1996 GSX restore from sitting under a tree for a decade

[JuliusCaesar]

Couple things…..:
Picked up a free 1996 gsx that has been sitting in a field for probably 12 years with no key. It’s a mess but I like to restore so it’s my new project. PO said it ran when parked and they had issues with it fouling plugs. Sometimes it was mag plugs and sometimes pto plugs. Local dealer at the time couldn’t figure out what was wrong. So they parked it.
Engine has never been opened that can tell. Pulled carbs off and while some green on the choke and throttle plates, The insides where surprisingly good as jets where clean but seats were not holding pressure and just leaked by. So I’ll need new OSD kits. Must have been non ethanol fuel back then.
Rear electrical box was badly corroded. No resistance on the fuses so that is shot and I have a completely new box with electronics in the way.
Pulled one rave valve and much to my disappointment the engine is full of water. Pistons are seized to jugs. I guess engine is coming out. Pulled pipe and water poured out.
Can I pull the crank out with the Pto flywheel still attached? It’s seized on there I’d buy a crank and Pto flywheel for replacement just wondering if there would be anything in the way?
Intake grate is broken off. Ride plate is still there and pump came out easily. Screws must have come out of the grate and it just broke off. Still a small piece left that’s attached to the ride plate. Does that just come off and can I just insert another one there.
Not sure how many hours are on this as I can’t get display to light up. Maybe because of the shitty rear box. Hate to throw a grand into this and not have it start. Anyways. Hope to have it on the water by July.

 

[mikidymac]

Yes cases can be split with PTO still on.

 

[burtshaver2021]

Well, I have some experience although it is fairly limited but to try and answer your question about throwing a grand into it and not having it run. I think you’re probably best to leave this one alone, not only is it a non runner which is fine but it’s been sitting for possibly 12 years with the crankcase full of water. I would say at best you’re looking in the neighborhood of 1400.00 to get this back on the water. Just rough estimates but say 300.00 for new pistons and rings, 800.00 for new crank, 170.00 for carb rebuild, 200.00 for machining of the cylinders, new fuel lines? 30.00, new fuel selector valve 50.00, have you checked the prop and wear ring? Does it give you 2 beeps with the key inserted? Or does it at least attempt to crank? Like a thud from the starter? I would have a real good look at the cylinders and cases before putting a dime into it, to see if they have froze and cracked, even if they aren’t cracked, I’m revising my estimate to 1600.00 minimum to get on the water. Is the hull in fantastic condition? If it is, might be worth it to keep it laying around and look for another GSX 787 that may have a rougher hull. You could probably buy a running one for the same or less than your going to put in this. If you do decide to restore this, I would like I mentioned check the cylinders and cases for damage, and at least get power to the starter to verify electronics are any good. I have the same one, mine has no spark, good compression. I’m pretty sure this model year was known to have trigger coil bracket that broke causing no spark.

 

[JuliusCaesar]

i would not want to put a TON into the unit. With the water in the engine, i know the crank is shot, but i can find a "used good one" on eBay for a couple hundred, flywheel for $50 and then new pistons for a few hundred. Probably into it for under a G is possible. I would surmise the jugs can be salvaged if it's just the rings stuck. It wouldn't be used very much....maybe 10-15 hours a summer if that. I have a 93 XP that runs well that i rebuilt. just wanted something a bit faster than 43mph. I have a 1997 tigershark daytona that runs about 55 with some mods, but it's not really a great ride if you know what i mean. I'll see how it goes.

Does the intake that goes into the ride shoe just pull out?

In canada, we have some higher prices for used units. The US is the place to grab deals, but with the tariffs and crap, not worth the trip

 

[JuliusCaesar]

Well, I have some experience although it is fairly limited but to try and answer your question about throwing a grand into it and not having it run. I think you’re probably best to leave this one alone, not only is it a non runner which is fine but it’s been sitting for possibly 12 years with the crankcase full of water. I would say at best you’re looking in the neighborhood of 1400.00 to get this back on the water. Just rough estimates but say 300.00 for new pistons and rings, 800.00 for new crank, 170.00 for carb rebuild, 200.00 for machining of the cylinders, new fuel lines? 30.00, new fuel selector valve 50.00, have you checked the prop and wear ring? Does it give you 2 beeps with the key inserted? Or does it at least attempt to crank? Like a thud from the starter? I would have a real good look at the cylinders and cases before putting a dime into it, to see if they have froze and cracked, even if they aren’t cracked, I’m revising my estimate to 1600.00 minimum to get on the water. Is the hull in fantastic condition? If it is, might be worth it to keep it laying around and look for another GSX 787 that may have a rougher hull. You could probably buy a running one for the same or less than your going to put in this. If you do decide to restore this, I would like I mentioned check the cylinders and cases for damage, and at least get power to the starter to verify electronics are any good. I have the same one, mine has no spark, good compression. I’m pretty sure this model year was known to have trigger coil bracket that broke causing no spark.

i've never dealt with DESS so i'm wondering how i can tell whether it get good power to the unit or at least have the dash light up so i can see if electronics work?

i guess i could ohm out the MPEM and see, but there should be an easier way?

