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  1. #1

    Please help ASAP! 96 XP ran fine all day, died on hose abruptly! Won't start!

    Please help... my wifes 96 XP 800 just died and we have NO idea what happened. We ran it for the first time today out in the delta and it ran great all day. We get it home and hook it up to the hose and after about 2-3 minutes of idling on the hose, it just DIES. I mean, not putter putter die. I mean, dead.

    Afraid that I water-locked it somehow, we took the plugs out and tried to start it up. No water came out of the plug holes, but instead you hear this high-speed clicking. Kind of like when yer a kid and you put a paper cup in your tire on your bike. It won't start now, and we're terrified somethign really bad happened. We're supposed to go up to Trinity next weekend, and we literally just spent about a grand on the ski last year (carbs, impeller, all new seals, etc etc etc).

    I'm working on it right now, so any immediate help would be greatly appreciated!


  2. #2
    XPTEX's Avatar
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    sounds similar to my problem with my 96 XP... Ran fine then died on me in the water... when i tried to restart got that same noise your describing. the bindix might be bad.. good thing is on the starter the bindix is built in so i changed out the starter and that worked so it could be your starter.

  3. #3
    Quote Originally Posted by XPTEX View Post
    sounds similar to my problem with my 96 XP... Ran fine then died on me in the water... when i tried to restart got that same noise your describing. the bindix might be bad.. good thing is on the starter the bindix is built in so i changed out the starter and that worked so it could be your starter.

    What the heck is a bindix?

    Ugh... things just got worse I think . I had pulled the plugs and spun the motor, and it made the funny noise I talked about, but spun. Well we put 1 plug back in and then put the compression tester on the other plug and tried to spin the motor. It wont even turn over now. It'll spin about 5 degrees and then jams stopped. Could I have somehow caused this, or does it sound like maybe a bearing in the motor was just 'ready to go'?

  4. #4
    XPTEX's Avatar
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    if you want you can check the motor cylinders by taking off the protector plate.. backside of motor bottom... has 2 wingnuts plastic parts.... remove that then grab your driveshaft and see if you can turn i back anf fourth.. if that turns your ok with the engine... it only turn alittle you wont be able to rotate it all the way... it really sounds like a bad starter when was the last time that was changed? and i know where you can get one cheap 60 bucks and its easy to replace

  5. #5
    Quote Originally Posted by XPTEX View Post
    if you want you can check the motor cylinders by taking off the protector plate.. backside of motor bottom... has 2 wingnuts plastic parts.... remove that then grab your driveshaft and see if you can turn i back anf fourth.. if that turns your ok with the engine... it only turn alittle you wont be able to rotate it all the way... it really sounds like a bad starter when was the last time that was changed? and i know where you can get one cheap 60 bucks and its easy to replace
    So I can turn the motor back and forth a tiny bit ... mabe 10 degrees each way? I'm looking into a bad starter ... but would that cause the motor to die while it was running on the hose? I mean, if the 'bindix' went bad, could that do it?

    I'm trying to find instructions for removing the starter... I removed the two main bolts with no luck.

  6. #6
    Ridin' the Rancocas 04RXP22's Avatar
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    Same thing happened to me on my 97 SPX I had.

    Replace the Started Relay.

  7. #7
    Ok, I took some pics. I took out the starter and I don't see anything obviously wrong. Can anyone let me know if anything is missing? I also posted a video showing how much the motor will turn left and right:

    http://snoopy.wiredgeek.net/~mwise/g...246151da4d8c42



  8. #8
    Ridin' the Rancocas 04RXP22's Avatar
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    You go to start it and all you hear is clicking..... It's the Starter Relay. Not the starter. If it was the bendix, the starter would still spin but not engage. YOu would hear a whirring noise rather than a clicking.

  9. #9
    Quote Originally Posted by 04RXP22 View Post
    You go to start it and all you hear is clicking..... It's the Starter Relay. Not the starter. If it was the bendix, the starter would still spin but not engage. YOu would hear a whirring noise rather than a clicking.

    Ok, I tore it apart some more and found the problem... I took the carbs off and noticed a few metal shavings in the bottom of the intake manifold tubes, shown here:

    http://snoopy.wiredgeek.net/~mwise/g...serialNumber=1
    http://snoopy.wiredgeek.net/~mwise/g...serialNumber=2

    Next I took off the rotary valve cover... and found the problem. The rotary valve was binding up because the 'plate' that rotates on the gear got all gummed up with some metal bits and jammed. Though the plate could easily be replaced, it looks like it did some damage to the two surfaces that it splits. I'm not sure what to do at this point ... can these parts be replaced?

    Here's the first bit of damage I noticed:
    http://snoopy.wiredgeek.net/~mwise/g...serialNumber=1

    Here's the back of the rotator valve cover plate:
    http://snoopy.wiredgeek.net/~mwise/g...serialNumber=1

    Eeek
    http://snoopy.wiredgeek.net/~mwise/g...serialNumber=1
    http://snoopy.wiredgeek.net/~mwise/g...serialNumber=1


    Once the 'plate' was removed, the motor turned freely, but you can see the damage:
    http://snoopy.wiredgeek.net/~mwise/g...serialNumber=1



    (Additionally, I took some movies of the crankshaft rotating pretty freely once we got the rotator valve out. I noticed a slight bit of 'binding' right at the same portion of the rotation each time. I tried to take a movie to demonstrate it, please check it out...

    (vidoes are still uploading.. all pics can be found here)
    http://snoopy.wiredgeek.net/~mwise/g...ken/?g2_page=4

  10. #10
    The obvious parts I should replace look like these:

    290924502 VALVE-ROTARY $42.49 $42.49
    290831765 O-RING $7.49 $7.49
    290810738 COVER-ROTARY $176.99 $176.99
    SubTotal $226.97
    Type of shipping & handling: Standard Shipping (5-10 days)


    But my concern is the damage to the block... is there any way to pull that piece out and replace it, or if I can sand it smooth? or something?

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