2004 STX 15F dead engine

chiayf418 · 06-19-2009, 10:55 AM

I was riding my PWC on the sea last sunday for more than 2 hours. Everthing is OK and the ride is smooth. But on the way back the engine stopped suddenly. I tried to restart but nothing happened. I can't hear a slightest click of the starter. I tow it back and check the battery and fuse . They are all OK. The cable leading to the starter is not loose. The stop button was opened and it is OK. Nothing in the jet pump or water intake area. What else can I do? Can I bypass the switch to try turn over the engine? How can I do this? I can't flush the engine and I worry about the salt water in the cooling system now.

chiayf418 · 06-21-2009, 10:40 AM

I short the starter relay today and the starter cranked well. I also connected the battery positive lead to the wire from the push start button. It cranked well too. The enigne did not start. So I am suspecting the power some how can not be supplied to the ignition and starter system. I disconected most of the connectors and pull the harness out but it lookd intact . When I disconnect a grey connector with 16 pins( leading to to ECU) I found one of the pin broken at the root (I am not sure whether it is due to the disconnecting force. It is hard to pull that connector apart)
The broken pin is for a red wire with blue marks spaced about 1 inchn apart.
Can some one advise what to do next. Is there any wiring diagrm that I can refer to.

chiayf418 · 06-28-2009, 04:37 AM

I bought the service manual. I found that the red wire has no continuity at brown joint connector R (refer wiring diagram 14-12). But The the connector is kind of seized and could not be pulled apart. Any good idea please how to solve that problem, or do I have to cut the 4 red wires to bypass connector R?

chiayf418 · 07-03-2009, 09:02 AM

Since I got no better suggestion from the forum, I cut the red wires and joint them outside the joint connector. Reinstall one broken pin at 16 pin connector (grey) by soldering. reconnect all the connectors. Started up fine. Flush the cooling system for 10 minutes. Tomorrow I will re-wrap the harness.

chiayf418 · 07-03-2009, 09:04 AM

One more question. Is the regulator supposed to be hot when the engine is running?

dank · 07-08-2009, 10:12 PM

It should be warm but if it gets hot then the battery may be drawing too much current. It should blow a fuse.