'91 SP Fuel Sender Removal and Fuel Siphoning

[Hludlam]

I am new to this forum and I am the original and only owner of this '91 SP which, years ago, I had a dealer install a fuel gauge sender after purchase. These senders came standard on the XP model. It no longer works and since I need to drain all the fuel from the tank due to very old fuel, I thought I would do both these projects at the same time.

I, unsuccessfully, have searched the SeaDoo shop manual, Seloc manual, and this forum for some idea of how to gain access to the fuel tank for draining and how to remove the fuel gauge sender without removing the engine. Most important to me is to learn exactly how do I drain the tank and secondarily how to remove the fuel sender gauge.

Thanks for any help on these matters.

 

[Sportster-2001-951C-Stock]

Earliest year SP I easily found was '94, is it like this one?

http://partsfinder.onlinemicrofiche...3&make=seadoopwc&a=313&b=8&c=0&d=-FUEL-SYSTEM

 

[Hludlam]

The '94s are not the same . I read that the '91s stayed the same in '92 and '93 and changed in '94. Also, from the diagram you sent , the sender and the pickup are side by side. On the '91s, they are fore and aft just in front of the oil tank. The sender is most aft of the two.

 

[Sportster-2001-951C-Stock]

In that case perhaps yours is the one that makes use of a rubber fuel line as part of the pickup in the bottom of the tank. I've heard those rubber lines tend to rot off down inside the tank and cease feeding off the tank bottom.

Otherwise, I would suggest placing the fuel selector valve in the "reserve" position, disconnect the fuel line from the carburetor, open the fuel cap slightly to provide a vacuum break, and siphon from that line.

Assuming the rubber line in the fuel pickup is rotted off, I'd guess you get most fuel by siphoning through the filler hose.

As far as disassembly goes, I'm not familiar enough with that model to help much.

 

[LouDoo]

Hi and welcome to the Seadoo forum. Honestly, I don't have and answer for your question, but I know someone who will be able to help you. Rod are you out there? [MENTION=49703]RodInEscondido[/MENTION]

Lou

 

[RodInEscondido]

I have a 91sp that I will be more than happy to peek inside whenever the rain stops to insure I am not giving out bum info ... yes rain in north San Diego County, just had a thunderstorm go right over the top of me ... kinda neat, been a couple years since that happened.

The 91 fuel pickup looks to be the same as the 89/90 in that there are lines going down into the tank for regular and reserve fuel pickup with filter/check-valves on the ends. As stated above the lines tend to rot off with time and the little screen filters have check valves that I have seen stuck both open and closed (also found at the bottom of the fuel tank when the fuel line rots off).

Without peeking inside again, I will just speculate for now based on 89/90 versions that the oil and fuel tanks should be able to be removed thru the front hatch ... with some wiggling around to get the fuel pickup removed and out of the way along with fuel fill.

I have found the easiest way to siphon the fuel on these is with a rather long length of clear fuel line (helps to see what is going on to keep that old gas out of your mouth if using that method). Poke the end down the hole for either the fuel pickup or the fuel level sensor. I use a brake bleeder to create vacuum at the other end to start the siphon. Siphon into container below the ski for better flow. Tie-wrap an appropriate length of bicycle spoke or baling wire to the part going into the tank to keep the line from curling and breaking the siphon.

I do highly recommend removing the oil and fuel tanks for cleaning, especially if old oil and gas has been sitting. One I did had some honey-like stuff on the bottom which could never have been cleaned out without removing the fuel tank.

I will update this when I go out and peek inside the 91sp.

The ponder sets in if a newer model pickup/sensor assembly would work ... a much better design but depends on depth of the sensor and what it takes to drive the fuel gauge. Gotta stop this thinking stuff.

 

[LouDoo]

Thanks Rod, I hope you noticed that I didn't call either your ski's or you vintage, I'm getting mellow in my old age. BTW we're going back to Alaska next week.

Lou

 

[Hludlam]

Sportster, Lou and Rod, I really appreciate your input on this matter. What I originally thought might be a fairly easy and quick fix is rapidly changing into a real project. I have also learned that I most likely will have even more complex issues to deal with as my ski has sat for over 6 years. Since I don't have the skill, tools, space or time to do such an overhaul, I am considering either paying to have it done or getting rid of it. Thanks for saving me from falling over a cliff.

