I have a need to replace the cylinder base gasket on my '96 XP. Its leaking water. Not having anything else checked out and hoping its not a cracked block (I'm hoping for the best here). On a scale of 1 -10 ten being highest what level of mechanical skill would be needed to replace the gasket? I am pretty handy with tools and can make my way around an engine pretty well. I've just never worked on one of these before. The manual talks about a checking "gap pinch" when replacing the cyliders (I think thats what its called). That has me through off - right off the bat.
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'96 XP Cylinder Base Gasket
- Thread starter SeaDoonew
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Yup the cylinders. Is water getting in the motor or spraying in the hull?
The squish is to make sure the pistons dont get too close to the head. Not really needed on a stock machine...just use the #5 gasket. (I think...someone please verify)
The squish is to make sure the pistons dont get too close to the head. Not really needed on a stock machine...just use the #5 gasket. (I think...someone please verify)
Well you need to figure out where that water is coming from specifically....most of the time the freeze plugs rot on the pipe and need to be replaced or welded. Or is it shooting out from between the cylinder and the cases?
Dr Honda
Well-Known Member
I see you are in Corrina. So... it probably didn't freeze. On this board we see guys that let the engine freeze with water in it... and that will split the Jugs. (the cylinders) The initial thought is that the gaskets have gone bad... but after they look, the aluminum is actually split.
OK... since you are close to the ocean... I would start to look for a leak around the pipe. And... as above... the welded in plugs are known to decay, and leak. If you look on your pipe, there are a couple weld plugs. Check them, and let us know what they look like.
The base gasket is better to error on the thick side... but I would take the engine apart, before buying one. You will be able to see the make on the gasket, and replace it with the same one. A think gasket is safe, but you will loose a little power.
OK... since you are close to the ocean... I would start to look for a leak around the pipe. And... as above... the welded in plugs are known to decay, and leak. If you look on your pipe, there are a couple weld plugs. Check them, and let us know what they look like.
The base gasket is better to error on the thick side... but I would take the engine apart, before buying one. You will be able to see the make on the gasket, and replace it with the same one. A think gasket is safe, but you will loose a little power.
Greetings Minnwtonka4me,
Thanks for your assistance on this issue too. To answer your question, as far as I can tell the water is coming from the gasket right between the cylinder and the engine block, just over the engine ID tag (Sea Doo XP 1996, 787) but directly under the exhaust port connection. The guy I bought the ski from had made an impromptu repair job using some kind of silicone based sealant. There is no other visible damage to the cylinder (I'm trying to remain hopeful it's still just a bad gasket), but I may be contacting you about replacement parts... Ha ha ha. I guess I won't know until I open it up.
Thanks for your assistance on this issue too. To answer your question, as far as I can tell the water is coming from the gasket right between the cylinder and the engine block, just over the engine ID tag (Sea Doo XP 1996, 787) but directly under the exhaust port connection. The guy I bought the ski from had made an impromptu repair job using some kind of silicone based sealant. There is no other visible damage to the cylinder (I'm trying to remain hopeful it's still just a bad gasket), but I may be contacting you about replacement parts... Ha ha ha. I guess I won't know until I open it up.
Yeah and I am a used parts guy...use the site sponsors for new parts.
Dr. Honda,
I didn't consider a freezing issue you are right. I do live in Southern California and we do not get snow in Corona. The original owner lives in what we call the high desert and they do get a light dusting of snow from time to time. There has also been another impromptu repair job on one of the underside freeze plugs on the tuned pipe, but I don't think its leaking from there. In any case this WILL be another area to focus on for more permanent repairs (I've heard JB Weld works well).
I am still hopeful it's just a bad gasket, but I'm also keeping an open mind to more serious repairs or part replacement. I wont know until I open it and take a look.
I tried taking my ski to a local commercial repair shop but they won't touch it for anything less than a couple hundred bucks, and even then they don't want to touch it unless I agree to have them rebuild the whole top and bottom end. They claim liability issues, and I do understand that, but I also know thats what disclaimers are for. Its not for me to say how anyone runs their business but if they prefer to make 100% of zero in sales instead of a sales amount of a lessor value thats their issue.
This is where guys like you and Minnetonka4me are a huge value to us guys that are left with no other option but to take on the challenge ourselves.
I didn't consider a freezing issue you are right. I do live in Southern California and we do not get snow in Corona. The original owner lives in what we call the high desert and they do get a light dusting of snow from time to time. There has also been another impromptu repair job on one of the underside freeze plugs on the tuned pipe, but I don't think its leaking from there. In any case this WILL be another area to focus on for more permanent repairs (I've heard JB Weld works well).
I am still hopeful it's just a bad gasket, but I'm also keeping an open mind to more serious repairs or part replacement. I wont know until I open it and take a look.
I tried taking my ski to a local commercial repair shop but they won't touch it for anything less than a couple hundred bucks, and even then they don't want to touch it unless I agree to have them rebuild the whole top and bottom end. They claim liability issues, and I do understand that, but I also know thats what disclaimers are for. Its not for me to say how anyone runs their business but if they prefer to make 100% of zero in sales instead of a sales amount of a lessor value thats their issue.
This is where guys like you and Minnetonka4me are a huge value to us guys that are left with no other option but to take on the challenge ourselves.
Yeah most reputable shops are that way with these old ones. You can warn a guy even put it in writing, but when the chit hits the fan and the shop wont fix the motor, they go out and bad mouth you everywhere they can. You may not be that guy, but believe me...those tards are out there.
Look for guys locally on CL...there are plenty of guys out there and if you can show a guy you understand its an as-is repair...they will prob do it.
I think you prob just have a bad base gasket....its pretty unlikely its freeze damage. Could also be corrosion from salt water on the inside.
Look for guys locally on CL...there are plenty of guys out there and if you can show a guy you understand its an as-is repair...they will prob do it.
I think you prob just have a bad base gasket....its pretty unlikely its freeze damage. Could also be corrosion from salt water on the inside.
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