787 RFI Starter Removal

[JoeRJGR]

Does anyone have a procedure for removing the starter from a 1999 GTX RFI? Looks like the previous owner replaced the starter and didn't use the correct alan heads, but instead used hex nuts. So I dont know what size they are....plus I cant see a blinkin thing even with mirrors and a scope! I have rebuilt ford and porsche engines and have to say this thing is the hardest machine I have ever worked on...

Thanks for the assistance.

 

[etemplet]

Probably 13mm hex for the size of the wrench. Bolts are 8mm. I just removed the exhaust pipe, diconnected the plugs from the throttle body and moved it out of the way. Then you can get at the starter. Not a bad job but sometimes just taking the ski apart is easier than fighting.... LOL Good Luck. There is a bolt on the back of the starter that is on the underside of the engine. Don't forget to remove that one. Good Luck

 

[JoeRJGR]

Probably 13mm hex for the size of the wrench. Bolts are 8mm. I just removed the exhaust pipe, diconnected the plugs from the throttle body and moved it out of the way. Then you can get at the starter. Not a bad job but sometimes just taking the ski apart is easier than fighting.... LOL Good Luck. There is a bolt on the back of the starter that is on the underside of the engine. Don't forget to remove that one. Good Luck

Yep...sounds like it's coming apart...thanks!

 

[POPPS]

No need to disassemble the ski,,,but a need for the right tools,,,an important move is to not remove the bracket that holds the starter to the engine,,it is there to prevent the starter from wobbling/oscillating/moving/etc,,,,but also holds the starter for you while you remove the 2 front bolts,,,also, leave the ground attached,,just remove the ground at the battery,,of course you have already removed the positive at the battery and at the starter,
,,when you reinstall, attach the bracket first loosely,,it will hold the starter for you while you struggle with 2 front bolts,,,if you lhave trouble getting a socket on the bolts,,,use a 1/4 inch drive socket,,,it may just fit,,or ,a iniversal socket may help with a long 1/4 extension..,its probably 13mm,,,
this job all about the tools,,,that hex head no doubt is 13mm,,,and I have a 13mm universal 1/4 drive for the job,,,when someone has dumped the original hex head bolts,,,

 

[etemplet]

My picture was just showing what it looked like, not that all that stuff has to come off. That was an engine I had just installed. I don't see a way to remove the starter without removing the exhaust pipe and the Throttle Body needs to come off to remove the pipe.... that's how I do it anyway. I'm lazy so if there is a better easier way... I'm all in for that.

 

[POPPS]

Maybe I am missing something,,,isn't the starter on the right side at the front,,,if yes,,,the pipe does not have to come off,,,but the carb will be in the way,,,if its a 720,,then yes pull the xhaust pipe.

 

[etemplet]

Maybe I am missing something,,,isn't the starter on the right side at the front,,,if yes,,,the pipe does not have to come off,,,but the carb will be in the way,,,if its a 720,,then yes pull the xhaust pipe.

It's an RFI so the pipe is on the right side. It's easy to pull..
I changed a couple of starters on 720's without pulling the pipe. It's tricky and painful if you're short. LOL Good thing is my head is in the engine compartment so my cursing doesn't carry as far.

 

[JoeRJGR]

Just to confirm, this is an RFI I am dealing with, and I appreciate everyone's input...

Why not remove the two bolts that hold the starter to the bracket as opposed to removing the bracket from the engine? I can at least see those bolts. Also, in addition to the ground wire that screws in from the back, the shop manual also shows a nut on the back of one of the starter bolts that has a wire clamp on it. I have not idea how to remove something that I cant see or even touch..

 

[etemplet]

Welcome to Seadoo -dum (the land of Seadoo ) last one I did I removed the throttle body, then the exhaust. You'll then have access to the starter. Popps point of installing the bracket bolt first on assembly makes it much easier to get the front bolts installed. Good Luck.

 

[JoeRJGR]

Thanks.. ordered a new exhaust manifold gasket already.. hope to get it apart to tonight. Thanks for the input!

 

[JoeRJGR]

Any advice on where to get an OEM starter? I understand the Chinese stuff is junk

 

[mikidymac]

Seadoo Warehouse is a site sponsor. $235 direct from them or a seadoo dealer.
Starter Ass'y Includes 1 - 17.

