Dirt appearing in fuel filter..

[JonRusso89]

Hey guys, so heres the deal. After picking up a 99XPL a few weeks ago I have been sorting out some issues. After a new wear ring, jet pump rebuild, carb rebuild, replaced all fuel lines, new fuel filter, cleaned baffle, cleaned raves, and cleaned fuel selector, the ski ran awesome. Great acceleration and top speed of around 64 on the GPS. Today, some issues arose. It began showing signs of clogged carbs. Idled rough, and wouldn't rev above 5k. I unscrewed the brand new fuel filter to find that there was a decent amount of dirt floating around in it. My suspicion is that some of this made it through the strainer and clogged the internal fuel filters. The only thing is I can't figure out where the dirt is coming from. I had found dirt in the old fuel filter that reappeared a couple times. The tank appears clean and there is no dirt in the screen on the baffle. My current working theory is that the fuel selector is breaking down and the dirt I'm seeing is parts of the internals of the selector. Is this possible? On a side note, has anyone ever run any other sort of fuel filter? My plan is to bypass the fuel selector and run a filter to prevent the carbs from getting clogged again. I was a little concerned with restriction causing it to run lean. The filter I was planning to use is a 50hp Honda outboard filter. Any thoughts?

 

[Dr Honda]

I use an extra filter in all my toys. It's a paper filter from the local autoparts store, with 1/4" fittings.

Yes... the internals of the fuel valve could be breaking down... but all that's in there is a hunk of rubber. If it's dirt in your filter... that wouldn't be it.

All I can say is to clean out the filters, and add it should run.


This on has 5/16" fittings.. but it will work. Autozone has the same one with 1/4" fittings. (dont' remember the part number off the top of my head)

 

[JonRusso89]

Thanks! I used the term "dirt" loosely. "Black debris" may have been a more appropriate term. I can't be sure as to what exactly it is, but it could very well be broken up parts of rubber. Thanks again for the reply.

 

[JonRusso89]

Update - Today was a little disappointing. Pulled the carbs and cleaned them thoroughly. Didn't appear to be any blockage, but I know that doesn't always matter. One carb had a small amount of debris resting in it. Put them back on, and installed an inline filter very similar to the one you posted. With the fuel valve bypassed, and the inline fuel filter in place, it ran just as bad as yesterday. The symptoms are as follows.
- Idles rough and sometimes wants to stall.
- Won't run above 4 sometimes 5k RMPs
- At idle and up to around 3k it will sort of "pop" out of the exhaust every few seconds. It surges slighty and splashes water up behind the ski.

I checked and cleaned the water regulator a few weeks ago during my last bout with running issues. It seemed fine. I'm getting close to being stumped on this one. Any thoughts?

 

[LouDoo]

One thing I found on my 96GTI when I did the fuel lines last year, there is a rubber seal inside the fuel selector valve that had deteriorated. I replaced the valve. You might want to check there. You can temporarily bypass the valve.

The only other thing I could think of is bad gas.

Lou

 

[JonRusso89]

Thanks, but that was my first thought. I bypassed the fuel selector, cleaned the carbs again, and installed a fuel filter, still ran the same. Second thought was also that I got bad gas from the pump, so I hooked up an external tank with fresh gas and ran it for 10 - 15 mins and still had the same results. I just pulled the carbs again, I'm going to inspect the reed valves, basically because I can't think of anything else. Any and all thoughts are appreciated, thanks!

 

[dave100]

Fouled plugs, maybe .... that's how mine runs when I'm on one cylinder.

 

[jhjesse]

Unscrew the plug wire caps and clip the wires back about a 1/4 inch, then replace the plugs.
Insure that the RAVE O rings are not damaged.

 

[Seadoobuddy]

Sorry for jumping in w/o an tip. I've seen the advice to clip back the plug wires 1/4 inch several times. What does that correct or do?
Newbie from Michigan.

 

[JonRusso89]

Changed the plugs several times. They don't appear to be fouled, but I change them every time I begin trouble shooting. I haven't cut back the wires, I threw a spark tester on it today and it showed a strong healthy spark. The rave o rings do look like they are in rough shape. I'm curious though as to what made you suggest the o rings. Would that cause a vacuum leak? Thanks.

 

[JonRusso89]

Sorry for jumping in w/o an tip. I've seen the advice to clip back the plug wires 1/4 inch several times. What does that correct or do?
Newbie from Michigan.

The ends become corroded and cause a weak spark. Cutting them back gives you fresh un-corroded wires for your plug caps.

 

[JonRusso89]

Unscrew the plug wire caps and clip the wires back about a 1/4 inch, then replace the plugs.
Insure that the RAVE O rings are not damaged.

To be clear, the actual o rings are not damaged. In my previous post I was referring to the rubber gasket at the base of each rave valve housing. The o rings on the shaft of the rave valve appear to be fine.

 

[jhjesse]

Changed the plugs several times. They don't appear to be fouled, but I change them every time I begin trouble shooting. I haven't cut back the wires, I threw a spark tester on it today and it showed a strong healthy spark. The rave o rings do look like they are in rough shape. I'm curious though as to what made you suggest the o rings. Would that cause a vacuum leak? Thanks.

The RPM's that your engine achieves before starting to cut out left me with the impression that you could possibly have a "power curve" problem. In other words your RAVE valves, otherwise known as power valves were not working properly.

 

[Kozerxp]

Check compression

 

[LouDoo]

I guess I missed something, I thought we were talking about dirt or contaminants getting into the fuel system.

Lou

 

[Kozerxp]

He has cleaned the fuel system multiple times and have checked and rechecked everything and his ski still won't run correct or did u miss that part?? It something most people overlook just a free no cost thing to check a make sure is ok it seems all else has failed him already

 

[LouDoo]

O.K. sorry, I haven't checked for a couple of days, I didn't know, I thought he was still getting dirt in the fuel. Chill. I won't make anymore posts on this thread.

Lou

 

[JonRusso89]

The RPM's that your engine achieves before starting to cut out left me with the impression that you could possibly have a "power curve" problem. In other words your RAVE valves, otherwise known as power valves were not working properly.

Usually some of these symptoms would lead me to suspecting the raves were hanging up. However, not only will it not accelerate past 4k, but it also idles poorly. I cleaned and checked the raves anyway, but to no avail. Thanks for the response.

 

[JonRusso89]

O.K. sorry, I haven't checked for a couple of days, I didn't know, I thought he was still getting dirt in the fuel. Chill. I won't make anymore posts on this thread.

Lou

No worries, you're correct, my OP was in reference to contaminants in the fuel system. However, that did not turn out to be what is causing my running issues. Still figuring it out, so any thoughts are welcome. Thanks again.