96 GTI.I've had enough. Time to part it out i think....

[MattysGTI]

So i bought my 96 gti from a friend 3 years ago and out of the 6 times i have actually gotten to ride it i only had one good day on the water with it. It spent all of it's life at a freshwater lake. I've spent 95% of my time since buying it replacing parts and fixing this damn thing only to now have the engine seize while getting it started and running after a mere 2 mins. I'm sick of this! I'm also out of work now and can no longer afford to keep wasting money on something that sits on a trailer more than anything.
I have replaced within the last 2 years:
New mpem
New stator
new rectifier
speedo sensor
battery
More stuff i can't recall at this moment
and recently replaced all fuel line with black automotive fuel injection hose,drained and cleaned the fuel tank, Cleaned out the carbs with new filters as one was clogged.
also just replaced the starter and starter solenoid.

Got it running yesterday after it taking 20 mins with fresh gas along with spraying a bit in the carbs directly. finally l got it running constantly for 2 minutes when it shut off out of nowhere. Went to re start it and i got a click. tried to turn over by hand with plugs out and it is locked solid. I realized this was most likely and oiling problem as i heard a slight metal/whining noise while turning over/running. You see, When i first put the carbs on. I didn't notice at first that the cable coming off the carbs that connects to the oil pump housing under the carbs became disconnected. I reattached it after turning the motor over a bit the last time i tried starting it but the starter became weak so i had to wait for a new starter which i installed yesterday and boom, now its seized. I'm assuming the cable that was disconnected is a flow control valve for the oil injection as throttle increases? could that also be the cause of the seized engine as i believe thats why? I'm so sick of this thing that i may be listing it in the classifieds as is for parts or fix with trailer cause i cannot afford it anymore nor do i have any patience left... So feel free to make comments or offers for this friggin thing.

 

[LouDoo]

If the oil cable broke the pump goes to full open, so that's not the cause. I've actually have a 96GTI and love it, I was just commenting on this forum what a pleasure the 96GTI is to ride. Anyway what you experienced may not be a death blow, there could be other causes than an seized engine, if you would like to investigate further to get some help, post back and let us know.

Lou

 

[MattysGTI]

Hey Lou, The cable wasn't broken, Just disconnected. Maybe i re-installed it incorrectly? I did notice also that since doing the fuel line and carbs that in between while sitting there was a small puddle of oil on the ground that came from the exhaust at the back of the ski. i wasn't sure if it was just build up from trying to start it at the time or? I honestly enjoyed the one day it ran great but i was only trying to fix it now in order to sell it for the extra cash and to re-coup some of the money i sank into it. It just seems to me that the engine is done and i'm not sure in what other ways it could be locked like this. When ti died i tried to re-start it immediately with the water hose still on. i thought maybe the cylinders may have gotten filled with water and hydro locked but unfortunately not the case as i removed the plugs to find no water in the cylinders. In the two minutes it did run, There was ALOt of smoke coming out of the exhaust also... the compression on both cylinders is 135psi.

 

[MattysGTI]

OK, After regaining my composure and not being one to give up completely, I decided to pull the exhaust and remove the starter for the 5th time now based on searches of the forum this morning to find out i'm yet another person to make the bad decision to buy an ebay starter. Once i removed the starter and plugs i was able to turn the motor over by hand with the pto. sigh, (smacks forehead) so now i'm going to write the seller a message. i noticed some tiny dings on the end of the starter shaft and also a decent amount of play in it. i haven't hooked it to a battery yet to see of the shaft is bent. It does however atleast have the same amount of teeth as the factory one. and before anyone mentions it, i already tried to rebuild the factory one but it did not fix the starters weak condition like i had hoped which prompted me to spend the 60 bux for the ebay one. lesson learned. Where can i buy a cheap replacement that won;t fail like this? I cannot fathom spending 230 on a new factory one. also, as for the large amount of smoke while it was running. is it possible that when i re-attached the cable to the oil pump that i opened the valve to far when i spun the lever to mate up with the cable? the inside of the exhaust is coated with oil and is black as night.

 

[LouDoo]

I'm happy to see it's not a seized motor, probably the best bet it to PM minnetonka4me and get a good used starter, ask him to take a look at it and if it needs rebuilding have him rebuild it.

Lou

 

[El Toro 33809]

Matty, we have a 96GTI too and really enjoy it. We had one issue, one of the prior owners used too short of bolt to hold the air breather ( under the spark arrester) to the carb. It vibrated loose and took out the gear on the rotary valve shaft. Other than that, it's been bullet proof!

 

[MattysGTI]

Thanks Lou, I'm glad too. I think once i receive the refund from the seller, I'm going to order one from sbt.

 

[MattysGTI]

Thanks for posting El torro, I did enjoy the ONE good day i had with it. that sucks about the short bolt issue you had. I may take it out a few times more before i sell it at least. I think i deserve it after everything it has put me through lol.

 

[LouDoo]

Not telling you what to do, but in my opinion the 96GTI is the best cruiser that SeaDoo ever made. I know you've had your problems but its got the most reliable motor that SeaDoo ever used, produces decent horse power (85HP), will run 45MPH all day and top out at 50MPH. It's got an elongated X4 hull, the X4 is SeaDoo's racing hull, for the size of the ski it's very agile. I can't speak for others but mine has been bullet proof. You can ride this ski all day. You might want to consider keeping the ski.

Besides, if you decide to keep it, I'll lend you my launch crew in my avatar, we don't need no stinkin trailer.

