Someone please help! (Charging problem)

[joelmatt89]

I have a 1996 xp. I bought in the winter, so I couldn't drive it, first time in the water it nearly sunk because it was missing a clamp on the drive shaft. Now it runs decent but the charging system doesn't work. Here is what I know the battery has 12.2 V when sitting and 11.9-12.1 V when idling. I replaced the stator with a used one off ebay that came off a working ski. It looked pretty decent, I also swapped the recifier off of another working ski to see if that was the problem. Whenever the ski starts it immediately blows the 15A fuse that appears to run between the rectifer and the selonoid. It is the only 15A amp fuse I believe. The starter relay has broken twice so I believe there must be some sort of short somewhere, obviously, but does anyone know which direction to point me in. Does that fuse possibly indicate a problem area. I'm not sure what to test my wiring diagram has the wrong color codes so it is pretty hard to check resistance between alot of the wires. Some one please help me I AM DESPERATE.

 

[JPX]

Hmmm, reaching a bit here now.....maybe pull out the starter and bench test it? Internal short may be killing something? Flooding a boat could be have caused some corrosion in the starter.

 

[joelmatt89]

Thanks for the reply, it starts so I would be surprised if the short was there, but the starter was bad and it has been replaced since it took on water.

 

[JPX]

Could also be a bad ignition coil? This is a real brain teaser problem, man.

 

[kustomkarl]

When the engine is running, set your voltmeter for 20 VDC and put the leads on the correct terminal posts. With the engine running, you should be reading anywhere from 14.5 to 14.8 VDC. (typically this test is done at 5,000 rpms) This tells you your charging circuit is good. If the voltage is higher, the regulator is bad. If you’re not showing a charge and you've replaced the rectifier, you may want to do a test on the Magneto/stator/charging coil. If you’re not a premium member and you don't have access to a manual, this test will be hard to do without it. There are 2 fuses that protect the charging system. Check the 15 amp fuse in the MPEM and the 15 amp fuse between the solenoid and the MPEM.

The magneto and stator create un-regulated AC current. The "rectifier" converts that AC to DC current and the regulator maintains the current between 14 to 14.5 volts DC for the engines operation and charging circuit.

It sounds like the regulator is bad...causing the fuse to blow.
Keep us posted.

Karl

 

[joelmatt89]

Thanks Karl, I think I am going to try testing the stator. I don't think the rectifier is bad since it came out of a working ski and when I switched the broken skis rectifier into the working one it still worked fine. Somebody on another site told me if that fuse is blowing it usually means your stator is bad. So for know that is my plan I'll let you know what happens.

 

[rexsteiner]

correct me if im wrong but if you suspect it is in the charging system, couldnt you unhook the charging wire, start it and if it blows the fuse again then its not in the charging system? and if it doesnt blow than try ohming the magneto to ground and if there is any reading then there is a short in the mag.

 

[joelmatt89]

Well I haven't tested the stator yet but I am almost sure thats is it because I swapped the rectifier out of the ski that wasn't working into the ski that was and it was charging at 13.5. I got a pretty good deal on a stator with the housing and pickup off ebay so I'm hoping that will fix the problem

 

[joelmatt89]

Someone elso told me if you unplug the stator it wont run

 

[joelmatt89]

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i put in the new stator and the charging system was over 13 V, tha battery I had in it was dead so I hads to put a battery in that wasn't taking a charge very well. It started up the jet ski and i rode it for about 15 minutes then all the sudden the battery started flashing and the it died. It would crank over but it wouldn't start. I am planning on testing it tommorow with a fresh battery that was taking the charge better on my charger. I am assuming the battery just wasn't taking a charge and the engine was able to run until the battery got to low. I mean it took like 2 days to get it fully charged on 10 A at home so my fingers are crossed I really hope that is the problem. If someone want to reassure me that that makes sense feel free. By the way the battery light flashed four times before it died and then stayed on does that mean anything or is that just chance. Thanks so much for all your help.