96 GSX Remove Fuel Baffle

[snoonan]

Any suggestions on removing the Fuel Baffle on a 96 GSX. Do you have to take the engine out? I have removed the steering, but there just doesn't seem to be enough room to pull the baffle out, even with tilting the fuel tank.

I have a problem with air getting sucked in the fuel line. So far the Fuel Selector and water separator/filter passes a vacuum test. All of the fuel lines have been replaced.

Any help is appreciated.

 

[JPX]

I thought you had to move the oil tank out of the way to jostle the fuel tank a bit more.....and it should come out through the steering mount hole.

Wasn't sure if you already did this - did you tank off the fuel lines first? Those things really get in the way. If you have grey fuel line, they will most likely just yank right off the baffle ports.

Also might help to remove the filler necks for both fuel and oil.

I found this fascinating webpage on someone sectioning a GS class hull. It really helps visualize the location of everything in the hull!

http://www.glen-l.com/jetski/seadoo-gs.html

 

[snoonan]

Got it!

Thanks,
It's just my luck. I played around with it on and off for about two days and then posted for help, then figured it out! I was thinking about trying to turn the tank and couldn't because it just didn't look like much room to move it. But finally moved it up and forward enough to just barly get it out. It looks OK so I'm going to test all of the components, ie: Fuel pickup and selector outside of the ski with a small fuel pump I have to see if it pulls air. The selector passes a vacuum test, but perhaps it's only when there is fuel in it. It would make the most sense besides the baffle since the amount of air I see in the line changes depending if it On vs. Reserve. It may just be the selector is inconsistent since it was working for a bit.

Thanks for your help, and cool picture. I never saw anyone separate the Hull!

 

[JPX]

The fuel selector may hold vacuum. But the real test is if it lets flow go through it. I'd use some carb cleaner and a lot of compressed air to purge it out in the ON and RES positions (point the OUT port away from you when you do!) . If you can't get it to clear out, just buy a new one since they are pretty cheap.