 

[IDoSeaDoo]

Wait a minute... you said the dealer installed a fuel sender? As in, you had a fuel sender that USED to work? If that is the case, you must already have the newer style fuel baffle, with a fuel sender float. Chances are, your float just soaked up the alcohol in the fuel and sank to the bottom. They make new plastic floats to fix this issue for $20. It's not hard to pull out the baffle and pop in the float. I'd say... 30-60 minute job. You'll need a screw driver and some masking tape to mark that hoses go where. A mirror and a flashlight is mandatory too.

Post a pic of your fuel sender and we can tell you whether it's the new or old style.

 

[IDoSeaDoo]

As for siphoning the fuel, that's simple: just get some 1/4" hose down into the bottom of the tank, with the other end lower than the bottom of the tank. Suck up enough fuel to get it going and let her drain. I'd go through and rebuild the carb if it's sat for 6 years. Chances are, your diaphragm is shot, and you have dried fuel crust everywhere. Was the engine fogged before beings stored? Does the thing even turn over anymore?

 

[RodInEscondido]

Thanks Rod, I hope you noticed that I didn't call either your ski's or you vintage, I'm getting mellow in my old age. BTW we're going back to Alaska next week.

Lou

I noticed.

The quote "beware the ides of March" pops up from ancient memory, but I cannot recall if it refers to Alaska weather or something else ... ;-)

 

[RodInEscondido]

Sportster, Lou and Rod, I really appreciate your input on this matter. What I originally thought might be a fairly easy and quick fix is rapidly changing into a real project. I have also learned that I most likely will have even more complex issues to deal with as my ski has sat for over 6 years. Since I don't have the skill, tools, space or time to do such an overhaul, I am considering either paying to have it done or getting rid of it. Thanks for saving me from falling over a cliff.

Now just wait a minute, we old folks (or maybe it is just me) out here regularly falling off cliffs with old SeaDoos need company; ya can't just quit yet. Learning about these old (vintage) rigs is kinda fun and nothing suggested so far is really difficult or costly ... just a bit overwhelming at first (just look at some of my early posts ... no, I rather you didn't).

I looked in my 91sp, which I thought was completely stock, and see the fuel pickup is at the rear of the tank and a thingy looking like it was designed as another input like the pickup but covered over, just forward of the fuel pickup. I will supply a picture shortly. The service manual says the fuel pickup hole is forward and the rear hole is for the fuel level sender on the xp. The same setup on the 92 with the rear hole for fuel level sender on xp and gtx. The 93 shows only the forward hole used, for the pickup on all but the spx which has the integrated fuel pickup and fuel level sender.

Yes, a picture thru the front hatch would clear things up.

 

[Hludlam]

OK, you guys have convinced me to proceed with this project at least until I get stymied. I have syphoned out most of the fuel and it was very nasty so I will try to remove the tank via the front compartment to get all the fuel and clean it up properly.

The fuel level gauge only worked for about 2 seasons so it probably is the baffle with float type. I will soon find out. Here is a picture of the top of the fuel tank.

 

[RodInEscondido]

For some reason I am not able to email my picture from my phone, but your picture looks like the inside of mine except my fuel pickup is in the after hole and the front hole has a molded-on cap. To do the mod you have would require removing the fuel tank and either cut off the forward cap to the proper height or just replacing the fuel tank with one from an xp.

If you unscrew the fuel pre-filter (just above the fuel level pickup) and remove the tie-down straps for the fuel and oil tanks you may have enough room to wiggle things around, remove the fuel level pickup and fuel pickup and slip the fuel tank out the front hatch.

 

[Hludlam]

Well I suspected something would come up that will have me rethinking what to do with this ski. Yesterday, I decided to see if I could start it up by attaching an above deck fuel tank directly to the carb using new premixed fuel. The battery is new and fully charged to 13.4 v. The starter turned over for about 2 seconds and died. I got the all too familiar "tick, tick, tick" sound from the solenoid. I tried jumping the terminals on the solenoid and got nothing. I did ohm tests on the upper and lower terminals of the solenoid and they both checked out as working perfectly. So, it must be the starter and that remove and replace job plus the tank removal and who knows what else brings me to my tipping point. You see I really need a three seater ( 6 grand kids all under 7 years). So, this reclaimation project on a boat that has sat for over 10 years is officially over. I want to thank everyone for their generous input and sincere effort to help a complete stranger. You guys are to be commended. Thanks.

