Sea Doo Techs need help

[mrtool2u]

Working on a Sea Doo GSX Limited with a friend and it has a problem. It keeps blowing the 15 amp fuses,either the one in the back by the solenoid or the one mounted up on the CDI box. We have (I THINK) narrowed it down to a plug that goes into the motor by the oil pump,which I assume is the inner coils. The plug has 3 yellow wires,1 yellow/white wire and 1 black/yellow wire. It is intermittent,,sometimes it will start and run,and other times it will blow as soon as you put in the fuse. On a ampmeter it was pulling 17 amps before I pulled it off. When we unplug the plug from the motor,the problem goes away,but the motor will not start then. Any and all info much appreciated.

 

[Jeff Walkowiak]

Re: Sea Doo Techs need help

it's probably a bad stator but just to be sure unplug the trim motor wires as those get water in them and blow fuses all the time,, if it keeps blowing the fuse with the trim un plugged then there is a short in the stator,, the 3 yellow wires are the charging wires that go to the rectifier, should be 3 yellow and a red, each yellow produces 2 amps of charge to the rectifier and those are ac current the rectifier changes them to dc possibly the rectifier is bad as well, I un plug all 3 yellow wires and re conect one at a time at the rectifier, with the engine running, when the bad winding is conected the fuse will blow, just leave that wire un plugged and re conect the other 2 if the fuse stops bolwing you can run it that way and the only draw back is that you only have 4 amps of charge for the battery rather than 6 but it should be sufficient, or you can spend a bunch of time and money and replace the windings in the stator.

 

[Jeff Walkowiak]

Re: Sea Doo Techs need help

also in that plug is the signal from the timer base for the ignition so if you pull the plug from the front cover the engine won't run,, go in the electrical box and un plug the yellow wires from there, that will allow the engine to run while you do the above mentioned proceedure.

 

[mrtool2u]

Re: Sea Doo Techs need help

Jeff,thanks for your input,,but there is no red wire,just the 3 yellows, 1 yel/wht and 1 blk/yel wire. This thing will blow fuses before the motor ever starts,,just when it is powered up. I will try with disconnecting the 3 yellow wires and post my results back,,,thanks for your help. PS,,where would I find the year and size of this boat...I cannot seem to find a motor size on motor.

 

[Jeff Walkowiak]

Re: Sea Doo Techs need help

year is last 2 digits of the vin number. motor id is on a sticker at the rear of the engine //usually, however if it was a rebuilt engine from s b t they remove the stickers, and put a number sticker on the engine for warranty purpose's so you have to call them with the number to get info, once you get the year and the model I can tell you the size of the engine. If it has the grey electrical box the rectifier has 3 yellow and a red the red goes to the battery the yellow come from the stator the little stripes on the wires don't matter. my guess is it is a 951 engine and the trim motor needs to be un plugged as those will blow the fuses instantly if they are bad, and it is a common issue. Also pull the front plug and remove the backing to see the pin conectors from behind as wires sometimes melt inside those plugs and short out. Also when you say there is no red wire that tells me you are looking at the stator plug not the rectifier in the grey box, to disconect those yellow wires you need to be inside the grey box you will see a square rectifier as I described with conectors to un plug the yellow wires as I previously stated.

 

[mrtool2u]

Re: Sea Doo Techs need help

Jeff,,one of the yellow wires did seem to be the culprit. Am I able to just cut the wire in the harness coming from the motor and tape it off.The harness from the motor plugs into a big(black I believe) box mounted in the front of the boat,with 2 other wire harnesses,and it looks to be sealed with no way in. The boat is a 1998 GSX limited,,any idea what size motor it should be. And yes there is a red wire that goes to the hot side of the solenoid.

 

[Jeff Walkowiak]

Re: Sea Doo Techs need help

it is a 951 engine and the electrical box is mounted and sealed, the field wire is shorting out and yes you can remove it but first inspect the plug where it goes in the stator cover to see if it is shorting out in there , the little rubber packing is easy to pull out from behind to inspect the pins in the plug, I use a pin tool and would just remove the wire from the plug that is the problem wire, that way you have not cut anything and it can be put back later if the stator is replaced just tape the wire to the harness with some electrical tape