1996 Sea Doo Gts won't start

[miknjan]

Okay here we go. I'll try and get this all out without boring anyone. Last summer we swamped one of our two skis. Immediatly following it wouldnt start, After a little work we got it running for about 4 minutes then it just died no hesitation nothing just boom....... dead. Now when we try and start the ski it acts like it wants to start but it just dies . The plugs are soaked in fuel! we have rebuilt the carb and nothing changed so we swapped carbs on the 2nd ski and it runs great. I'm thinking it's ignition, it has good spark with the plug out and grounding to the engine case. but the engine only sputters for a second and fuel spews from the carb. We have replaced all filters and drained the fuel tank. pulled the box and checked for water contamination (none). also have good compression both cylinders about 135 and 137.Any Ideas??

Mike Jensen
Denver Co. :(

[Bustoff]

Re: 1996 Sea Doo Gts won't start

Sounds like your needle valves are in need of attention..

[frankey01]

Re: 1996 Sea Doo Gts won't start

IF you can get it started with the other carbs installed then it is not ignition. I would do what I did and completely rebuild the carbs including the needle valve assembly. It worked for me now I just need to tun it in to run correctly, but TS may have found out my mistake for me.

[miknjan]

Re: 1996 Sea Doo Gts won't start

Both carbs work great on the one ski that didnt get turned over needles seems to be fine. I am not familiar with the ignition on these machines.Im wondering if there are 2 circuts to the ignition 1 is a start and one is a run. because as soon as it fires like it wants to run, it just dies.... like no spark. hence to wet fouled plugs. I might try and swap the whole ignition boxes just to see if the problems follows because we do know the onw ski works great ,but was hoping someone has had this problem before.:o

[1fastski.com]

Re: 1996 Sea Doo Gts won't start

try pulling the boots off the spark plug wires and cutting back the wire just a little to get fresh wire showing , then twist the boots back on . also make sure you have NGKBR7ES also make sure you do not still have water in the engine . it sounds like you do . you can gound you spark plug wires on the grounding post and have you spark plugs out and put your fingers over the holes and crank the engine over , see if you get fuel or water on your fingers .

[miknjan]

Re: 1996 Sea Doo Gts won't start

Thanks 1fastski it sure sounds you know what your talking about, I've read alot of post here that you have helped on. Is there a way to check the engine for water?? Like a drain plug??? or do you just lick your finger after plugging the park plug hole:D ?? didnt get around to swapping the gray boxes today(sun) will research the water in engine a little more. Thanks!!!

[DaveG]

Re: 1996 Sea Doo Gts won't start

When our '92 gts had those same symptoms (the ski would try to start and had wet / fouled plugs) it turned out to be a stripped rotary gear.

Dave

[miknjan]

Re: 1996 Sea Doo Gts won't start

Thanks DaveG are rotary gears hard to replace (meaning special tools needed) or is it something a decent mechanic can figure out??

[DaveG]

Re: 1996 Sea Doo Gts won't start

I'm not sure exactly how dificult it will be - we just replaced the engine as it was an SBT engine under warranty.

Check below as there is a long thread on dooing it to a '91-'92 SP which should be a very similar procedure.
Dave

[mikey20]

Re: 1996 Sea Doo Gts won't start

you can pull off your intake to check the rotory shaft. it shouldn't have much if any play and should turn smoothly with the rotation of the engine.

[miknjan]

Re: 1996 Sea Doo Gts won't start

does anybody have a photo /diagram /drawing of the puller mentioned. in one of the post about the rotary gear?? I have access to a machine and sheetmetal shop so manufacturing one shouldnt be a problem just need an idea of what to make.:)

[Bill O'Neal2]

Re: 1996 Sea Doo Gts won't start

You can go to any Sea Doo dealership and look at their RV shaft puller or a picture of one that is in every Sea Doo Service manual in the tools section.

To make one, you need a 1.5 inch piece of pipe, 2 inches tall. Weld a plate on one end. Drill a hole in the center of the plate so a 6mm bolt will slide through the hole. That is all you need other than a 6mm x 50mm bolt and some 6mm washers ( about 10 washers).

Place the "cup" over the rv shaft after you remove the retainer snap ring that holds it in the cases. Screw the 6mm bolt through the hole in the cup and into the end of the RV shaft, using some washers between the cup and the bolt head. Tighten the bolt. It will pull on the shaft as you tighten the bolt. Go as far as you can , then remove washers and continue tightening until the RV shaft comes out of the side of the motor.

That is the "official" way of pulling the shaft.

Now, here is how I do it. Using a dent puller with a 6mm bolt in the chuck, I screw the 6mm bolt into the end of the shaft and start slamming the hammer as though I was pulling a dent from a fender, only a little harder. The RV shaft pops right out of the cases.

[miknjan]

Re: 1996 Sea Doo Gts won't start

Okay....I guess this weekend we are going to pull the engine and check for water and rotary gear seeing as mother nature decided to snow on us I have read that when reinstalling the engine I'll need to realign the motor to the output shaft. Is it something that I can get around by marking the alingment before removal or do I need to but the tool?? Any help would be greatly appreciated. ALmost at wits end!!!

[Technical Support]

Re: 1996 Sea Doo Gts won't start

As long as it's the same engine going back in, and it's aligned to begin with - yes just note where all the shims are.

What's snow?

[frankey01]

Re: 1996 Sea Doo Gts won't start

I believe from previous postings that if you remove motor without removing the mounts that you are able to remount without the tool and you dont have to buy the tool you can rent it from SBT go to their homepage and look it up in products