 

[burtshaver2021]

i would not want to put a TON into the unit. With the water in the engine, i know the crank is shot, but i can find a "used good one" on eBay for a couple hundred, flywheel for $50 and then new pistons for a few hundred. Probably into it for under a G is possible. I would surmise the jugs can be salvaged if it's just the rings stuck. It wouldn't be used very much....maybe 10-15 hours a summer if that. I have a 93 XP that runs well that i rebuilt. just wanted something a bit faster than 43mph. I have a 1997 tigershark daytona that runs about 55 with some mods, but it's not really a great ride if you know what i mean. I'll see how it goes.

Does the intake that goes into the ride shoe just pull out?

In canada, we have some higher prices for used units. The US is the place to grab deals, but with the tariffs and crap, not worth the trip

I’m not sure about the intake grate, I’ve only ever had the intake grate off of a Tigershark. I would think it would very easily come off.

 

[burtshaver2021]

i've never dealt with DESS so i'm wondering how i can tell whether it get good power to the unit or at least have the dash light up so i can see if electronics work?

i guess i could ohm out the MPEM and see, but there should be an easier way?

Sorry, not overly familiar at all with testing electronics. I’m just as much the helped as I am the helper. I do believe I recall seeing some test procedures for the DESS post in the manual. When I first got my HX as a non runner with no DESS Key, the first thing I did was take the whole machine to my Local BRP dealer and had them program a new key into my MPEM. I think it cost me 150.00 CDN. At that time. If you look around you can find people that do this. West side Powersports is one. Not much you’re going to be able to do without a key, so that will be your first step. I’m interested to see how this plays out, so please let me know how you make out

 

[JuliusCaesar]

Sorry, not overly familiar at all with testing electronics. I’m just as much the helped as I am the helper. I do believe I recall seeing some test procedures for the DESS post in the manual. When I first got my HX as a non runner with no DESS Key, the first thing I did was take the whole machine to my Local BRP dealer and had them program a new key into my MPEM. I think it cost me 150.00 CDN. At that time. If you look around you can find people that do this. West side Powersports is one. Not much you’re going to be able to do without a key, so that will be your first step. I’m interested to see how this plays out, so please let me know how you make out

for sure, i'll keep you posted as a fellow Canuck. FWIW, the PWC in Canada always seems to have a higher price point for skis. In the US they are a dime a dozen hence the reason i'd like to toss a G in this project and see where it goes.

 

[burtshaver2021]

for sure, i'll keep you posted as a fellow Canuck. FWIW, the PWC in Canada always seems to have a higher price point for skis. In the US they are a dime a dozen hence the reason i'd like to toss a G in this project and see where it goes.

I find they are a little less up Muskoka way, but I agree, more here than most places in states

 

[mikidymac]

With water in the engine you are going to have rust and pitting in the cylinders. You are going to need to have them bored oversized with new pistons and rings. Just new rings aren’t going to cut it.

With a good battery pushing the start button repeatedly should wake up the gauges even without a coded DESS key.

Intake grate is just bolted on and sealed with RTV silicone.

 

[JuliusCaesar]

Well we are making progress on the project. Took a hell of a time to get pistons out of jugs. Crank is shot and so is CB. VTS just clicks when.battery is attached. So pulled that and motor works when attached to 12v so must be the box in the vts is no good. Sent jugs out to my buddy to more .5 over. Have used crank and CB from a 1998 speedster on the way fro TX and picked up WSM piston kit on eBay. Total cost so far about $540US including bore.

Engine has never been opened and PO bought it brand new from dealer and only dropped it in The water a couple times a summer. I’d be surprised if there is 100 hours on it but can’t tell without a key which was lost somehow over the years.

 

[burtshaver2021]

That’s about 770.00 CDN that’s some good deals, pistons, rings and gaskets cost me near 400.00 150.00 a hole to bore, make sure they chamfer the ports after the bore and I would chamfer before the final hone

 

[JuliusCaesar]

just an update on this. We are getting closer! grey lines are gone (i didn't change the grey vent lines as there as no need to) and carbs will be rebuilt tonight. Bottom end is back together and need to locate a magneto cover gasket as i ruined the original one tearing this thing done to replace crank and CB shaft. VTS was pulled and outside boot was shot. VTS motor works when i jump it with my battery, but i have a feeling the module is toast, we'll see when i can actually get a key made for this thing.

