Superjet 650 Propblem???

[dirkdiggler]

I went to test me 1991 Superjet compression today and it seemed to have a problem!!

The ski has good start/stop switch
New battery

When I hit the start button the motor does not turn over but I do hear a little "pop" noise in the electrical box when ever the button is pressed. Then after about 5 presses of the start button and 5 "pop" noises later the ski starts turning over like normal. Then I check the other cylinders compression and I get the "pop" noise everyother press of the Start button.

When the ski does turn over I do NOT hear any bad/unusal noises from the starter.

Any Ideas????? Bad ground, starter dieing etc......???

 

[oxnard111]

check your grounds first... clean the ground on the battery terminal. Then check the ground on the starter... it is hard to get to though.

A quick check if you have another battery cable is to hook a temporary ground from say the exhaust manifold to the battery and see if it keeps doing the "pop" noise. that will help you tell if you have a bad ground connection or possibly even a completely bad ground cable.

 

[dirkdiggler]

can the pop noise be something broke in the Electrical box ??

 

[oxnard111]

can the pop noise be something broke in the Electrical box ??

could be, but not likely b/c it is an intermittent problem. but that doesn't mean anything. wydopen opened an ebox once to see one red cable completely snapped off the post it connects to inside the ebox.

 

[meatball]

the clicking is probably the solenoid but from what you describe, it seems like your start/stop switch, Usually when they go, they go out, and if its dirty then it will be intermittent, but corrosion or something else could have caused the solenoid going off, which means that the circuit is not complete.

Go over a checklist

If you have done it, then disregard it (don't assume that every things good even if its new when you are diagnosing, barring exceptions)

-Try and short the starter by taking a jumper from the negative and tap the starter mounting and see if it turns over. If it does, then its your circuitry

-If its the circuitry, its probably the ground on the starter. Or the start switch, those things have a very loose lifespan and can fool people (as it has me). If you can see no problem with the ground (paint corrosion, etc.) then its most likely the switch if it turns when you short it.

-If it doesnt turn when you short it, well... Its the battery.

 

[dirkdiggler]

Whats the easiest way to remove the 650 motor??? Should I remove exhaust first then reomove engine?? Or....should I remove the engine with the exhaust still attached???

I am going to replace my ground cable and motor mounts while I have the motor out!!

Where can I get a cheap marine grade ground cable from???


Thanks for te help!!

Anyone know a direct email address to an admin on PWCToday.com??? I cant remember my password to log in and for some reason its not emailing me when I request it. Its been three days and still no email with user name and password!!

 

[BBYamaha]

seems like pwctoday email is screwed up, I to have recieved no emails for 3 days maybe the will figure it out in a few days

 

[chrisdoc0608]

take the exhaust off then remove motor mount bolts and disconnect fuel and start stop lines... i just take the e/box out with the motor so i dont disconnect anything from it. dont forget the throttle cable to the carb either. and make sure to note where your shims are at so you can put them back in place once you are done

 

[chrisdoc0608]

seems like pwctoday email is screwed up, I to have recieved no emails for 3 days maybe the will figure it out in a few days

i asked abt it in the site feedback section but no real response :Thinkingof_:

 

[dirkdiggler]

what is the best way to remove the Exhaust??? I would like to replace very few gaskets if possible!!

Any ideas on where to buy the waterproof Ground cable???

 

[chrisdoc0608]

leave the head pipe on and disconnect the rest, so if it is stock then leave the large thing that says yamaha on it on, if am remove the disconnect the mid section from the head pipe and remove it and tail section of the pipe

 

[dirkdiggler]

650 engine removal

I am about to place and order for some parts!!
What gaskets will I need for removing exhaust parts when taking out the motor??

To be honest, after looking at my exhaust on the 650, I cant even figure out how to get this thing apart!!

What needs to come off in order to remove motor??

 

[meatball]

First off, do yourself a HUGE and buy a Clymer for about 30 bucks. Then it explains everything however.

For the time being, if you dont have a good memory of where ******** goes (and its your first time) leave it alone. You dont need to forget something and have screws missing or elsewise. Anyways, I usually remove the headpipe, then unbolt the exhaust manifold. OR! If you have the extensions, PLUS a universal (that allows you to loosen and tighten around corners) you can get the engine out just by taking the headpipe out and then using whatever works to get to the motor mounts. It takes experience, a manual is necessary for your first time.

After 6-7 engine swaps, if your like me, they take about an hour or so. (I also have a cherry picker in my shop though, so replacing motor mounts is a breeze! I just lift it slightly up and slide em in!)

 

[meatball]

Better idea, heres a detailed guide compliments of SBT

http://www.sbtontheweb.com/pdfs/y650701x.pdf

PS- still get the manual. They help a lot.

 

[dirkdiggler]

I can see/get too all the mounts with exhaust attached to the motor. Is there a reason why I should not remove motor with exhaust attached???

 

[chrisdoc0608]

with out the exhaust fully attached its easier to maneuver the motor out of the hull. just give it a shot with the exhaust on if you think you can get to everything, cant hurt to try

 

[wetjet701]

just take loosen all the motor mount bolts and replace them 1 by one, And then you really don't gave to remove the exhaust to replace the battery cable. That way you don't get yourself in to, too much work

 

[dirkdiggler]

with the exhaust attached, I can access the 1 bolt holding the motor down to the mount but cant get too the motor mount bolts! I cant get to the ground cable on the starter with motor still in the haul!

 

[wayne]

remove motor mount bolts
remove battery
remove hose clamp on exhaust and remove hose from exhaust
unbolt ebox and lay on engine
take off coupler cover
remove water line from bulk head
remove carb lines and choke cable or primer at carb
lift engine out

then you can sit engine on its side and loosen the bed plate on the starter side and not have to replace any gaskets. i have done this with no issues.

just remove the one bolt that holds the engine to the motor mount.

remember to label your shims for each motor mount so that you get them back in their proper places.

 

[dirkdiggler]

Thanks Wayne!!

Have you done it this way before??