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96 XP wont pull top end RPM's

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the_hog

the_hog

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Recently started having this problem with one of my XP's It will come out of the hole just fine but once it gets to mid range it wont pull anymore R's no matter how much throttle you give it. Now you can trim it up and bounce it to get it to cavitate and the R's will come up and hold WOT RPM just fine but once you let off or put it into a turn and the R's come down it does the same thing. Once in awhile coming out of a turn it will get to the mid range and lag kinda like a turbo lag then take off to full WOT RPM without cavitating it. Any thoughts?
 
Check the water regulator on the waterbox and verify that the rave valves move up and down freely. Your not leaking from the head pipe welch plug are you? The one pointed at the wire plug in the front of the engine leaks first.
 
How do your plugs look? Ever cleaned the RAVEs? What about your throttle cable? Pull on the throttle lever all the way, then grab the butterfly on the carb and see if it will twist more. That's a good way to check to see if you're adjusted properly there. As mentioned previously, make sure your water regulator is properly configured. Should have the right spring in there (longer and beefier than the RAVE springs) and should be turned 3 turns out from full bottom.
 
Unplugged the rectifier no change, also tried trimming the spark plug wires back a bit, bypassing the fuel water separator and fuel Selector, pulled carbs off and inspected/cleaned no junk in the filters, RAVE valves are functioning and water injection RAVE valve seems to be operating good and no water leaks spraying any electrical connections. I'm at a loss, CDI? Coil? Can get WOT rpm's on the trailer and any time on the water when the pump is not loaded but as soon as you load the pump it won't pull any topend R's

Plugs look good, if anything slightly rich, throttle cable was verified working and butterflies opening all the way when I pulled the carbs. Its got to be electrical doesnt it, since its only doing it under load?
 
If it's not the rectifier then I don't think it's electrical. Sometimes the pickup bracket on the inside of the mag cover will break and act inconsistent while it's in some stage of tearing off. Yours seems pretty consistent though. I would ride it with the seat off and look down in there for something that jumps out at you. The high speed needles are closed all the way, right?
 
Didnt check the high speed screws when I had the carbs off. I have no reason to believe they arent at the stock settings. This ski was prepped by Nick and ran awesome all summer until the 4th weekend, so no reason to think the they arent at the stock settings. I will verify next time I work on it, but pretty sure thats not the problem. Rode it with the seat off and nothing jumped out at me.
 
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If the WATER REGULATOR is faulty, it is letting water into the exhaust at WOT, and using the horsepower to push it out, resulting in less thrust. The WR should be shutting off the water flow into the exhaust pipe. Check the WR bellows ect, by removing.
 
How bout a stick wedged in the grate or pump veins? Maybe the impeller took a hit when you ate something? Just trying to think of these things that could cost rpm but not on the trailer.

How bout the rear riser exit hose does it feel floppy when you grab and squeeze? Those can delaminate and have floppy parts blocking the flow from the inside.
 
I thought pump issue right away to so that was the first thing I checked, nothing in the pump/grate or veins and nothing wrong with the impeller.

Rear riser exit hose? Are you talking about the exhaust hose from the waterbox to the exhaust outlet? If so havent checked that yet.


I have to say thanks for all the help so far, this has been pretty frustrating.
 
No problem. An exhaust leak under the seat can cut rpms. Try sliding the seat back on the next wet test to see if it comes back alive. Yes the exhaust hose from the wb to the outlet.
 
I've rode it without the seat and there was no change. I will check that exhaust hose next time and see if there is any blockage. I have a feeling its going to be something really simple and I am going to be pissed when I figure it out.
 
Those purple waterboxes had the baffles come loose on the inside sometimes. It's possible that a broken baffle is loose in there adding too much restriction to the exhaust flow.
 
I will give the waterbox a check as well. Plan on working on it again tomorrow, I have another 96 XP that I going to swap front eboxes with and see what happens.
 
Check the water box and exhaust hose, no blockage. Swapped front ebox with my other ski, no change. Double checked everything that has been said in this post and everything that I have checked before and found nothing. I dont know what else to do. I got nothing.
 
How bout trimming 1/4" off each end of the plug wires, did we cover that? New spark plugs, right?
 
Yup new plugs and trimmed the ends of the spark plug wires. Only thing left I can thing of is swapping coils, going to try that this weekend.
 
No reason to believe it is out of time, no back firing, no sputtering, no fuel coming back through the carbs.
 
Is it starving for fuel ?
As is, are the carbs delivering enough in the midrange to get you onto the main jet ?
Just thinking clogged pilot circuit.

Do you hit a point where when you give it just a bit more gas that nothing happens?
And while your reving it up slowly does it rev up to that point smoothly in proportion to your throttle input.
 
Didnt get a chance to swap coil so thats still an option. Its not the water regulator though, eliminated it and it still acts the same.

Its not starving for fuel, pulled carbs and cleaned them. Get to about half throttle and no more RPMs, rev it slowly and get to half throttle or so and you get now more RPMs.
 
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I think you have already swapped grey boxes to eliminate the regulator/rectifier, right? Then I would pull the mag cover. Small metal chips from the starter hitting the flywheel teeth can cover the magnet on the pickup over time. The bracket on the pickup is known to be weak on those also and may have cracked or torn partially on it's way to breaking off.
 
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