My son cut, polished and waxed the ski. Looks quite good! Will have to fix the seat as the cover is worn and some of the foam needs attention, but we are getting there. I would say i'd be into this thing for about $1000 Cdn with the crank, CB, bored .5 over on cylinders and new WSM piston kit with top end gaskets, 2 new mikuni kits, VTS boot and new red start button. Pump has clean gear oil in it when i looked but replaced it anyways. Nice little project for myself and the boy and i know he's pumped to get this thing out in the water.....probably in two weeks time. The 1993 xp we restored just doesn't go fast enough for him at 80km/h.

 

[burtshaver2021]

just and update on this. We are getting closer! grey lines are gone (i didn't change the grey vent lines as there as no need to) and carbs will be rebuilt tonight. Bottom end is back together and need to locate a magneto cover gasket as i ruined the original one tearing this thing done to replace crank and CB shaft. My son cut, polished and waxed the ski. Looks quite good! Will have to fix the seat as the cover is worn and some of the foam needs attention, but we are getting there. I would say i'd be into this thing for about $1000 Cdn. Nice little project for myself and the boy and i know he's pumped to get this thing out in the water.....probably in two weeks time. The 1993 xp we restored just doesn't go fast enough for him at 80km/h.

Pics

 

[JuliusCaesar]

pics don't do it a ton of justice, but the boy comes in and looks in the shop and happy with his results.

 

[burtshaver2021]

pics don't do it a ton of justice, but the boy comes in and looks in the shop and happy with his results. View attachment 67828View attachment 67831View attachment 67832View attachment 67833

Looking great, tell the boy I said “nice job”

 

[JuliusCaesar]

it is ALL back together except for the pump. The carbon seal was shot, but hat, clip and boot are good so debating to grab a cheapy off amazon just for the new orings and carbon or i have an extra carrier bearing from my tigershark i didn't use and was thinking of using that with the carbon seal boot and call it a day. Both the shaft of the seadoo and the tigershark are same diameter, so we'll see. Going to get a key made at the local guy here who still deals with older 2 strokes. Probably just get him to take the DESS off completely so that i can use any key to get it started....we'll see how i feel when i get there.

I fixed the guage with some polarized film i picked up on amazon for $9 and it works perfectly. Ski has 227.3 hours which is much more than i thought it did, but in all reality not counting the decade it sat in a field rotting, it was only used for 10 or so hours a summer. The seat still needs to be redone as it's cracked and split from sitting in the sun for so long and i'll either fill the cracks with some expanding foam and new seat cover. With all parts said and done, probably have a grand into it, which is a bit more than i wanted to spend, but it was "free" and a great project for the boy to see how it all works.

Just need to hear it run and mission complete...........now did i remember to turn the low and high speed screws to stock............damn.

*** bonus edit is that the VTS works!***

.Cheers.

 

[JuliusCaesar]

Had my local 2 stroke seadoo mechanic get a key made for the DESS. He got it started, but it needed a new starter solenoid so he put that in for me for just the cost of the part ($55). He said it ran fine on the hose but noticed an exhaust leak from the v band where the pipes join. Yeah, that was a PITA for sure, so I guess I need to go back in and reseal with a bit more copper gasket maker and another set of hands to hold it while tightening each bolt slowly in a sequence and the band. He did compliment me on the rebuild as he said it was real cleanly done. I said thanks for the compliment. I like to rebuild them as clean as possible and as close to factory routing as possible.

 

[burtshaver2021]

Had my local 2 stroke seadoo mechanic get a key made for the DESS. He got it started, but it needed a new starter solenoid so he put that in for me for just the cost of the part ($55). He said it ran fine on the hose but noticed an exhaust leak from the v band where the pipes join. Yeah, that was a PITA for sure, so I guess I need to go back in and reseal with a bit more copper gasket maker and another set of hands to hold it while tightening each bolt slowly in a sequence and the band. He did compliment me on the rebuild as he said it was real cleanly done. I said thanks for the compliment. I like to rebuild them as clean as possible and as close to factory routing as possible.

I’m not sure if the copper ring is the same as in a 717? But I just had mine apart, I annealed the ring and then sanded it with some 800 grit on piece of glass and some wd-40, the ring became thicker with the annealing and that would soften it as well. I just did it with a propane torch till it became red hot.

 

[JuliusCaesar]

Just put it back together with a bit more copper gasket maker. We’ll see. Going to torque it 89 in/lbs