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1997 Sea-Doo XP -Engine Won't Turn

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  • 1997 Sea-Doo XP -Engine Won't Turn

    I have a '97 Sea-Doo XP that has been in storage for four years (yes, four years). I bought it new in 1997 but rode it very few times. The machine at best has 48hrs running time on it. The engine is so clean that you can just about eat off of it (really) I've always taken care to spray Sea-Lube into the opening where the rubber plug on the airbox is located. I have always done this before shutting it down. I've also taken care to grease everything on a regular basis. The machine has been quite reliable too. I've always 'babied' it.

    I won't get into why I had this machine in storage for so long, but I just decided that I should get it running this year. To my dismay however, the starter solenoid kicks out but the engine does not turn. All I hear is the starter solenoid hitting the flywheel. The engine does not turn. I removed the spark plugs and pointed a flashlight down the spark plug holes but I see no evidence of rust or corrosion. The engine does not turn without the spark plugs either. I am not a Sea-Doo mechanic and have limited marine engine knowledge but I worked for Chrysler for a number of years as a mechanic. So, I do have mechanical knowledge. I just need some ideas besides the engine itself that would cause what I have explained. I think starting simple is the best approach here.

    The machine has been stored in a warm dry environment for the last four years so, it's not like it's been subject to harsh elements. I just can't imagine this engine being seized with the way I've taken care of it. I'm hoping there is simpler explanation. That's why I'm asking advice from those who have more experience. If anyone knows of a checklist that I can try for process of elimination, I would be very appreciative.

    Thank you.

    fast586
    Last edited by fast586; 08-03-2005, 09:14 PM. Reason: grammerical errors

  • #2
    Re: 1997 Sea-Doo XP -Engine Won't Turn

    After 4 years of storage i'm pretty sure that you'd have to rebuild the carbs without question. A lot of people rebuild their carbs on a regular basis. The fact that yours has been in storage probably is more of a reason to give them some attention (especially if they were kept dry-ie: no fuel to keep them wet). I'm just saying this because even if you do get the engine turning, your carbs may not be in good condition and may cause a problem.

    The engine. Well, after 4 years i'd expect that you should do the following:

    1: pour 1 oz of seadoo oil into each cylinder and keep the spark plugs removed.
    2: With the jetski unarmed (ie: Don't attach the key), remove the PTO guard and try to turn the engine gently via the PTO. This will get the oil to lube the internals of the engine. After that you can try and crank the engine using the starter motor-i just thought it'd be better to get things moving slowly first! Wipe up any oil that gets spat out of the spark plug holes and reinstall the plugs (may need to be replaced after 4 years).
    3: You engine may not be turning due to a dead battery. After 4 years in storage, i'd be guessing that the battery is dead and although it may register a good voltage on a multimeter (no load), it may not perform well when placed under load. IE: the voltage would drop to an unacceptably low level and would not turn the starter.
    4: You engine may also not be turning due to the bearings that exist between the PTO and the jet unit (including). Without doubt, you should replace your jet pump fluid (probably before running) and get all bearings checked. These bearings may have seized during the storage period if not lubed properly.

    **Just 1 thing: if you have connected your battery to your ski with jumper leads then make sure they can handle the current drawn by the starter. Jumper leads that have too small a gauge willl have a poor current capacity and you will get a large voltage drop across them. Thus the started will be deprived of enough power to turn the motor.

