Yeah, I ended up having to use a stubby 3/8” ratchet with a low profile Allen socket. That thing was TIGHT and it was tough to get much leverage but I finally got it to break loose!Sometimes there is a socket head bolt holding it on and few of us have something shallow enough to get in there. Go back with a regular hex head. Lots of times that bolt isn't even installed or the whole bracket is left off.Then you have the mystery bolt under the engine you have to feel for.
Yep. Be sure you seal the starter with some RTV or something by the o-rings. Any moisture in there will cause the brushes to corrode and it won't work. Even OEM starters. I don't replace the bearings unless something is bad. 95% of the time I clean it all up and replace the brush holder alone. Chances are you get too large an o-ring for the bolt that connects to positive cable. I end up using the old one as it is smaller. Good Luck!
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RESTO 95 XP800 Resto Thread
- Thread starter Loganab13
- Start date
Had a rare day off today so I decided to take a look at the starter. Per the advice of @etemplet, I tore down the starter that came on the ski to try and figure out if it's an OEM or some sort of aftermarket. I'm still not 100% sure since the tag is painted over, but the internals seemed to pretty well match all of the other known OEM starters I've rebuilt in the past, with the exception of the exterior being painted black instead of white. To my surprise the internals were almost spotless and the brushes were in good shape. So I decided to roll the dice, clean everything thoroughly and put it back together. I bench tested it afterwords and sure enough, it appears to work like a charm.
I still haven't had the chance to send my MPEM off to @Minnetonka4me to get keys programmed to it and I didn't feel like swapping the gray box in from my 96 since it was getting late, so hopefully I'll have more time this coming weekend to check compression and see if it'll start. I noticed the rear e-box was broken at the battery tray, so I pulled it out and will replace it with a spare I had laying around. The fiberglass around the screws holding the box to the hull is stripped, so I'll have to address that as well. Rivnuts maybe?
I still haven't had the chance to send my MPEM off to @Minnetonka4me to get keys programmed to it and I didn't feel like swapping the gray box in from my 96 since it was getting late, so hopefully I'll have more time this coming weekend to check compression and see if it'll start. I noticed the rear e-box was broken at the battery tray, so I pulled it out and will replace it with a spare I had laying around. The fiberglass around the screws holding the box to the hull is stripped, so I'll have to address that as well. Rivnuts maybe?
Looks like I picked a good one to save.
I swapped the gray box from my 96 in, sprayed a little premix down the carb throats and it cranked twice and fired right up. Only issue, after checking compression, I went to start it up and it blew the 15A fuse in the rear e-box. I replaced it and it immediately blew again. I vaguely remember chasing this issue when I restored my 96, but can’t recall what fixed it other than checking grounds. Any ideas?
I swapped the gray box from my 96 in, sprayed a little premix down the carb throats and it cranked twice and fired right up. Only issue, after checking compression, I went to start it up and it blew the 15A fuse in the rear e-box. I replaced it and it immediately blew again. I vaguely remember chasing this issue when I restored my 96, but can’t recall what fixed it other than checking grounds. Any ideas?
If this is an XP with trim motor pull the 7.5 amp fuse from the trim.
Deutsch connector for the VTS unit is unplugged, first thing I tried and it still popped the fuse. I’m wondering if there’s metal shavings or something going on with the stator. Need to test for continuity at the rectifier tomorrow I guess.
I "saved" a 1995 787x XP800 last year. It's almost the identical condition as yours. Left outside for 10 years, the seat was trashed from being sun baked I was able to get it running but stator was bad and had issues with the ebox. Compression was 150 and the engine bolts were never touched. Paint was perfect and not chipped. But after a day of running buoys it start slowing down and I stopped riding. I eventually pulled the motor figuring all the seals were trashed. Nope the front bearing came out in pieces and had a minor seizure. Rebuilt the crank and honed the cylinders. More ebox issues but finally got it running ok. Replaced the VTS, the fuel tank float and battery box. I have WAY too much time and effort into this boat but after racing it at some local races (even winning a few motos) it takes me back to the 90's when these things kicked my ass in runabout class.
Good luck with yours and keep us posted.
Good luck with yours and keep us posted.
I was bummed about the condition of the seat and the missing bar pad when I picked it up. The real kicker is I had a mint yellow bar pad from my 96 that I sold thinking I’d never use it after switching to aftermarket bars. I just love the way these 95’s look with the hump seat and stock bars.
That sucks to hear about the seizure. I plan to check everything I can as thoroughly as possible before running it. This will be my winter project so I’m in no rush. Post some pics of yours when you get a chance!
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