Advice on how to put fuel baffle back on 1996 GSX

[nammer]

Hi, i was replacing the gray fuel lines on a 1996 gsx that I just picked up, i used a tire iron to get the rubber seal of the fuel baffle off the fuel tank, now..... I can't push it back on, it sounds simple enough, just use a lot of force, but does anybody have any secrets or tricks? I tried lubricating it with some oil, but still no good for me, thanks in advance!

 

[68ragtop]

If your just talking about the rubber seal with the two hose clamps, just spray some WD40 on it. should make a world of difference.
they are snug, but shouldn't be nearly as bad as taking it off.

How did you get your baffel out? there was a couple of us that just did this with the same ski yesterday.
Ironic?

 

[nammer]

i couldn't get it out, not enough space, i hate this ski!!!! i wanted to take the tank out too, i couldn't do that as well, I hate this ski!!!

i just bought it, so wanted to do the lines and put it in the water, i hope it runs

how did you get your baffle out?

thanks for the response as well, i'm workin on it now, so i appreciate the quick response

 

[nammer]

also have you had experience with aftermarket voltage regulator, are they supposed to be the same setup? cause on the one i purchased, they look pretty much the same, but the male and female ends are opposite on the oem and aftermarket regulator, i just wanted to make sure the wires are still the same

 

[ocod]

i couldn't get it out, not enough space, i hate this ski!!!! i wanted to take the tank out too, i couldn't do that as well, I hate this ski!!!

i just bought it, so wanted to do the lines and put it in the water, i hope it runs

how did you get your baffle out?

thanks for the response as well, i'm workin on it now, so i appreciate the quick response

Through the storage bin.
Unstrap tank and push it forward then tilt it so baffle can be pull out.

 

[nammer]

hey oscar, long time no see

i don't recall being able to do that either, i twisted and turned it so much, and even lots of force, but I couldn't seem to maneuver it out, but i gave up, plus i couldn't take tank out to clean anyway, so it's all going back together now

 

[SabrToothSqrl]

Don't you remove the steering too, on the GSX, to remove the fuel baffle? then life it out through the steering hole...

I have a 99 that needs a new baffle, but meh...

 

[Minnetonka4me]

Through the storage bin.
Unstrap tank and push it forward then tilt it so baffle can be pull out.

Incorrect on the GSX/GSI/GS skis...


this is the only way....take the steering out...dont unhook anything except the steering cable, then take the 4 bolts out and let it hang to the side.

Unstrap the oil tank and slide it to the side and towards the motor.

Empty the fuel tank, unhook the filler neck, then pull it forward and tilt it at the right angle. The pickup needs to come out through the hole where the steering was.

Reverse for reassembly.

 

[68ragtop]

I pulled mine out yesterday this way on my 1996 GSX, it can be done, but its tight, the tank is very tall.

Please read this post from yesterday. Ignore the "SPX" part this is about a GSX.

http://www.seadooforum.com/showthread.php?56895-Fuel-sending-removal-on-a-96-SPX

 

[brock1]

Incorrect on the GSX/GSI/GS skis...


this is the only way....take the steering out...dont unhook anything except the steering cable, then take the 4 bolts out and let it hang to the side.

Unstrap the oil tank and slide it to the side and towards the motor.

Empty the fuel tank, unhook the filler neck, then pull it forward and tilt it at the right angle. The pickup needs to come out through the hole where the steering was.

Reverse for reassembly.

YEP...just did it the other day ...good luck busted my knuckles ALOT

 

[Minnetonka4me]

top 5 worst seadoo jobs...worst is sponson replacement on a GSX-RFI w/ the sound baffles.

 

[nammer]

thanks for the replies guys, i tried wd40, still no good any other advice, i cannot BELIEVE the rubber is that tight, i tried using an angled screwdriver to loosen it too,

also, can i pour gas in and try to crank it up, even though the baffle is not on tight, i understand there should be a closed system, but as long as there is gas in the baffle, i would think it's similar to having the gas cap open and starting it?

 

[ocod]

Incorrect on the GSX/GSI/GS skis...


this is the only way....take the steering out...dont unhook anything except the steering cable, then take the 4 bolts out and let it hang to the side.

Unstrap the oil tank and slide it to the side and towards the motor.

