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96 XP rev problem(not carb related I don’t believe)

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Brprxt215

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I got my 96XP running finally. After buying a brand new Wally World never start battery I couldn’t get it to fire. Replaced solenoid, ignition coil, cut back all positive and negative leads. Pulled starter had it load tested and then pur everything back to original parts. Bought agm battery and fired right up went to load test it on the trailer today. Found a hole in the J pipe on one of the Welch plugs so that needs to be fixed. But when revving it up sometimes it would rev up to full throttle and bounce off the rev limiter let it come back to idle and it would maybe rev up to 3/4000 rpms and sound like it was putting a huge strain on the motor. Let off again and give it full throttle again and it would hardly rev up and seem like the strain was there again. Let off throttle go to idle and hit the gas again and it would rev fully up and bounce off the rev limiter. Could this be a possible recticifier issue? Note( the ski had not been started in a couple years. I am trying to revive it and give it life once again. I drained all the old fuel as much as could possibly get.) put 2-3 gallons of premix in originally because that’s all I had. Injector is not blocked off so would make it run a little rich. Now that I got it running I added 4.75 gallons of ethanol free fuel before water testing. Cleared all the fogging oil while running it on trailer in water. Smoked like a banshee! I just do not know if maybe it was clearing out the old fuel. I ran it for maybe 3 minutes with the revving being fine then straining itself. Sorry I am not sure how to post a video or I would:/
 
Sounds pretty normal for revving on the trailer. Also sounds like it could be a bad regulator, it's such a consistent problem and the new one is under 20 shipped. You will know for sure the moment that you try to ride it.
 
Rev it up to five grand while checking DC voltage on the battery. Service manual for your ski will have the acceptable range you're looking for.

Also check for AC at the battery when revving up as that's what the regulator is putting out that is screwing up the mpem.

Other thing you can do is disconnect one of the leads from the regulator (I don't remember which one) and see if the problem persists.

I'd also check for air leaks.
 
How about this question...my fuel baffle isn't working. I have a spare one from a parts boat I have access to.

My question is this..How do you test a baffle without installing it? Can I put a tester on it?

And is it possibly a bad gauge?

I hate to go through the process of installing it, just to find the second one bad.
 
Just plug it in to the fuel plug that goes to the gas tank and turn it upside down to test it.
 
How about this question...my fuel baffle isn't working. I have a spare one from a parts boat I have access to.

My question is this..How do you test a baffle without installing it? Can I put a tester on it?

And is it possibly a bad gauge?

I hate to go through the process of installing it, just to find the second one bad.

I assume you mean your gauge isn't working?
Put a multimeter on the two pins of the connector and move the float up and down... The resistance should vary, I'm sure you can find the proper impedance range by searching here.

If it doesn't vary by moving the float or it's out of range then it's not working.

There's ways to fix it depending on what the problem is, mine had a blown fuse in it, for others the magnet falls off the float.
 
You check a fuel baffle by putting a multi-meter set to ohm on the 2 wires coming off of it. If there is no reading then it will not be sending a signal to the gauge and the gauge will read empty.

You unplug the red wire from the regulator to test to see if that is the problem but do you even have a problem? They don't rev clean on the trailer. The ski is jetted to be under a load so they are rich when free revving.
 
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