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Ok this is what I do know so far. Just bought the ski, previous owner says would run for 3mins then stall, he sugested a carb rebuild. The carb is a Mikuni 38mm BN. What I have done - replaced dead battery, rebuilt carb (first time I have ever done so but was very simple and straight forward, espically with the help from SBT's .pdf - only problem I had was at the end there was one extra o-ring, I am not sure where I missed it, I thought on the seat of the needle-seat, but looked and there was no o-ring just a orange ring). So the problem is I have spark I have fuel, but not starting. If I use starter fuel and spray directly into the carb it will run till it burns the fuel (yes i know this is bad b/c its not premixed but only did it once to confirm spark). As far as fuel goes it will pull suction on your finger from the carb, refiles the fuel filter, and I took apart the carb again to replace the needle with a extra needle I had and there was fuel threw out it that wasn't there before. So now it sits, not starting and not sure where to look now, all shops need 3 weeks to fix it since memorial weekend and I am sure will charge me a fortune for something simple, any help please. Thank you, Dustin
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Make sure you don't have an obstruction in the fuel system, like a clogged line, or bad fuel switch.
Take some pre-mix fuel and see how long you can get it running that way.
Remove the fuel cap and make sure you aren't creating a vaccuum (bad check valve).
Does your carb have an internal or external pump? If external, did you rebuild it also? -
The orange looking line running from the right side of the carb looking at the front of it near the throttle cable, runs to the lower block, is that the fuel delivery line or what is its purpose? I know the line that runs into the side of the carb (the main fuel line) is not clogged b/c I can sphion fuel up to it. The fuel pump I am pretty sure is internal because there is no visible external and the ski is stock, I was told this fuel pump works off of crank pressure. I have not tried the added pre-mix fuel to the carb yet, but will try, not sure how much to add not to flood it and keep it running with out spilling to much in, don't have a spray bottle. I will check for the vacum and I will do my best to locate the check valve. Also where is the fuel switch (its not the reserve/normal fuel switch is it)? Sorry for the lack of knowledge I am basic mechaniclly inclined just not familar at all with jet ski's.
On a added note I have a second JS 440 with the same carb that if all else fails I was going to pull off of it and try it on this one, I just hate to take apart a working jet ski and end up with two non-working jet ski's. The one working is a white 81 js 440 the one not working is a 78 js blue 440.Comment
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Ok scratch all previous comments, just was working on mixing the fuel gas into the carb and was getting no spark was test plugs and apparently the wiring is worn out, need new spark plug wires, any good brands or places to purchase from (cheap [img]/graemlins/winkanim.gif[/img] ?
[ May 21, 2002, 06:17 PM: Message edited by: Dustin ]Comment
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No spark could also be your CDI ignition failing - it sounds like the problem is intermittent to me...
Also, I read here that replacing the spark plug wires alone is kind of difficult since thay are potted directly into the CDI...Comment
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The spark plug wires fell apart in my hand when I removed it from the plug. I have searched the web and can not find a place to order replacement wires from. Where can I find replacement plug wires at?Comment
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hey dude
i have a complete electrical box for a stand up 440/550. Let me knwo if you want it. has the coil and plug wires
e mail me
RobComment
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I am definitly intrested in the plug wires, already sent you off a email, let me know what you think. Thx for all the help SBT yall are definitly the best PWC site on the web thus far.Comment
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Dustin if youre still not getting spark did you chekc the wires coming out of the stator. in some cases the wires are too close to the fly wheel and get chewed up by the fly wheel spinning especially if soemone forgot to tighten up the small clamp that holds the wires tight to the case. I did that on a 440 I had and it took me a while to figure it out cause I wasnt thinking
RobComment
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