1996 Sea-Doo GSX rebuild

[kmellow]

Hello all,

Two questions number one whenever I start my Sea-Doo it sounds like the starter doesn’t engage? Like it’s just spinning. If I grab the impeller shaft and wiggle it it’s like it re-engages and allows me to start it normally? I replaced the starter once no change. Second question it has been sitting for quite a while and I would like to rebuild the motor is it easier to do that through the seat access or should I consider separating the boat halfs ?

 

[mwat65]

Pull the motor right out of the top opening. After you unhook everything of course. On the starter issue. Are your starters aftermarket? If so there’s your issue.

 

[kmellow]

I bought it from a Sea-Doo dealership? It sounds and acts exactly the same way as before? I’m wondering if there is some broken teeth on the flywheel?

 

[mwat65]

It’s possible that the teeth are worn down or broken

 

[JMAN1]

If you are considering rebuilding your motor I would recommend just doing a core swap for a professionally rebuilt motor. When I broke it down I only saw a $200 price difference between buying all the parts and rebuilding yourself (which will take a lot of man hours and specialty tools or some creativity) and just swapping your current motor with one ready to go. Plus if you buy from the right person they will have thorough reassembly notes and give you a full exhaust and intake gasket kit to go with the rebuilt motor. Did a complete overhaul on my 96 GSX last month. Also I pulled and replaced the motor through the top of the hull opening. It was tricky and having an overhead hoist helped immensely! While you have your motor out is the easiest time to slide your gas tank as well and pull the fuel sending unit to replace the float because mine was saturated and no longer floated.