective as to how difficult it is to change the rotary valve cover, and what is involved?

Any other suggestions as to what could cause the ski to respond as described, or suggestions for another fix?
 
I've taken the second set of plugs out and they look fine (can't explain the looks of the first ones, pictured earlier).

Given the way that the ski just shut off as if the lanyard was pulled, and my extensive work to overhaul the entire fuel system, I'm now thinking that it's something electrical.

To that end, I've checked all of the fuses, and with the exception of the 7.5 (from bad VTS), all we're good. I've also used an inline spark tester to check each plug wire and they are getting good spark.

I've read other threads where Dr. Honda has said that a bad VTS (such as I have) which remains electrically connected could fry the MPM, and wonder if that's what has happened here, especially considering that the 7.5 fuse was blown when I bought the ski, and has since blown the same fuse a second time, after I replaced it.

So, my new questions:

1. Would a fried / faulty MPM explain the primary and intermittent symptoms of hard starting after a short (cold, first of the day) run? Could it explain why the ski just suddenly died while running, and without warning? Does the MPM slowly go bad (i.e. it gets worse as it gets progressively worse) or is it simply working or not, meaning, it either works or fails. How to test the MPM?

2. Could this be a bad solenoid, core, mag and/or rectifier? Where to start looking?

3. I have read some things about a "rear e-box" which I assume is not my gray box containing fuses - but I can't locate another box. Does my ski have one, and if so, where is it?

4. Are there any known connections that I should be checking for tightness / contact, that have known to cause problems for others?

Any advice / suggestions are most appreciated, as I continue to try to determine the root cause.
 
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