278001497 278001936

$234.99

 

[JoeRJGR]

Yep thanks

 

[JoeRJGR]

It's an RFI so the pipe is on the right side. It's easy to pull..
I changed a couple of starters on 720's without pulling the pipe. It's tricky and painful if you're short. LOL Good thing is my head is in the engine compartment so my cursing doesn't carry as far.

Etem,

When you take off the Throttle body, do you just move to the side? I can get to the top front starter bolt without removing anything, and I thought I would try that first. Its some type of thin shouldered bolt with a concave top..isn't a 13 or a 12 and Im scared Im going to strip it. Seems like the guy just grabbed any bolt he can find. After the exhaust will I be able to access it on the right side?

This ski has 60 hours on it and it is in great shape overall. Im wondering if its a new engine. Everything is sprayed silver. Engine, starter, etc. is that factory?

Thanks for your help!

 

[etemplet]

Got a Mirror??
As for the throttle body, just disconnect 3 plugs, make sure you mark the one for the throttle position sensor. Usually they have red tap on that one. Remove the airbox and 4 bolts holding the throttle body in position. Leave the cables connected but be gentle moving it around. After you remove the exhaust pipe move the throttle body toward the front of the ski out of the way.

I can't imagine doing that job with the pipe in place. That damn bracket bolt is a pain in the azz even with everything removed. Be careful not to cross thead it when going back in. Use your fingers to get it started.

 

[etemplet]

I wouldn't pay that kinda money for a new starter. Buy a used OEM and replace the brushes or rebuild it if you like. Good Luck.

 

[JoeRJGR]

Got a Mirror??
As for the throttle body, just disconnect 3 plugs, make sure you mark the one for the throttle position sensor. Usually they have red tap on that one. Remove the airbox and 4 bolts holding the throttle body in position. Leave the cables connected but be gentle moving it around. After you remove the exhaust pipe move the throttle body toward the front of the ski out of the way.

I can't imagine doing that job with the pipe in place. That damn bracket bolt is a pain in the azz even with everything removed. Be careful not to cross thead it when going back in. Use your fingers to get it started.

Got it, thanks..yep there was red tape on the one sensor..did not mark it, but will now... Thanks

 

[JoeRJGR]

Got a Mirror??
As for the throttle body, just disconnect 3 plugs, make sure you mark the one for the throttle position sensor. Usually they have red tap on that one. Remove the airbox and 4 bolts holding the throttle body in position. Leave the cables connected but be gentle moving it around. After you remove the exhaust pipe move the throttle body toward the front of the ski out of the way.

I can't imagine doing that job with the pipe in place. That damn bracket bolt is a pain in the azz even with everything removed. Be careful not to cross thead it when going back in. Use your fingers to get it started.

is this red goo some type of sealant? Thanks

 

[mikidymac]

I wouldn't pay that kinda money for a new starter. Buy a used OEM and replace the brushes or rebuild it if you like. Good Luck.

Last I heard Westside was charging $200 for used OEM starters, Ouch!

 

[etemplet]

Damn, I got a gold mine..... LOL I've bought a few of the $110 SBT Starters as try outs. I'd love to take one apart and look inside but I'm not doin it... not on a new starter. LOL They say they are high torque...

 

[etemplet]

is this red goo some type of sealant? Thanks

Looks like High Temp RTV. Dunno why that's on there. All I ever put on those is grease when mounting them.

 

[Poormanracing]

That goo was someone going over board but there should be just a smig of rtv don't know why the factory did that.no need to take pipe and throttle body off.the bolts will be 13 mm unless the previous owners retaped stuff.when you start removing things bolts start to break then your screwed.plus if you remove the throttle body get new rubber gasket.the after market starters from wsm or sbt are fine been using them for over 20 years .just keep water out of bildge.

 

[etemplet]

Perhaps I need to upgrade my Seadoo tools but I've fought these starters even with the exhaust pipe and throttle body removed. I admit I don't do this for a living but I like keeping the blood and skin attached as much as possible. Somewhere at the bottom of the picture, the starter lurks beneath the engine. I have another RFI starter to pull on Wednesday. If there is an easier way, I'm all ears.

 

[Poormanracing]

1/4 inch drive tools and a swivel that is stiff that doesn't flop around and use a long extension so you don't work right at the motor

 

[etemplet]

I guess the "limber" swivel is my issue then. LOL I'll give it a look on Wednesday. Thanks for the info.