Super Jet Help: Stator Wiring Grommet Comes Loose = Swimming Back to Ramp

Location
OH
I was riding the superjet Sunday and it was doing fine, got behind a boat and it died instantly. As I was swimming back down the river the bilge pumped put some pretty oily water. So I thought maybe a fuel line had come loose. Got it back to the trailer and noticed the stator wire grommet had come out of place (see picture). It let the stator wires touch the flywheel teeth. The wires were not cut in two but chewed up. I guess it shorted out and that is why I lost ignition. I got the ski running back at the house. So here are my questions for you guys.

#1. What could have caused the stator wire grommet to come out? Blown crank seal?

#2. Is the stator wiring design really as bad as it looks? The wires appear to be less than ¼ inch from the flywheel, even when it is installed correctly. It would seem the wires would be into the flywheel pretty often.

#3. I really don’t want to repair the wires, so can I buy a new wiring harness alone? Or am I going to have to buy a whole new stator?

#4. Anyone know the torque spec for the flywheel crank bolt?

#5. What would cause all the oily water in the hull? Carbs look perfect, no broken fuel lines, everything looks perfect except the stator wire grommet.

#6. Can someone post a link to the harbor freight puller that doesn’t require removing the gas tank? I searched their site but want to be sure I get the one you all are using.

Also, I just ordered a cold fusion flywheel lock, so I should be covered there.
Thanks in advance for your help!!

1.jpg 2.jpg
 
Location
New Jersey
I just removed my flywheel from a 650, and I used the Harbor Freight Pittsburgh Bolt Type Wheel Puller Set Item 69889. I did the work with the motor out, but the puller sits 5-1/4" out from the flywheel.

The wiring near my flywheel is much tighter between the grommet and the stator than what is shown in your photos. Although close to the flywheel there is zero play in the wires.
 

OCD Solutions

Original, Clean and Dependable Solutions
Location
Rentz, GA
That grommet is a tight fit so you definitely have a bigger issue there. Most likely a leaking front crank seal but if you have any epoxy work in there, I'd be checking it out.

All it would take is a small passage of air to let some oil in there to make it slippery, (and soften the grommet slightly), and I'm sure it pops with even less case pressure.
 
Location
Stockton
Looks like your grommets has a broken shoulder too. I put silicone on both side of it when I install and best to just pull the tank, it's not hard don't fight it. Half the Time it's easier and takes less time to do more disassembly than it is to work around stuff
 

227

Its all about the surf!
Location
Oceanside, CA
1) You have to pull the fuel tank to get enough room to pull your flywheel

2) I use a standard 3 place puller that I bought at Sears for about $30 probably 200,000 years ago. It still works perfectly

3) There's no problem with the Stator wire design I think you have a unique case. For any type of Stator repair call John at Jet Ski Solutions http://www.jetskisolutions.com/ You will be happy you did.

4) When reassembling make sure the grommet and the mating surfaces of the case are clean and free of any oil. I also coat all the mating surfaces of the flywheel cover, cases and gasket on both sides with copper heat silicone that you can buy at
Pep Boys or any other auto parts store. When the silicone dries its pretty much impossible to get a leak.
 
Location
OH
I will get the tank and fly wheel off next time I get a chance. I still do not know what caused the grommet to come out. The bottom of the motor is stock. I will upload pictures after the flywheel is out.
 
Location
Stockton
I will get the tank and fly wheel off next time I get a chance. I still do not know what caused the grommet to come out. The bottom of the motor is stock. I will upload pictures after the flywheel is out.

You'll know more when you get it apart I'am sure.

Based on the torn grommet shoulder, I was wondering if something could have come loose inside and came around with the flywheel and impacted the grommet forcing it out and causing other damage? Be interesting to see what's going on in there.
 

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Location
Haiti
second pic in post #1 shows a VERY clean looking flywheel. front crank seal failures i've seen get that whole area pretty dirty. unless the stator grommet failed almost immediately after the crank seal failed.

i'm agree with @Harbor and i'm curious to see if anything came loose in there.
 
