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96 XP wont pull top end RPM's

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Tested the stator using this procedure and got 243 between the yellow/white wire and yellow black wire, under 1 between all three yellow wires and no continuity.


http://www.pwctoday.com/showthread.php?t=381705



So as far as I can tell the stator is good. Will a stator test out fine if there is metal covering the pickup magnet, or the pickup bracket partially broke?
 
The shavings will collect on the pickup coil tip. That little round nipple facing the cup is magnetic. Not sure if this has been asked, but have you made sure that pulling the throttle all the way takes up all the carb slack? Check this by pulling the throttle all the way and then see if you can turn the butterfly on the carb by hand any further. Also, make sure your choke isn't stuck closed partially. Have you tried to run it with the air filter off?
 
Carbs butterflies and choke are fine. If it was either of those it wouldnt hit the rev limiter while on the trailer or when the pump isnt loaded. It is backfiring now, so I am going to check rotary valve timing, if that checks out I will pull the mag cover and check out the stator and pickup bracket.
 
Confirmed that the rotary valve timing was correct, so the only thing that is left is the stator after that I am at a loss.
 
Video ?
I'd like to hear it while its doing that. How stiff are the check valves in the carbs? (I'm wondering if they are closing when then shouldn't or not opening at all...)
Also what do you have the pop off set to and low speed?

Did you try giving it a bit of choke to see if it would pull past that point?
 
I am with you there, cause you said it can be intermittent. Well at first it was pretty consistent but now on the trailer it will sometimes run to the rev limiter, someone not reach top end rpm, sometimes stutter and sometimes stutter and backfire.
 
Didn't he say he tested the stator though? Don't you have to pull the mag cover to do?

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Ok i feel dumb for not responding publicly I have been in contact with Tim and I thank you guys for all the great ideas.

This boat was gone thru top to bottom. Carbs, fuel lines, oil inj lines, water reg, raves, all electronics working, etc.

Your last post needs to be elaborated on or a video made.

At this point it's time to do things regardless if they make sense. Swap the battery, swap the front to rear harness, he'll swap carbs with your other boat. I would also tell you to pull the front housing. There's no way of testing a pickup breaking off. You have done everything but that at this point.

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Pulled mag cover, everything tested out fine. Was some metal shavings on the pick up magnet, Nick said to clean it all off and I did. Reinstalled everything and still no change. I did realize a new symptoms though, after a restart the first throttle pull is revs fine to the limiter but any throttle pull after that it stutters and backfires. So swapping carbs from my other XP tomorrow. Just wanted to add Nick has been great throughout this, he has helped me out anytime I needed and is 100% standing by the machine he sold me.

rsz_20150808_130906.jpg
 
That's the rectifier/regulator. I have had them do the exact same thing. Swap that or grey boxes before the carbs.
 
Swapped carbs, no change, still acts the same. Swapped front eboxes weeks ago, no change, unplugged rectifier in both eboxes, no change.
 
Well do the rectifier again. I know that symptom. I've got myself home before by holding the throttle wide open then starting it without letting off when I had a bad rectifier. It's a 96 issue. Put a volt meter on the battery and rev it, bet it's over 14v.
 
I'm anxiously awaiting to see what fixes this ski because I have one just like it that I have been fighting with all summer. Keep us posted, thanks.
 
Well Matt gets the gold star, first thing I tried this morning was unplugging the rectifier and now it will rev to the limiter all the time while on the trailer. It doesnt make any sense cause the front ebox that is in it is the one from my other XP that was running just fine when it was swapped and runs just fine with the ebox that came out of the one with issues. And I also unplugged the rectifier in this one after I swapped it. Charging the battery now and hoping to get it on the water this afternoon to see if it solved the not being able to pull top end RPMs while the pump is loaded issue.
 
It will it will! That's now the most sorted out 96XP going haha. Careful with the regulator unplugged though that's just a test. You don't want to damage the other electrics by throwing 16v+ at it for any length of time. Happy to here all this is almost behind you. Sounds like you might want to order two.
 
Happy to report it ran good with the rectifier unplugged. Revved all the way out just fine even with pump loaded.


All I have to say is WTF! lol And thanks to everyone for helping out.
 
I have a 97 sea-doo challenger with the 787 engine in it and it was blowing mpems and I replaced that and cleaned the shavings off the stator and had the cap off and put it all back on and it will not rev over 3,300 rpms plugs are wet unhooked the red wire to the reflector and still missing at 3300 rpms exhaust seems really hot ! any ideas ?
 
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