1996 XP 787

[JoeyEgan]

Hi All,
I’m based in the UK and have got hold of a rough and ready XP.

awesome looking machine for it’s age, I’m in the process of refurbishing it, I’ve pulled everything out and will replace parts as necessary.

it did supposedly run, but I’ve never seen it running.
The wiring loom was a complete mess and everything was filthy inside.

I’ll update the thread as I go, I’m new to Jetski’s so any advice is welcome.

I was looking to change the steering setup and switchgear for something a bit more modern. But have no idea where to start.

please let me know if there is anything I should be looking out for as I go.
TIA

Joe

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[mikidymac]

Looks good but you have some work to do.
Looks like they used the infamous Gray Tempo fuel line on the pipe cooling line.

For the steering upgrade you want the UMI steering system but they have become like hens teeth. Hard to find and expensive.

 

[JoeyEgan]

Yeah, definitely a good project. All the hoses will be upgraded for sure.
I’ll look into the UMI Steering, I’ve found parts are harder to come by in the UK though

 

[JoeyEgan]

The fuel valve seems to be stuck in the hull.. any suggestions?

 

[mikidymac]

Remove the knob then there’s a big plastic nut under it. After that just pull.

 

[JoeyEgan]

Remove the knob then there’s a big plastic nut under it. After that just pull.

I think it’s seized in there, I’ll keep at it

 

[noviceskier]

I think it’s seized in there, I’ll keep at it

since your replacing it I just got some pliers and got the brass fitting by and turned. After that I tapped the end where the nut screws on and tapped it till it fell in my hand inside the hull

 

[vogs77]

Does it crank, have you checked compression yet? Looks a lot like the one I am working on also.
https://www.seadooforum.com/threads/picking-up-a-96-xp-needs-some-tlc.108384/

 

[JoeyEgan]

since your replacing it I just got some pliers and got the brass fitting by and turned. After that I tapped the end where the nut screws on and tapped it till it fell in my hand inside the hull

I’ll give it a shot.

 

[JoeyEgan]

Does it crank, have you checked compression yet? Looks a lot like the one I am working on also.
https://www.seadooforum.com/threads/picking-up-a-96-xp-needs-some-tlc.108384/

It feels good when I crank it by hand, I’ll get the compression tester on it tomorrow and let you know what it reads.. I’m looking for around 150 right?

 

[emspjay]

Nice project! These are a blast to ride! You will love it!

 

[vogs77]

150 would be great, finally after 4 gauges on mine I got 2 to match at 155.

 

[JoeyEgan]

I removed some decals today and managed to get the Fuel Valve out.



I also took the head off, its in a bad state (see photos), chips out of the inner rim of the cylinder heads and along the seal rim of the head. also a small crack on the outside of one of the heads. Im amazed that I got the bolts out in one piece, but I'm now looking for new heads an a top end rebuild kit.

 

[mikidymac]

Contact Nick or Jess at Westside Powersports Seadoo for replacement parts. @Minnetonka4me

 

[JoeyEgan]

Contact Nick or Jess at Westside Powersports Seadoo for replacement parts. @Minnetonka4me

thanks! Hopefully they ship to the UK!

 

[POPPS]

Yeah, definitely a good project. All the hoses will be upgraded for sure.
I’ll look into the UMI Steering, I’ve found parts are harder to come by in the UK though

 

[POPPS]

Unless you are racing closed course, no need for after market (expensive), steering systems.

 

[JoeyEgan]

Unless you are racing closed course, no need for after market (expensive), steering systems.

Thanks, I’ve decided to stick with the original parts for now, I will change the bars however.

 

[JoeyEgan]

I’ve just received a big box of goodies, including a top end, fuel valve and various bits, plus separately a brand new speedo, still in its box with the protective plastic on the face. can’t believe I found that, got it for a steal too!

As soon as the gasket kit gets here I’ll be getting on with the rebuild.