    Hope this helps. You'll get it going. I'd be looking at a dead battery first and get it lubed initially before running full ball to prevent engine wear:emoticont

    Comment


    • #3
      Re: 1997 Sea-Doo XP -Engine Won't Turn

      Thank you for the advice Ozzie Sea-Doo

      I forgot to mention that the battery is new. So I've got that covered. I haven't tried any of the other things you make mention of though. I will give it a go. I am also in the process of looking for a comprehensive repair manual for this machine too. I've located a number or sources. You also mentioned turning the PTO after removing the guard. I had been trying to locate a place where I could attempt to manually turn the engine. So, I very much appreciate your advice and will follow up all your leads. :emoticont

      Thanks again Ozzie Sea-Doo

      fast586

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      • #4
        Re: 1997 Sea-Doo XP -Engine Won't Turn

        Under the shock absorber under the rear of the seat under the rear hatch you will find a black cover with 4 bolts and nuts holding the cover on. Loosen the four nuts and lift the square black metal cover. Under it you will see the rear driveshaft coupler. Using a prying device ( Big screwdriver ) pry and turn the driveshaft. If the driveshaft turns, so will the crankshaft. If it turns you have a starter problem. If not, either the pump or a driveshaft bearing, or motor is froze with rust. Remove the pump and try again.
        Last edited by Bill O'Neal2; 08-03-2005, 08:55 PM.
        Bill O'Neal <br>
        WCM
        <a href="http://www.watercraftmagic.com"

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        • #5
          Re: 1997 Sea-Doo XP -Engine Won't Turn

          Thanks for your suggestions too Bill O'Neal 2. I very much appreciate all the quick responses in this forum. Tomorrow sounds like it's gonna be a busy day. I'll be trying out all these very helpful suggestions from both Ozzie SeaDoo and yourself. ;)

          fast586

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          • #6
            Re: 1997 Sea-Doo XP -Engine Won't Turn

            no worries, glad to help.....You did grease the driveshaft bearing before you put it into storage right? That's the grease nipple on the drive shaft (just after the PTO on the inside of the hull-it'll probably be hidden away under your PTO cover). If you didn't that could be your problem-ie: a bearing could have seized. Also your jet pump may have a problem with a bearing which could also be causing the problems. Let's just hope that it is a bearing because they are way cheaper to repair than a whole engine!

            Also, make sure you charge your battery if you are constantly placing it under load to keep it in good nick. Good luck.:emoticont

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            • #7
              Re: 1997 Sea-Doo XP -Engine Won't Turn

              Hi Ozzie SeaDoo

              There is a hardened output shaft with a rubber convoluted collar down below the shock area but inside the same compartment where the battery is located. The shaft has a grease fitting on it. If that's the one you are referring to. yes I did grease that shaft with Sea-Doo marine grease before storing the machine. If you're referring to another shaft hidden away under a metal cover in the same general area, then no I didn't. I'll be removing the metal cover for the PTO today to check it out. Needless to say, if by chance I get away without spending any major money here, I will be sure to pay much better attention to things I didn't know I had to pay attention to.

              You also mentioned a possible problem with the jet pump bearing. When you mention jet pump, I suspect you are referring to the impeller or blade which provides propulsion ability?

              Thanks again for all your help Ozzie SeaDoo!

              fast586
              Last edited by fast586; 08-04-2005, 10:58 AM. Reason: Spelling

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              • #8
                Re: 1997 Sea-Doo XP -Engine Won't Turn

                Hi again,

                Yeah, it looks as if you have properly greased your driveshaft using that little grease nipple and the seadoo grease. When i say the jet pump i mean the black pump which is bolted onto the back of the ski (on my 95 XP it is about 300mm long, 200mm wide and bolts onto the back of the hull via 4 bolts). That entire unit is called the jet pump. You can remove it by undoing the bolts and tapping gently from side to side (not more than a few mm's to break the seal). Then use backward force to pull the jet pump unit off-without pulling it to one side (ie: just pull straight back). This will remove your jet pump unit.

                After that is removed, you should see the water intake on your ski and the driveshaft will still be there. Now.....if it is a seized bearing in the jet pump unit (which youn have now removed) then you should be able to turn the motor-use your hand to try turn the PTO so you can exert enough torque to turn the motor. The spark plugs should be removed for this so that you don't have to overcome the compression as the pistons approach top dead centre. ALSO....YOUR ENGINE HASN'T MOVED IN 4 YEARS-YOU NEED TO MAKE SURE IT IS PROPERLY LUBED BY POURING 1 OZ (ABOUT 30ML) INTO EACH CYLINDER TO PREVENT DAMAGE. Hopefully you'll be able to get is moving. Give it say 10-20 turns by hand first to gently get the engine re-lubed.

