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At the end of my rope with 96 xp!

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tschowen

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Ok, I posted a while ago about my 96 xp bogging and I've tried everything that everyone suggested with no luck. Here is a re-cap: Before the one and only time I had it out this summer, I cleaned the carbs (particularly the mesh filters), put in new plugs and cleaned the power valves. It ran with zero issues all day long. The next day, it started right up for me but when I hit the throttle, all it did was bog down. I would occasionally try to blip the throttle and once or twice it actually took off, but this was not consistent at all. Ever since then, in the water or on the trailer, it will start right up, rev 2-3 times and then bog. The first time I hit this forum, it seemed obvious to me that it was my grey fuel lines at fault, so I replaced them along with the fuel selector and fuel filter and cleaned the carbs again, all with no results whatsoever. I have since tried swapping the carbs and the MPEM out, still with no luck. The compression is a perfect 150 on each cylinder. Someone told me that stators go out of these quite often and I'm starting to think it must be an electrical issue myself. Anyone want to chime in on this case? I can't stand to put away a ski for the season without it running properly.
 
try loooking at the exhaust system.
i have seen the big hose from muff to outlet fail
it will de-laminate and reduce the flow of exhaust
sometimes the muffler/water box can break a internal baffle
again preventing exhaust flow
slide muffler off of tuned pipe and test run, it will puke water and exhaust into hull ,but you will be ok for a minute

also check battery voltage with engine running
still could be carb issuses, expose the top of carbs and gently fog intake with start fluid as you try to rev engine up.
goo luck
mud
 
Just to add to Mud's advise...don't use starting fluid...It could cause a seizure. There is NO lubrication in starting fluid. The engine requires the oil in the injector system to lubricate the internals of the engine. If you must, use either a pre-mixed amount of the oil you use and fuel or use wd-40. Be careful of back fires too as it could happen spraying any kind of fuel in the carbs with the spark arester off. Think safety first.

Karl
 
yes, stators and especially pick up coils fail a lot on the older 800 motors. Your pickup bracket may be loose or covered with metal dust/shavings, very common. pull the mag cover and you'll know.
 
ok guys, I did what you said and popped the waterbox hose off of the main pipe and it started up and revved perfectly 6-8 times. The smoke was getting a little intense, so I shut it off and proceeded to remove the waterbox and outlet hose to check them out. No apparent delamination in the hose and nothing rattling in the waterbox (although I realize it can be plugged even though nothing is rattling inside). So I started it again, only to have the same bogging problem. Well, I guess it's time to pull the mag cover and look at that stator!!!! Thanks for all your suggestions. Although this is becoming my worst nightmare, I still appreciate all the moral support!!
 
before you pull the mag cover, check the rectifier. mostly because it's an easy check, just disconnect the red wire and run on the battery.
 
I've already removed the stator and sent it off to be tested and rebuilt. I received a different rectifier when I replaced the MPEM, so chances are both of them wouldn't have been bad anyway. Thanks for the tip, though and if I get the stator back in and still have the problem, I will try disconnecting the rectifier. If that doesn't work, I am most likely going to smash the ski with my truck. I'll let you know how it goes!!
 
while you have the stator out, do a visual inspection of crank seal at mag side and pto side, see if there is signs of leaking or seal pushed out.
had one blow out rear seal, dont remember what she acted like?
again check battery voltage when running, a over charge situation will cause a issue like your having
o-ring in place in fuel filter cup? does choke being put on help?
pull air box cover off and put your hand on intake when reving, put some restriction on intake , this will make carbs pull more fuel , does this help?
and for starting fluid, i said gently fog, not run the machine off of it
never knew when you use start fluid it disables your oil pump, hmmm
 
You might be running way way too rich..

I had the same issue before I adjusted the oil to line up properly..

I would give gas, sometimes it would go, sometimes it would bog and not get into highs...

Now, it gets into highs right away lol...
 
Did you rebuild the carbs when you had them apart?

Just wondering, I had a problem with the gray lines and took the carbs apart and cleaned, but then I saw that the round black diaphgrams were bad you could tell by looking at them and the front one was worse than the back. My front cylinder would foul up the plugs worse than the back, anyway bought a rebuild kit, changed the lines, cleaned everything else. I had to take it apart and put it back together several times till I found all the problems and started making my own gaskets much cheaper.
 
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