1998 XP Limited Carb rebuild and fuel line replacement questions

[mikidymac]

Would you be so kind as to take a photo? I just removed the original hoses from my 99 XP and there wasnt one in there. The hoses were clearly original, old, nasty, crunchy, with the oetiker clamps on them.

It’s not shown on the 99’ XP parts diagram so probably not.

 

[etemplet]

Would you be so kind as to take a photo? I just removed the original hoses from my 99 XP and there wasnt one in there. The hoses were clearly original, old, nasty, crunchy, with the oetiker clamps on them.

Dang Sorry... a little late for a picture. These carbs are on a 2000 GTX. I did get a size on the bore I just have to take a measurement on the wire size I used. I measured the outside diameter which was around .200" So 3/16" hose or 5mm should work. 1/4" was way big. The fitting on the carbs was close to the accelerator pump after the bend.

The parts "where used" says this part was on the 2000 and newer skis.
This is the part number and description. JET 270500443

 

[Boyd12]

Thanks any way! It turns out mine doesnt have one! Yay!

 

[etemplet]

Thanks any way! It turns out mine doesnt have one! Yay!

I find that strange. LOL but it's a good thing for you.

 

[SabrToothSqrl]

Question for the thread. Is there anyone that rebuilds carbs and does a quality job?

A few years ago I was able to get brand new 951 carbs around $400. I know that's not cheap, but then you sell your old ones on ebay or whatever... then you get brand new everything in one shot... (still have to get new jets though).
new carbs, throttle plates, injection pump, hoses, etc. R&R all the things!
Remove & Replace!

 

[bawray]

I definitely DID have a restrictor jet in the hose feeding the accelerator pump. I split open the old hose and there it was. BTW...below is a parts list (for a 98 XP Limited)...I believe this incorrectly lists the jet (#18) as a screw! I have seen a few mislisted parts in these diagrams...weird as they must all come from the same source.

But...now I have a new question on how to install this jet in the new hose. What is the correct way to install this restrictor jet in the new hose from the fuel pump to the acc. pump? Should the flow to the acc. pump go through the end with the large opening first or the small opening first? I have experimented by placing the jet inside a good, new hose...I use a syringe to apply a little pressure and spray gasoline through the hose with the restrictor jet inside. Problem is I can spray fuel in either direction. If I spray into the end with the larger opening I get a good steady flow coming out the other side. If I spray into the end with the small opening I get a much thinner higher pressure stream coming out the other side but it still flows through pretty good. And..if I remove the syringe and fill the hose with gasoline (without any pressure) fuel will flow through the jet and drip out in both directions. So, is this restrictor jet working properly? I do realize the acc. pump will be causing a vacuum which should hold the fuel in the line and keep it from returning to the fuel pump. RIght?

Or...does it even matter which direction I insert the jet in the hose?

 

[bawray]

Here are some pictures (these pictures are zoomed in quite a bit because this is a really small jet...and...no that's not a casing from a 9 mil...it is the restrictor jet).

The jet:





The large opening:



The small opening (yikes! It looks a little buggered when I zoom in on it!):

 

[bawray]

I just checked the parts list for a 99 XP...no restrictor jet shown...really strange...especially since I believe the parts list on my 98 shows the jet but incorrectly lists it as a "screw". I wouldn't trust these parts list...can you imagine trying to put a screw in that line? I have seen too many incorrectly listed (and not listed) parts on these "OEM" parts lists. I did finally find the jet listed correctly...for a 98 GSX limited...it is called a "recharge" jet (part # 270500348). I am assuming this is the correct jet for any ski with an accelerator pump???

 

[etemplet]

Hmmmm after measuring and looking at the picture.... a 22 cal projectile with a hole in it would probably work just fine. It'd be a little large but the hose would open up easily. VIOLA !!

 

[mikidymac]

It is just a restrictor so it really doesn't matter which way it goes.
I would go by the diagram and put the tapered part towards the pump unless someone remembers cutting theirs out and it was different.

