RESTO 1996 SEA DOO GSX - Resto #1

[Vindoo]

After getting back into riding I stumbled onto a 96 GSX that was on C List for 400 bucks, sans trailer. Drove across the state, bought it and loaded into my truck made the ride home. The Doo is super clean cosmetically, all stock always garaged. Still has a nice shine. The PO claimed it ran great but quit one day, it was diagnosed as needing a MPEM by someone. I swapped the box from my 96 and ended up with the same condition, no crank. Put the supposed bad box into my boat and it ran fine. Turns out it need a starter solenoid. Put one in and after just a bit of cranking she started. Pumped. We couldnt run it on water because the pipe was rusted. The shutdown occured over a year ago, it was salt, never flushed. Water shot out when it started! Anyway, I had a runner. Began to tear it down and here are some pics...

Is this really a resto? Not sure...Maybe more of a rebuild?

 

[Vindoo]

Upon teardown things didn't look so rosy anymore, it was apparent I would need some parts due to corrosion. The pipe was in horrible, unusable shape.

Part of the pipe had fused/welded onto the clamp.

The drive shaft was nearly impossible to get out and obviously is toast.

Brass ring replaced, two used pipes we had amongst myself and cousin, used drive shaft from Minnetonka on the way...
More to come...

 

[Matt Braley]

Nice find! That is clean and you got such a good model. Looks like your going right to the problem areas.

One thing I would do on a keeper 96 GSX is replace the rectifier/regulator in the front grey box. They love to fail on this model and it acts like your hitting the rev limiter at about 3500rpm.

 

[soccerdad]

Looks like you got a nice one. hopefully there are not too many hidden ghosts. I love mine, although it has been a problem child since day one. I need to post my resto thread. Changed out or fixed most everything in it. Just replace the mats last night. I have some info on them that I will post in my thread. Can't wait to see more of yours!

 

[macedonia64]

Ive been working on freshening up my 96 gsx as well!

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[macedonia64]

Ive been working on freshening up my 96 gsx as well!

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[Jetskigoodies]

I have lots of parts for that gsx that are fresh water parts, If you gave me a parts list I could do a bundle price. Shipping may get expensive but would be actual shipping cost. I have almost every part for that gsx.

 

[Vindoo]

Thanks....I already purchased a few parts and the list isnt quite as big anymore but I will keep that in mind.

Engine is out, boat is pretty well disassembled.... Broke some head bolts but they are out thanks to the local machine shop.

Having a blast with the build so far...

 

[Matt Braley]

I don't know what your machinist charges but if you snap more than one bolt it is cheaper sometimes to just get a good used cylinder.

I've never seen that brand of rolling storage cart before........nice.

Macedonia64- I like the aftermarket stuff you have going there. I have built the world's most aftermarket 96 GSX and would love to answer questions or help source rare parts, just lmk

 

[Vindoo]

Thanks for heads up but he did it fairly cheap as I do some work for them. The cart is my cousins and he has had it for over ten years.

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[AdamXP800]

Was this ski a runner when you purchased it? That is an insane amount of corrosion

 

[Vindoo]

Ive been working on freshening up my 96 gsx as well!

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Love it, nice job.

 

[macedonia64]

Thanks vindoo.

Matt so far its just handleing stuff. Ive been following your builds and was hoping to hit you up when I move on to go fast stuff so im glad you spoke up. Im building a spec hx now. when its done im moving onto this one.

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[Vindoo]

Before painting.\

Engine all primed up...

And painted..

Still waiting on some parts but have made allot of progress. Hoping to have it running by the weekend.

 

[Bnelson]

Lookin good!!! If you really wanna make it pop do a couple of coats of clear on it... Really brings out the shine, I believe that's what JSG does to all of his engines

 

[ricochet88]

x2 on the clear i just painted my spx motor with JSGs recommendation to clear over it. im glad i did makes it look alot nicer should last longer too.

 

[Greg]

FL Gators fan? Looks nice.

 

[Vindoo]

Yup, I cleared the pipes, engine and waterbox all of which came out great. Still waiting on just a few things before we take her out and see how it runs.

Back in...

Buffed it out and waxed it also...

 

[Jetskigoodies]

Looking good, the clear really make a big difference and makes it easier to clean off any oil spills. What color did you use on the head pipe? I like it.

 

[fowlhabbitnj]

What type degreaser you use inside the hull looks great nice job.

 

[jammin777]

super clean or purple power works really well.

 

[Vindoo]

Thanks everyone...The paint is Satin then cleared.

And I cleaned the hull with an aerosol engine degreaser, I think it was Gunk brand.