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Question

I have a 1996 polaris jet ski that was running fine. My daughter was turning to go the other way and all of a sudden it died. On the display it said error went to all 0's and then the red light flashed several times. After that when you tried to start it, it just went click, clunk. We got it home and I found a loose battery cable, tightened it and recharged the battery. I hit the reset button on the mainbrain and tried to start again. It did the same thing. So i unhooked the battery cables and let it sit for 15 minutes, hit reset on the mainbrain and then put it all together. It is still doing the same thing. I am at a loss.

Submitted: 153 days and 23 hours ago.
Category: Boat
Value: $15
Status: CLOSED
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Posted by Jeremy Railsback 153 days and 23 hours ago.

Answer

Hi,

Pull out your spark plugs and tell me what the ends of them look like,

Brown, Gray, Black??

Remeber which cylinder each plug came out of.

 

153 days and 23 hours ago.

Reply

Front one is brownish black, middle one is more brown, back one is more black - by the way this is a sl780. I just put new ones one and only rode for one day and that is when this happened.

Posted by Jeremy Railsback 153 days and 23 hours ago.

Info Request

With the spark plugs out will the engine turn over by hitting the start button?

153 days and 23 hours ago.

Reply

No. It clicked twice and then clunk and went back to click clunk......Surprised It will not turn over

Posted by Jeremy Railsback 153 days and 23 hours ago.

Answer

Can you remove the tether cord and reach down behind the engine and try to spin it by hand?

I just want to make sure you don't have a seized cylinder.

153 days and 23 hours ago.

Reply

okay, can you please tell me how to remove the tether cord and exactly what to spin. If this were a car I wouldn't have that prob. However, I am jet ski retarded...lol

Posted by Jeremy Railsback 153 days and 23 hours ago.

Answer

That's ok

The tether cord is the cord that you wrap around your wrist and plug into the handle bar.

It's the kill switch of sorts if you fall off the ski.

That's just a precaution .. I don't want the engine to magically fire while your hand is down in there.

 

Now on the back side of the engine. (towards the back of the ski), There should be a black plastic cover that goes over the drive shaft .

Probably has a hose clamp holding it tight.

You'll want to remove that so you can see the drive shaft.

It's just a straigh shaft out of the back of the engine and goes out through the bottom of the ski.

You should be able to grab ahold of it and spin the engine over with the spark plugs out.

 

153 days and 23 hours ago.

Reply

OKAY - we are almost there. I followed what you said, it acted like it was stuck so i got a pair of vice grips to turn it, it loosened, i tried turning it over and it was trying to and it siezed again. So we are getting somewhere! I did this a few times but keeps siezing. Now what? You're awesome by the way - well, depending on this next answer - lol.

Posted by Jeremy Railsback 153 days and 23 hours ago.

Info Request

are the spark plugs still out?

153 days and 23 hours ago.

Reply

yes

Posted by Jeremy Railsback 153 days and 23 hours ago.

Info Request

uh oh.

 

Ok get out a 10mm socket and remove the 8 bolts that hold down the water manifold that runs across the top of the cylinders.

Then get get out a 12mm socket and remove the rear cylinder head first.

then middle then front.

Then turn it over some more and look down in the cylinders to see if you see any grooves in any of the cylinders.

 

153 days and 22 hours ago.

Reply

OKAY - that was scary - lol. I did just as instructed. I am going to call the back cylinder No. 1 the middle No. 2 and the one at the front of the watercraft No. 3. I fired it off and cylinder No. 1 doesn't move. No. 2 and No. 3 worked fine. When I pushed down on No. 1, it eventually moved up but never went down, the piston remained the same. I did not see any grooves in the cylinders. When the piston was down it would try to seize but as long as it was up it didn't. I also noticed some metal debri on top of the piston.

Posted by Jeremy Railsback 153 days and 22 hours ago.

Answer

ok so the back piston doesn't move.

 

You're doing fine... Just don't turn it over anymore.

Disconnect and remove the battery from the ski.

Then you'll need to remove the 3 bolts that bolt the exhaust manifold to that cylinder.

and the 4 bolts that hold that cylinder down to the block.

 

This will allow you to remove that cylinder.

Since the pison doesnt move you either have a broken rod, or piston.

By removing the cylinder we'll find out which it is.

 

153 days and 21 hours ago.

Reply

OKAY - Jeremy, it is a broken rod and it took chunks of the manifold with it on the inside, it didn't put a hole anywhere just chewed where the cyliinder meets the manifold. I am assuming it is the rod. There are two circle looking things and the medal is stuck in the middle. The rest of the chunks were sitting on top. Happy Father's day by the way.

Accepted Answer

Yeah that's terrible, but atleast you know what it is.

Happy Fathers day to you do!

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Expert: Jeremy Railsback
Pos. Feedback: 100.0 %
Accepts: 
Answered: 6/22/2009

Marine Mechanic

YAMAHA, MERCURY/MERCRUISER, HONDA, SUZUKI, VOLVO-PENTA, SEADOO, POLARIS CERTIFIED

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