Location
OH
Sorry for the delay... I pulled the flywheel without removing the tank or anything at all. Very very easy. Here is the puller I bought: eBay...

Take a look at the new pictures. Everything appears fine to me, so it seems the only problem I had was the grommet popping out. Correct me if I am wrong but looks like a new stator and I am good to go. I don't really want to repair the wires. But since the stealership wants $600 bucks for a stator, I might have to repair them. I found a few stators on eBay for $50, but I am not sure of the quality. Please offer any input on this!! Thanks
 

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JetManiac

Stoked
Site Supporter
Vendor Account
Location
orlando
Sorry for the delay... I pulled the flywheel without removing the tank or anything at all. Very very easy. Here is the puller I bought: eBay...

Take a look at the new pictures. Everything appears fine to me, so it seems the only problem I had was the grommet popping out. Correct me if I am wrong but looks like a new stator and I am good to go. I don't really want to repair the wires. But since the stealership wants $600 bucks for a stator, I might have to repair them. I found a few stators on eBay for $50, but I am not sure of the quality. Please offer any input on this!! Thanks

Why dont you just silicone the grommet in place as others have suggested? You have a 62t stator, it is unlikely the ones you are seeing on ebay are 62t for $50.
 
I will get the tank and fly wheel off next time I get a chance. I still do not know what caused the grommet to come out. The bottom of the motor is stock. I will upload pictures after the flywheel is out.
The crankcase is marked 64V, looks that the stator was replaced at one time. The wires were seriously damaged by the ring gear , when bushing came out. Don't even consider buying a new a/m stator off ebay. Yamaha charge coils are the only ones that last longer than a few tank fulls.
 
Location
OH
Why dont you just silicone the grommet in place as others have suggested? You have a 62t stator, it is unlikely the ones you are seeing on ebay are 62t for $50.
http://www.amazon.com/gp/aw/d/B00AA...076ae8dc&qid=1414716169&sr=8-4#ref=mp_s_a_1_4

There is the link for one with the correct part number according to the dealership. It also has feedback from a guy that put it on an 2008 SJ. It could still be junk. I don't mind to reuse my stator. I was just worried about splicing the damaged wires. Considering the lack of space I was worried about reliability
 
Location
OH
The crankcase is marked 64V, looks that the stator was replaced at one time. The wires were seriously damaged by the ring gear , when bushing came out. Don't even consider buying a new a/m stator off ebay. Yamaha charge coils are the only ones that last longer than a few tank fulls.
I can't say for sure, but I'd be extremely shocked if it has ever been replaced. I am the second owner. The first didn't touch anything on the ski. Bone stock. Mint showroom condition when I got it. But nevertheless I'm not rushing to pay $600 to the dealership for a new one one. I'm going to try to solder and heat shrink the wires. If there is room to fit the repaired wires in there, I should be okay. None of the wires were cut completely in two.
 
Brand new OEM are available for $441 online, and the wiring harness with grommet is available OEM also for $100. But if you don't have luck with your repair, JSS is a great option.

Shoot me a PM if you decide to go with a good used one, we have a few in stock here!
 

JetManiac

Stoked
Site Supporter
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Location
orlando
http://www.amazon.com/gp/aw/d/B00AA...076ae8dc&qid=1414716169&sr=8-4#ref=mp_s_a_1_4

There is the link for one with the correct part number according to the dealership. It also has feedback from a guy that put it on an 2008 SJ. It could still be junk. I don't mind to reuse my stator. I was just worried about splicing the damaged wires. Considering the lack of space I was worried about reliability

Sorry I missed the earlier part about the damaged wires. That stator on ebay is garbage quality.
 
Location
OH
Thanks for all the info. For now I just solder and heat shrinked the 2 damaged wires. I got everything put back together last night. Runs great. I put silicone on the grommet...
 

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