99 Seadoo XP 951 Blows 15 amp fuse from the Starter Solenoid to MPEM

[str8g]

I have a 99 Seadoo XP and was out riding yesterday when the electronics just cut out, no beeps,and the motor cut in and out around three times. I towed it back in to the hoist check the fuses at the MPEM and they were all fine. I checked the service manual and saw there was a 15 amp fuse located in the electonic box with the solinoid and coils, and that fuse was blown. I replaced the fuse and was able to start the motor in the hoist. The RPM guage went to 3 thousand and the speedometer was registering 50 to 60 mph and moved up and down if I moved the throttle in and out a little then the electronics (guages ect ) cut out, then the motor cut in and out around three times. Again it blew that fuse. I would consider replacing the MPEM but am unsure if it is the culprit or if it could possibly a short the wiring or guages ect. Any suggestions on trouble shooting this would be appreciated. Has anyone come across this before ?

[Technical Support]

Re: 99 Seadoo XP 951 Blows 15 amp fuse from the Starter Solenoid to MPEM

Start buy doing an ohms test on the stator. If you need the specs. go to seadoomanuals .net and down load a free service manual.

[str8g]

Re: 99 Seadoo XP 951 Blows 15 amp fuse from the Starter Solenoid to MPEM

thank you. I will hopefully have time to do that over the next couple days. I just installed an aftermarket one this past summer during an engine rebuild but we will see how that test goes.

[Technical Support]

Re: 99 Seadoo XP 951 Blows 15 amp fuse from the Starter Solenoid to MPEM

Tell us how things go.

[str8g]

Re: 99 Seadoo XP 951 Blows 15 amp fuse from the Starter Solenoid to MPEM

Ok finally a follow up, Just to refresh I had rebuilt the engine completely at the end of last season and replaced the stator with an aftermarket stator because two of the coils on the one I replaced were loose. I discovered this during disassembly for that rebuild. I had less than ten hours on the motor and stator after rebuild.
I figured I better remove the flywheel cover just to be sure that there were not any metal fragments from flywheel teeth ect. causing the stator to short to the flywheel. After some research this seems to be a reason to pop that fuse. When I removed the cover see pictures there was some glazing in the flywheel towards the stator coils but to be honest I am not sure if it wasn't that way before. also there was a groove on the bottom of the stator coils see other picture and some of the stator coils look to have gotten pretty hot and it looks to have cooked the insulating coating on those coils. I really could not find any evidence of metal shaving pieces ect anywhere but I ended up cleaning the flywheel and the inside of that case end as best I could with compressed air and a magnet. I then performed the resistance tests on the stator in the cover using the directions from the service manual outside of the Seadoo since it was already removed. There are three yellow wires from the stator. The first test is to check resistance between two of the yellow wires and then from one of those wires to the third yellow wire. These two tests should be between 0.1 and 1.0 ohm. they both passed with 1.0. The next test is the insulation test. For this test using the negative probe from the millimeter to the stator cover or iron body of the stator at the bolts, and the positive end to one of the yellow wires. You test each of the 3 yellow wires to the case. There shouldn't be any resistance at all, each wire had resistance. The stator failed this test. I replaced the stator with a used OE one I had. put everything back together and now I am back on the water.
I will be perfectly honest I am not sure what caused this or if it was something I overlooked in reassembling the engine. The flywheel teeth looked perfectly fine and I couldn't really find anything that would have taken out the stator such as a piece of metal but it only takes from what I can tell is a small fragment of metal 1/32nd to 1/16th in size to short the stator to the flywheel and the fact the flywheel is partially magnetic that is what could have happened. It could also make some sense that it is possible that if the threaded part of the flywheel was damaged from the flywheel puller during disassembly and a piece of thread fell into that area later that that could be a possibility as well but the treads for the puller looked fine as well. I also could have had a bad stator, the tolerances have to be pretty snug to work properly and also not make contact with the flywheel. The good news is I am back on the water and that's all that matters until next time.

My best advice is that if you are servicing any part of the inside of that area is to inspect it thoroughly and do these test for the stator. just to make sure they pass. To fix this I only needed one other part and that was an exhaust gasket. I had to pull the exhaust to work on it but I had gotten in the habit of order a spare one from SBT just to have one on hand just in case I needed one. I also am unsure if I were to replace a stator again if I would use an aftermarket one. Hope my experience helps someone.

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