2000 GTI and 97 XP back to life projects.

[Ruskie787]

Hello everyone. I recently acquired a pair of sea doos as winter projects. They are 2000 GTI and the 97 XP. A little back ground on the skis. I got both of them from a friend. The last time they were rode was in 2011 and since then they have been sitting in storage. The plan is to get both skis back to running condition and ready for upcoming summer. I’ve never worked on the skis before, but I am mechanically inclined and have experience working on cars/trucks. That should make it easy, right? I figured if I get stuck, there are a lot of knowledgeable people on this forum to help me out. Let’s get to the project!

I am going to start with the GTI first.

The plan for the GTI:
-Drain all fluids.
-Clean gas and oil tanks.
-Replace all fuel and oil lines.
-Replace selector switch.
-Check the sending unit for functionality.
-Rebuild the carb.
-Change jet pump oil.
-Check the wear ring.

I think this is a good list to start with. Once I tear into the ski, I’ll add anything else that will need to be replaced. Feel free to chime in if there is something I missed.

As they sit


The GTI


First thing is to drain the 4 year old gas.


Removing the gas tank next.



After taking the gas tank out, I noticed how dirty the inside of the hull is. I'll be cleaning it tomorrow.


What the inside of the fuel filter looks like. Gas tank has a bunch of dirt at the bottom as well. I'll be washing it out.

 

[mikidymac]

Nice score. I would replace the fuel filter o-ring, oil filter and carb needle and seat while you are at it. Looks like they used the correct oil too.

 

[Ruskie787]

Nice score. I would replace the fuel filter o-ring, oil filter and carb needle and seat while you are at it. Looks like they used the correct oil too.

Thanks for the input! I got all those parts on order.

I got the inside of the hull cleaned the best I could.



I also noticed my oil tank is leaking at the seam. With a few minutes of online research, I ended up purchasing a 96 GSX one piece oil tank.

The progress is pretty slow for now. I ordered the parts I need at the moment as well as silicone water lines and tygon tubing for oil lines. Once things start showing up I should have more to show.

 

[Minnetonka4me]

They look super clean thats for sure!

 

[Spimothy Leary]

very clean ! That will save a lot of time/grief/aggravation for sure.

two new oil filters probably wouldn't hurt

I might have a couple left over from my last bulk purchase, shipping was ridiculous for 2 so I bought 24.... and I think i'm almost out.

 

[Ruskeyjdm]

Skis look great! Good combination.
Interesting username
Russian?

 

[Ruskie787]

Thanks guys. The previous owner definitely took good care of them, aside from letting them sit.

Skis look great! Good combination.
Interesting username
Russian?

Born and raised! Are you?

 

[Ruskeyjdm]

Born, not quite raised. Was a year old when we moved to the US.
Good luck with the skis, lots of great people and tons of knowledge on this forum!

 

[Ruskie787]

It's been a while since I posted. I got tied up doing house projects, which always trumps any hobbies I am working on. I was able to manage to carve out some time and work on the GTI. I pulled the carburetor off and had it rebuild. Replaced the oil lines with new Tygon tubing and put a new in line oil filter. Below are some pictures:

Carb is off.


Time for a rebuild!


I used genuine Mikuni kit for the rebuild.


I did the "pop-off" test before and after the rebuild. The needle popped at 38 before rebuild and at 40 psi after. I figured it is good, since the values fall within the factory spec.


All back together.


Pile of the old gaskets and parts.


Overall the inside of the carburetor was very clean. It almost looked brand new. There was some green goo build up on the inlet line and in the filter, but not as severe as I've seen from other projects on this forum.

 

[Ruskie787]

While browsing through the forums and educating myself about sea doos, I stumbled upon a few threads regarding sending unit repair. Since I pulled my gas tank out for cleaning, the unit was readily available for me to inspect. I hooked up a multi meter to it and got nothing. I did it few more times with a new float in place flipping the unit and still got no reading. I guess it was time to cut it open. I was a bit skeptical about doing the repair, but with the right tools it was actually pretty easy. Below are the pictures of the repair.

I used a dremel and cut a small window in the location where F1 fuse was located.


I pulled the fuse out and put a bead of solder in its place.


Hooked up the multi meter and bingo! It works!


I then used the zip ties to close off the seams. It doesn't look very pretty, but it will work.


At this point I am done with disassembling the ski and it is time to put it all back together. At least, that's what my plan is.