For some reason the 1999 is the only year that doesn't show the jet.

 

[bawray]

It is just a restrictor so it really doesn't matter which way it goes.
I would go by the diagram and put the tapered part towards the pump unless someone remembers cutting theirs out and it was different.

For some reason the 1999 is the only year that doesn't show the jet.

Thank you TONS for all the posts and pictures!!! You are a terrific person for helping everyone on this forum and it is appreciated.

 

[bawray]

I finally have the carbs done and back on the ski. Once I reassembled the throttle/oil pump cables I adjusted the slack in the throttle cable and all cables seem to be connected properly and working fine (both carbs in sync and the oil pump marks are aligned, tension on all cables, the oil pump bell crank is turning and springing back fine). The issue is when I go to full throttle the oil pump bell crank will stick in the wide open position and not return. I can manually go in with my finger and push the oil pump bell crank back from the wide open stuck position. After pushing it back the oil pump seems to spring back correctly and will function correctly again until I go to full throttle again when it will stick there. Feels like there is some friction in the shaft causing it to stick.

My question is...will the oil pump have any more pressure on it with the motor running which will cause the bell crank to return properly when the motor is running or will this be a problem when the motor is running? If not and the oil pump will stick wide open how can I fix it?

 

[etemplet]

That dang little spring likely came off the oil pump. If you turn oil pump throttle backwards that happens quit easily. It is a pain to get back on with it in the ski but it is doable. Good Luck

 

[bawray]

That dang little spring likely came off the oil pump. If you turn oil pump throttle backwards that happens quit easily. It is a pain to get back on with it in the ski but it is doable.

Just cheched and the oil pump spring is definitely on and creating tension. I can turn it with my finger and feel good pressure. Just not enough pressure to prevent the sticking at full throttle. It seems the pump shaft has some friction at full throttle causing the sticking.

 

[bawray]

Just cheched and the oil pump spring is definitely on and creating tension. I can turn it with my finger and feel good pressure. Just not enough pressure to prevent the sticking at full throttle. It seems the pump shaft has some friction at full throttle causing the sticking.

When I removed the oil tank there was soom really thick gooey oil in the bottom and on the sides of the tank. Old 2 stoke oil turned to goo. I had to dump the oil and use a long flat screwdriver (and gasoline) to get it out. Could the same goo be clogging up the inside of the pump causing the shaft to stick?

 

[etemplet]

That little throttle thing can be dragging on something. Sometimes they get bent a tad. I'd pull the pump and flush it give it a close inspection. Could it be that you have a bad throttle cable? That is a two part cable at the split and I've had trouble with them at that point. Might try lubing in the section. Good Luck.

 

[bawray]

I will look for a thread on pulling the oil pump...sounds like a good idea.

And...anyone have a part # for an in-line oil filter from a local car parts store?

Thanks.

 

[bawray]

I will look for a thread on pulling the oil pump...sounds like a good idea.

And...anyone have a part # for an in-line oil filter from a local car parts store?

Thanks.

Pulled the oil pump and REALLY glad I did (thanks for the advice!). The bell crank was bent! When the throttle cable would pull the crank open it would rub on the pump body about half way around. By the time it was at full throttle it was rubbing the pump body so much it would stick open and not rotate back to idle. See red arrows in my pictures to see how the bell crank was bent and rubbing the carb body.

I just bought this ski so I have no idea how this happened. Ski was running really horrible when I took it out on the water for the first time so along with the carbs being clogged I am sure the oil pump would have been stuck in full open causing it to run oil rich at low rpms. I knew I would have to put new fuel line on the ski and clean the carbs but I didn't know this would be an issue.

I was able to bend the bell crank back straight with little effort. I have reinstalled the oil pump on the ski now (Holy $%&*! everything on the 951 motor is so difficult to work on!!!!!). I will put the air silencer and oil tank back on later and hopefully crank it up later tonight.