Empty the fuel tank, unhook the filler neck, then pull it forward and tilt it at the right angle. The pickup needs to come out through the hole where the steering was.

Reverse for reassembly.

I pulled mine out yesterday this way on my 1996 GSX, it can be done, but its tight, the tank is very tall.

Please read this post from yesterday. Ignore the "SPX" part this is about a GSX.

http://www.seadooforum.com/showthread.php?56895-Fuel-sending-removal-on-a-96-SPX

I guess there are exceptions to every rule

I only said it b/c there was ragtop's thread on subject just the other day

 

[68ragtop]

Do you have the rubber seal off completely? If you have it off, make sure nothing is obstructing it. If you spray the top of the tank & the baffle top & inside off the seal, you should be able to pull the sender wire up & through the seal & push it down over everthing. If not, maybe your rubber seal has become too hard & needs to be replaced.

Personally I would never even so much as hook up the battery when messing with the tank, untill everthing is sealed up & the fumes are gone. One little spark somehow with an opening in the tank & we might be reading about it in the paper. So I wouldn't recomend it. If your just looking to test your sender, do it with a multimeter.

 

[68ragtop]

I guess there are exceptions to every rule

I only said it b/c there was ragtop's thread on subject just the other day

Yes, that would be my fault....:leaving:

I was about to give up, or take a hole saw too the top of the hull. Thanks to Lou & ocod, I gave it one more chance, removed the electronic box & shoved it further forward. It was not easy at all & not easy to get back to where it belongs. But, nothing got wrecked. After all of that, I am going to order the newer white float, so I will be pulling it apart again....

 

[nammer]

hey 68 ragtop, thanks for your help, I didn't need to test the sending unit, i'm just trying to push the baffle back in place.

 

[SabrToothSqrl]

Worst sea-doo job #3 - 951 pipe on a GTX or GSX.
#4 - reattaching muffler strap on a GSX LTD
#2 changing oil filter on GTX (I'll never do that again, 11 years of use and 300 hours, it looked brand new inside). (I cut it open to look)

back on topic; so I don't have to unhook any of the electrical wires or choke / throttle cables? Just undo the steering cable and the 4 large bolts? That's not too bad.

Do the fuel lines have enough slack to get the baffle out or do you have to disconnect at the other end?

When doing my XP and GTX I don't think I had to...

 

[68ragtop]

hey 68 ragtop, thanks for your help, I didn't need to test the sending unit, i'm just trying to push the baffle back in place.

I would loosen the top clamp & remove the seal completely, then with everything lubed with WD, push it over with the baffle resting in its correct position. The baffel has a lip on it that is the same diameter at the top of the tank, with that pushed up in the seal, I think it might be causing it to flare inwards a little making it tough to get over the neck of the tank?

 

[68ragtop]

SbrTooth, I take it your looking to pull yours without removing the fuel lines. If your pulling the lines off, I would push it too the front & leave the steering alone. that seems like more work to me. Worst thing you might have to do is drop your fuel selector. Mine was already out, so I am not sure if that would have been in the way when I tipped the tank to access the baffle from the front.

 

[manolocross]

Do you have the rubber on baffle upside down??? I did the float on my bosses 96 gsx and had to remove steering assembly... Not to hard just time consuming.

 

[SabrToothSqrl]

I forgot it went to the fuel selector first.... hmmm.

I have 3 other skis with working fuel gauges, so I'm not overly concerned, but I do have all winter to play with it... but I'm leaning towards putting some speakers and an amp on it first...

 

[nammer]

thanks guys, i got it done, i'm prob just a retard, i sprayed the wd 40 from the bottom, but if i spray it on top between the rubber seal and the plastic it slides right on,

my next question is my 96 gsx will not rev over 4300 rpm, could that be a carb issue?

thanks for everybody's help

 

[kicker]

Could be the small filter in the carb that's plugged from the grey lines. I would definitely take them apart and clean them and put a rebuild kit in if required. Those grey lines left gunk all through my carbs.

Next clean the Rave valves.
My Rave valves got dirty last summer and the exact same thing happened......got it to 4300 rpm and that was it. Cleaned up the valves and went like stink again. My fuel lines and carbs were already done.
When it only goes to 4300 is that on land or water?