 

[IDoSeaDoo]

Hmmm, interesting. My old 91's must really have been 92's because both (the SP and my GTS) skis had just two holes in the fuel tank: one for the fuel inlet, and one for the baffle. I didn't even have an option to put in a sending unit. I did none-the-less by using a later model XP baffle, which did stick up a little high, but was still able to be secured. If you or the guy you sell this to proceeds with the project, you should have them pull out the fuel pickup baffle and replace the no-doubt rotten away pick up lines. Even if he manages to get the thing started with the old lines, those pickup lines are attached to a heavy one-way-valve/prefilter. Once he gets on the water, the vibrations will surely break the fuel pickup line apart, potentially above the fuel level (causing him to be stranded with plenty of fuel in the tank).

As for the starter, it is a bit of a pain to remove on this model, but it's only 3 bolts, 4 if you count the starter wire. These units are rather cheap and simple to rebuild, so it doesn't even have to cost the full $100 to fix this problem. I believe the rebuild kit is somewhere around $30. Just ebay it This is a great starter ski, good on fuel, simple and largely bulletproof. We've had one of these go for over 10 years without major issue. Great to learn on :thumbsup:

 

[Hludlam]

I will be talking to the guy who actually did the aftermarket installation of the fuel gauge back in 1993 next week so I will see if he drilled a new hole in the tank, changed out the tank, or my SP came with a knock out plug.

To summarize, this ski, at a minimum, needs a rebuilt starter, rebuilt carb, fuel tank removal and cleaning, fuel gauge repair, and fuel pick up repair. And who knows what may arise once the motor starts and I get out on the lake. If this were a 3 seater, I would undertake the project but not for this model.

 

[RodInEscondido]

Hmmm, interesting. My old 91's must really have been 92's because both (the SP and my GTS) skis had just two holes in the fuel tank: one for the fuel inlet, and one for the baffle. I didn't even have an option to put in a sending unit. I did none-the-less by using a later model XP baffle, which did stick up a little high, but was still able to be secured. If you or the guy you sell this to proceeds with the project, you should have them pull out the fuel pickup baffle and replace the no-doubt rotten away pick up lines. Even if he manages to get the thing started with the old lines, those pickup lines are attached to a heavy one-way-valve/prefilter. Once he gets on the water, the vibrations will surely break the fuel pickup line apart, potentially above the fuel level (causing him to be stranded with plenty of fuel in the tank).

As for the starter, it is a bit of a pain to remove on this model, but it's only 3 bolts, 4 if you count the starter wire. These units are rather cheap and simple to rebuild, so it doesn't even have to cost the full $100 to fix this problem. I believe the rebuild kit is somewhere around $30. Just ebay it This is a great starter ski, good on fuel, simple and largely bulletproof. We've had one of these go for over 10 years without major issue. Great to learn on :thumbsup:

Good info here.

I finally got my picture of view aft from fwd hatch on my 91sp.

 

[RodInEscondido]

I will be talking to the guy who actually did the aftermarket installation of the fuel gauge back in 1993 next week so I will see if he drilled a new hole in the tank, changed out the tank, or my SP came with a knock out plug.

To summarize, this ski, at a minimum, needs a rebuilt starter, rebuilt carb, fuel tank removal and cleaning, fuel gauge repair, and fuel pick up repair. And who knows what may arise once the motor starts and I get out on the lake. If this were a 3 seater, I would undertake the project but not for this model.

Makes me sad, but I understand. If you deliver, I will make an offer ;-).

As a fact of life, all these older machines need some TLC from time to time. At least this one you know the complete history. fisu (that is a highly technical term derived from saying quickly "if i was you") I would put some injector oil down the plug holes and spin it over a few times manually, cover it up and go back to it later. Get your 3 seater and have fun for now (well, maybe not right now).

We will probably still be out here to help if you need ... when you get going it kinda gets in your blood. Also this might be a good project for the grandkids to learn how to handle a wrench.

Rod

 

[IDoSeaDoo]

Yep, it's a great engine to learn mechanics on. That was the first engine I ever saw the inside of. My dad and I rebuilt my '92 GTS back when I was 14 (some 15 years ago now). It was a great little project, and really showed me that anyone could do this. Parts are cheap, and it's good on fuel. Also top speed is like 40, so it's probably the safest jet ski on the water.