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  1. #1
    SideFX's Avatar
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    Thumbs up No spark, broken sensor pick up, fix 1996 XP/ 800

    Thanks to the many on-line forums, I was able to diagnose and cure an issue I had with a 1996 sea-doo XP/800.

    This post is mostly image based with a few descriptions to help others whom may encounter the same problem as I did here.
    That being, no spark during a ride.

    Here is a time line of events before it happened.:
    I ride in rough water, sort of like doing slalom in and around the curls of wake.
    I also like getting air-born as well when the opportunity present itself.

    I was out riding, doing my thing, all was well. Then upon taking a sharp left in oncoming wake, the engine flat lined (died).

    There was lots of power in the battery, enough in fact to kill one of those cheapo starters, and it was new.
    So first note, don't trust a cheap starter as the Bendix will eventually fail you. Get a good quality starter. (That said, I reverted back to the original starter to get things 'turning' once again.)

    I paddled my way to shore and began looking over everything under the seat. Everything 'looked' fine, and it wasn't a gas/water separator issue either.
    All the fuses and Beep codes checked A-OK, just no spark at the plugs when turning over.

    So I began searching on-line for tips and clues, and finally narrowed it down to the stator pick up sensor being the issue since there was no reason for it dying, and that it happened during an 'EVENT'.
    I say event, because there is usually a reason why things happen. " The Law of Relativity!" LoL

    Seems that the pick up sensor in the '96 has an Achilles heel, and that is the metal bracket which it is attached to.
    When you land hard, which can happen, rather than feathering down, the sensor can move slightly as it also takes the vibrations.
    As with anything, do that 100, 200, 300 or more times, and things begin getting weaker and becoming more flexible.
    As such, it's just a matter of time before something gives, even motor mounts and exhaust bushings.

    So here are some images of the find, and some efforts I have taken to buy me more time into the future of rough water riding.

    [][][]

    I used RTV Silicone to 'beef' up a spare pick up sensor.
    You will see in the images where the break/shearing happened on the metal bracket once the sensor moved to closely into the path of moving parts.

    If anyone has advice or tips to offer, or even of a better sensor unit solution available somewhere, please add to this post.

    Cheers






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  2. #2
    The early 787 engines had that weak
    Inductive Sensor Bracket. The Bracket
    was updated to a more robust design
    years ago.

    Nice Silicon job !

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