                Your jet pump unit will require new jet pump oil and i'd suggest getting it checked out. If a bearing has seized in it then you won't be able to turn the impeller by hand. I really recommend getting your carbs looked at. They are probably stuffed after 4 years and if you are not completely sure, then just get a full service done at your local service shop. It's worth it for piece of mind.

                Lastly (i promise you'll finish reading eventually!), i've only had my ski for 1 year and am just giving advice on what i know. If you need specialist advice then refer to SBT tech or Bill O'Neil-They know this stuff like the back of their hands. That aside, i'm happy to help you with going by my experiences. Let us know how it goes.:emoticont

                Comment


                • #9
                  Re: 1997 Sea-Doo XP -Engine Won't Turn

                  Well Folks

                  After much anticipation, I found the reason why the engine in my ski won't turn over. Much to my dismay, the cylinders and areas around the pistons are a tad corroded. I started tearing down the engine this weekend. I was able to free one piston but the other is still not moving very much. I can see both rotary valve ports but I haven't been able to get the cylinder casting off. I can see the connecting rods and part of the crankshaft couterweights which by the way, look in perfect condition. It's just that the pistons for some reason, decided to be difficult. I'm having a very difficult time trying to free the forward piston from the cylinder casing, because of the corrosion around either the piston or on the cylinder wall.

                  I'm also trying to locate some type of lubricant that might loosen the corrosion and free up the forward piston so that I can remove it more easily. At a minimum, I'm looking at pistons, rings, upper end bearings and a good hone job. Plus, I'll need to get an upper end gasket set and all the necessary o-rings. My only hope is that nothing gets damaged while attempting to free the one stuck piston.

                  I removed the pump and everything was fine. I took it apart anyway, just to make sure I wasn't missing something. I'll just need to replenish the gear oil and replace the o-ring on the cone where it seats. I didn't know anything much about Sea-Doo engines when I started but I'm learning real fast-thanks in part to you folks!

                  This is really a sin though, to have to go in this deep with a machine that has no more than 48 original running hours on it. I just never thought anything like this could happen. Well, I know now that a marine engine is much different than any other engine and requires very special care. I want to thank you again for all your help Ozzie Seadoo and Bill O'Neal2.

                  fast586

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                  • #10
                    Re: 1997 Sea-Doo XP -Engine Won't Turn

                    Use PB Blaster. Let it sit for an hour and give it a shot. If not, use the blaster again and let it sit overnight. That should do the trick.
                    Dan Solie -
                    04 RXP (the "Instigator")
                    94 xp (freestyle mods)
                    95 xp (faster than the 94)
                    JS550 (the toothpick & the loaner)

                    For FREE Seadoo Manuals - Click HERE!!!!

                    http://www.tripleateam.com/water/v/U...ery/Dan-Solie/

                    **** Please do not PM me. I don't do PM's.... Please post your question on the correct forum so that all can see and learn. Thanks! ****

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                    • #11
                      Re: 1997 Sea-Doo XP -Engine Won't Turn

                      Thanks for the heads up dsolie. I'll try that and let you know how I make out. :)

                      fast586

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                      • #12
                        Re: 1997 Sea-Doo XP -Engine Won't Turn

                        That's a bugger, sorry to hear that the engine is the problem after all!

                        Look on the bright side-at least your a mechanic and have experience & probably contacts already. You should be better off than the average Joe Blo in terms of getting it fixed properly and at minimal cost. Just make sure you do everything (rebuild that jet pump) and you'll be happy with a reliable ski. Yeah, i didn't realise how much care my 720 needed when i bought it-know now after lots of work.

                        Hope it all works out well for ya:emoticont

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