Lou

 

[Dennis]

Matty, you may want to rethink buying a starter from SBT. Their starters are junk. On the other hand, I am very, very happy with their engines. :cheers:

 

[Seadoobuddy]

Matty,
I bought a starter last year for my nephew's Yamaha from DB electrical in Gray Tennessee. Good price and so far so good.
800-753-2242 or www.dbeletrical.com
About $60, shipped to my door.

 

[LouDoo]

Re: the starter, in my opinion you've got three choices, 1. Buy a new OEM, over $300.00, 2. Rebuild the OEM if you have one, and 3. Buy a used OEM from minnetonka4me (this is your best option).

I have never owned a starter from DB, but I do know that they are made in China, probably no better than the EBay starters.

Lou

 

[Rotor13B]

OK, After regaining my composure and not being one to give up completely, I decided to pull the exhaust and remove the starter for the 5th time now based on searches of the forum this morning to find out i'm yet another person to make the bad decision to buy an ebay starter. Once i removed the starter and plugs i was able to turn the motor over by hand with the pto. sigh, (smacks forehead) so now i'm going to write the seller a message. i noticed some tiny dings on the end of the starter shaft and also a decent amount of play in it. i haven't hooked it to a battery yet to see of the shaft is bent. It does however atleast have the same amount of teeth as the factory one. and before anyone mentions it, i already tried to rebuild the factory one but it did not fix the starters weak condition like i had hoped which prompted me to spend the 60 bux for the ebay one. lesson learned. Where can i buy a cheap replacement that won;t fail like this? I cannot fathom spending 230 on a new factory one. also, as for the large amount of smoke while it was running. is it possible that when i re-attached the cable to the oil pump that i opened the valve to far when i spun the lever to mate up with the cable? the inside of the exhaust is coated with oil and is black as night.

If you rebuilt the starter and it's still weak I would look at the power and ground wires to the starter. Also make sure you don't have a brush that is hung up or binding on the commutator.

 

[brock1]

buy it from minnetonka or 99spxxx ....they are very cheap and their OEM ......plus they stand behind all their parts .......you wont be dissappointed just PM HIM

 

[MattysGTI]

Thanks to everyone who took the time to post their advice and opinions. I'll get in touch with minnetonka or 99spxxx soon about another starter.

 

[MattysGTI]

I got a starter from minnitonka and it works great. I am however still having problems getting this thing to run. I was able to get it running yesterday for about 5 mins straight. it died and wouldnt stay running after that. Im at my wits end with this thing. I have tried changing the LSA from 1 all the way up to 2 turns out. When it was running it had the air box off but the arrestor in. Now i put it all back on and it wont even run for more than seconds. I readjusted the LSA again to no avail. When it was running yesterday as soon as i touched the throttle it died. wtf...
This all started after i replaced the fuel lines, filters and cleaned out the carbs. while trying to start it now its sputtering and spitting like timing is off somewhere. The last time this thing ran great it sheared the flywheel key and i had to repair it. since then the pto carb filter clogged up which led to the fuel line replacement and carbs being cleaned up. I just dont get it...BTW i took out the plugs and they were wet.these plugs are new

 

[MattysGTI]

Ok, The REAL underlying problem has been found. I had my ideas but i was hoping i was wrong and put off checking it until today. To my dismay, The flexplate loosened up yet again and sheered another woodruff key(with red locktite mind you). I had to cut the nut in order to get if off. so now i need a new key, a nut and a good cleaning of the metal dust/particles in the housing now. It never ends....

 

[Robj]

Did you put locktite in the shaft too, in between the flywheel and crank? I think the manual calls for blue locktite. Also did you use a torque wrench to torque the flywheel nut?

 

[creeegtara]

I am looking for a parts ski

i would be interested in puchaseing it complete as a parts ski please let me kow what you are looking for

So i bought my 96 gti from a friend 3 years ago and out of the 6 times i have actually gotten to ride it i only had one good day on the water with it. It spent all of it's life at a freshwater lake. I've spent 95% of my time since buying it replacing parts and fixing this damn thing only to now have the engine seize while getting it started and running after a mere 2 mins. I'm sick of this! I'm also out of work now and can no longer afford to keep wasting money on something that sits on a trailer more than anything.
I have replaced within the last 2 years:
New mpem
New stator
new rectifier
speedo sensor
battery
More stuff i can't recall at this moment
and recently replaced all fuel line with black automotive fuel injection hose,drained and cleaned the fuel tank, Cleaned out the carbs with new filters as one was clogged.
also just replaced the starter and starter solenoid.

Got it running yesterday after it taking 20 mins with fresh gas along with spraying a bit in the carbs directly. finally l got it running constantly for 2 minutes when it shut off out of nowhere. Went to re start it and i got a click. tried to turn over by hand with plugs out and it is locked solid. I realized this was most likely and oiling problem as i heard a slight metal/whining noise while turning over/running. You see, When i first put the carbs on. I didn't notice at first that the cable coming off the carbs that connects to the oil pump housing under the carbs became disconnected. I reattached it after turning the motor over a bit the last time i tried starting it but the starter became weak so i had to wait for a new starter which i installed yesterday and boom, now its seized. I'm assuming the cable that was disconnected is a flow control valve for the oil injection as throttle increases? could that also be the cause of the seized engine as i believe thats why? I'm so sick of this thing that i may be listing it in the classifieds as is for parts or fix with trailer cause i cannot afford it anymore nor do i have any patience left... So feel free to make comments or offers for this friggin thing.

 

[MattysGTI]

I put locktite on the shaft on the threads, none on the shaft between it and the flywheel. i know it calls for blue but i decided to use the stronger red since i had it on hand. I did also use a torque wrench.

Creeegtara i'll keep that in mind...