RESTO 1996 XP Back To Life

[IcyBlueMink]

Hello all, I am new to the forum but have been lurking for a couple years. I have recently picked up a couple more skis and plan to bring one back to life and hoping you all may be a little bit of help along the way and figured it would be cool to share my story along the way! Here's how it arrived, had seen it last year September on market place but the guy nevercame and picked it up so I snagged it this spring with the Polaris for $500 on the trailer.

 

[IcyBlueMink]

All cleaned up she didn’t look too bad except the paint was very faded and the stickers were in bad shape.

Figured I would make it look a little better and decided to tear the stickers off. Also took the black tip mats off as I am going to upgrade to the hydro turf.

Taking the stickers off was a PITA but with the heat gun and some elbow grease it came out decent. Thanks to the girlfriend for doing the majority of the work while I remained “essential”.
Decided to clean up the faded paint as well and did a wet sand, buff, polished and wax. While I’m waiting on parts in the mail. Nice mirror finish after sitting in the weeds.

 

[IcyBlueMink]

Figured after sitting a while it was time for a carb rebuild (as well as replacing the gray tempo fuel lines), so I ordered those parts and they are on the way. Previous owner stated it had ran before it was put up but when cranking on it it seemed to backfire both out the exhaust and through the carbs. Anyone have any insight on if this is more likely a timing issue or a fuel issue? I’m believing it to be fuel so hopefully cleaning up the fuel system clears up my issues. If not how hard is it to time one of these 787 motors?

 

[Major Woody]

The timing is fixed and the carbs need rebuilding. I don't know if that's what is causing it to run the way it does, but it won't likely run long with the carbs in the condition they're in.

 

[GGuillot]

Figured after sitting a while it was time for a carb rebuild (as well as replacing the gray tempo fuel lines), so I ordered those parts and they are on the way. Previous owner stated it had ran before it was put up but when cranking on it it seemed to backfire both out the exhaust and through the carbs. Anyone have any insight on if this is more likely a timing issue or a fuel issue? I’m believing it to be fuel so hopefully cleaning up the fuel system clears up my issues. If not how hard is it to time one of these 787 motors?

Yeah, fuel system first with the carbs rebuilt and so forth, but since you'll have the carbs off it's fairly easy to check if you would like to verify. You need a degree wheel. The procedure is in the service manual which you can download as a reference SeaDoo Manuals - FREE PDF Download!. Basically you get the MAG cylinder at TDC, with carbs off and rotary valve cover off, you set the rotary valve at the degree mark referenced with the degree wheel.

 

[IcyBlueMink]

Checked the process and looks easier than I believed it to be so I will be checking it for sure while I have the carbs off.. What do you use to find TDC? Don’t think my dial gauge will have enough reach to get to the piston. Should I have to pull the heads off for this process? I plan on replacing the heads as well with a mild aftermarket setup if anyone has a good lead on those I’d appreciate that as well.

 

[mikidymac]

Most dial indicators will fit down the plug hole.

 

[emspjay]

Nice find! And already looking good!!

 

[IcyBlueMink]

Got into the carbs today after work as I finally got the kit in that mail. Tore them apart and noticed the setting for needle were way off each other, probably a big reason why I couldn’t get it to run. After getting deeper in I noticed one of the screws for the check valve on the Mag carb was so tore up I couldn’t even get it out. After an hour of drilling it out until I could smack an Allen key into it and get it out I finally managed to get it out with mangling it. Figured it couldn’t get much worse than that until I got into the PTO carb and whoever had previously installed it had literally sheared the top of the pilot Jet off. I’ve done carb work (mostly on bikes) many of times and I’ve yet to see a carb that mangled!

 

[GGuillot]

What do you use to find TDC?

On my skis doing the rebuilds, I used a 1/4' socket extension. Eye and feel, I know that's technically not right but it worked for me.

 

[IcyBlueMink]

Thats probably what I’ll end up doing if my dial indicator can’t reach lol. Anyone on here have any leads on a set of aftermarket heads? Pump gas only looking for 43cc domes.

 

[mikidymac]

Thats probably what I’ll end up doing if my dial indicator can’t reach lol. Anyone on here have any leads on a set of aftermarket heads? Pump gas only looking for 43cc domes.

@Matt Braley does check the for sale section.

 

[IcyBlueMink]

I chatted with him on one of those threads . He’s got some interesting heads left over but none I know much about. Really would like to find a WestCoast one.

 

[IcyBlueMink]

Well I managed to finally get a Michigan day with decent weather and started wrenching after work today. Got new fuel filter, oil filter and fuel lines. Carbs got rebuilt and she finally managed to fire up. Hose is at my cottage right now so I couldn’t manage to get it to idle but glad the rest turned out. I think the next move is to drain all fuel that was in it and start fresher due to not draining it all out.

 

[mikidymac]

No reason to run it on the hose as you can still burn up the driveshaft seal. Once you know it starts, get it on the water.

 

[IcyBlueMink]

Managed to get a decent day to get on the water today and ski would continue to backfire and not fire up. I’m gonna check the timing once again but it should be in place. Anywhere else I should look? I’m getting solid spark, new plugs, fresh gas, lines, fuel filter and for some reason she keeps backfiring.

 

[IcyBlueMink]

Set the timing again to factory specs. Can not get this thing to fire up and run. Got my frustration for the day and left it as is. Any ideas would be appreciated.

 

[mikidymac]

Try unhooking the red wire on the voltage regulator.

 

[IcyBlueMink]

Hey miki, I pulled the red wire and now I have decent click from trying to start it but no spin, jumped the solenoid and it spun fine. I’m assuming the solenoid went so I ordered a new one and and new rectifier just because I don’t have a local place that stocks parts for these old fellas. Timing is within spec as I set it again and pop off is 30/32 on the carbs and hold at 10. I did notice when I pulled the box there was a little water in it. Should I find a new MPEM or you think this one will be alright?

 

[mikidymac]

I would check and clean all connections in the box but I would wait on a new mpem until you try the regulator and solenoid.

 

[IcyBlueMink]

I pulled all wires and cleaned and dielectric greased all the connections. Hoping this saves the MPEM.

 

[IcyBlueMink]

Cleaned everything up in the box and replaced Rectifer and Solenoid No start. Battery is brand new as well. Any ideas?

 

[etemplet]

Checked the process and looks easier than I believed it to be so I will be checking it for sure while I have the carbs off.. What do you use to find TDC? Don’t think my dial gauge will have enough reach to get to the piston. Should I have to pull the heads off for this process? I plan on replacing the heads as well with a mild aftermarket setup if anyone has a good lead on those I’d appreciate that as well.

You can get an extension for the dial indicator or you can be like Gene. Drill a hole in a 14mm bolt and screw it into the spark plug hole, drop a long bolt through the hole (long enough to touch the top of the piston) and place the dial indicator on top. Easy Peasy.

 

[etemplet]

I pulled all wires and cleaned and dielectric greased all the connections. Hoping this saves the MPEM.

did you put dielectric grease on the connectors themselves? I started doing that the last couple of skis and and cleaned every one that got that CRAP out of there after I had electical issues on both skis. It is non conductive grease. You'll hear people swear by it and others like me swear at it. LOL I use the dielectric grease on the rubber sealing surface that is all. I like clean dry connectors. I really believed that stuff caused issues on those two skis. Just my take... I don't need any help creating problems.

 

[etemplet]

Cleaned everything up in the box and replaced Rectifer and Solenoid No start. Battery is brand new as well. Any ideas?

Do you have the ground wire connected on the rear electrical box? that'll get ya. Also check your grounds. Good Luck.