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Engine install...

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Brendann99

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I'm working on putting in my motor i had rebuilt and figure I'd just have a thread going with all my stupid questions i'm going to run into.

I stupidly didn't label the battery cables. There are two red coming out of the black box. Obviously one to the starter one to the battery.

I'm guessing the one closest to the middle of the box goes to the starter and the one on the outside, closest to the hull goes to the battery. Yes? No?
 
Cables...?

Brendann99 said:
I'm working on putting in my motor i had rebuilt and figure I'd just have a thread going with all my stupid questions i'm going to run into.

I stupidly didn't label the battery cables. There are two red coming out of the black box. Obviously one to the starter one to the battery.

I'm guessing the one closest to the middle of the box goes to the starter and the one on the outside, closest to the hull goes to the battery. Yes? No?
Click to expand...

Did you take them off your solenoid? If not, then you should be able to look at them to tell which one goes where. It really doesn't matter either. All the solenoid is is a magnetic contact switch. When you hit the start/stop button, it sends a signal by wire (the smaller wires you see on the solenoid) to close that switch. When the switch closes, it's like you've joined the two red wires together to get the starter to roll over. When you let go of the switch, the magnetic plunger of the solenoid pops out, opening the circuit.:cheers:
 
OK. got that figured out. Next stupid question.

Does it matter which port on the oil pump goes to which carb? I'm thinking no. but thought i'd ask.
 
OK now I'm bolting on the carbs. Everytime I torque down the mag side carb the throttle doesn't move freely. If i back the bolts up a few turns it starts moving free again.

The only thing i can think of is the throttle plate is hitting the oil injector there? Is that even possible? Anything else I might be missing.
 
Nm. was sticking on a fuel hose clamp that was right in front of me the whole time. only took me taking the carbs on and off a dozen times to see it.
 
i am installing an engine in my 98 xp and i am having stupid questions as well because im a pretty big noob when it comes to jet skis.. unfortunately, i didnt mark which lines were water and which were oil.. the top two coming from the back to on the top of the head plate, and the other side connects to the exhaust. but their is the oil lines i dont know where they go.. on the carb side of the engine down on the crank their is a oil fitting it appears, and on the other side their is like a tube that connects with a T in the middle? anybody know what im talking about? then of course i have the two lines coming off the oil tank, dont know where those go, and the top of the tank has two barbs, what runs to those? any help would be greatly appreciated. thanks!
 
OK I'm all ready to go...tryin to start it....i replaced all the gray fuel lines over the winter. what's the best way to prime these? I don't want to crank too much with no lubrication. any advice?
 
MJPassarelli said:
i am installing an engine in my 98 xp and i am having stupid questions as well because im a pretty big noob when it comes to jet skis.. unfortunately, i didnt mark which lines were water and which were oil.. the top two coming from the back to on the top of the head plate, and the other side connects to the exhaust. but their is the oil lines i dont know where they go.. on the carb side of the engine down on the crank their is a oil fitting it appears, and on the other side their is like a tube that connects with a T in the middle? anybody know what im talking about? then of course i have the two lines coming off the oil tank, dont know where those go, and the top of the tank has two barbs, what runs to those? any help would be greatly appreciated. thanks!
Click to expand...

Two lines from oil tank:

One coming from bottom of tank goes to oil fitting on carb side. One coming from top of tank goes to oil fitting on other side.

The tube with the t-fitting i'm assuming is the one right by the oil fitting on the non-carb side? this is water and it goes to the line that goes out by where the exhaust exits the hull.

Two fittings on back of head cover:

carb side goes to hull right above jet pump.

other side goes to t-fitting coming off water pressure regulator (black and red cap)


At least that's how i hooked all mine up. Remember I'm a noob too. lol
 
Ok. Next question/problem. It's leaking oily nastyness out of the where the riser meets the cone. I used copper sealant and torqued it to spec. It sux. because that was a pain in the butt to get all lined up. Any advice on this thing?
 
ok I THINK i got it. Just took it all back apart. loaded it with copper sealer. Torqued the clamp before the manifoild bolts.

Next up. Break in procedure....I've read a few things, but anyone wanna chime in? as specific as possible?
 
I may have missed it while reading, on the front of the engine where there is some sort of throttle plate, the oil pump I'm assuming? Their is an oil line that is coming off it, where does that hook up to?
 
MJPassarelli said:
I may have missed it while reading, on the front of the engine where there is some sort of throttle plate, the oil pump I'm assuming? Their is an oil line that is coming off it, where does that hook up to?
Click to expand...

Ah yea oil pump. I left that line attached to the pump and reservoir and i'm not by my ski now to look. that goes to the inline oil filter, and then to the reservoir but i'm not by my ski to tell you where on the reservoir. you should also have to small lines off of that that go towards the carbs...
 
Ok sounds good, that's what I was thinking, for some reason that line was cut, maybe during removal. Hopefully I can get her together tomorrow, someone also said to install the exhaust manifold before the powervalves? True?
 
False. I don't think you could get the one power valves in with the exhaust manifold in the way. But again. don't take anything i say too seriously cause i'm a noob. But my motor came with powervalves pre-installed and i just bolted the manifold on no problem.

Also search around and you can probably find a shop manual and parts catalog .pdf online. Those have helped me out a ton.
 
I hate to ask this, but I'm just about to start my engine today for the first time and was told to "Prime the oil Pump". Mine is a 96 GTX with a 787 engine. Did you do this? If so, how? Can't find anything on this in the MX Manual?
 
There is a small cap you loosen, without the manual for this stuff it is easy to get lost fast, another clue - do not mix oil types in the tank or it can turn to thick goo, but for a quick idea on oiling mix 5 gallons premix using the whatever 2stroke oil you have and start up using this while watching the oil tank drop a little, I mark my tank with a pencil line on tape in the beginning of each year and use premix to give it that extra oiling and when I see the system drinking then I just use gas and go.
 
650Guy said:
I hate to ask this, but I'm just about to start my engine today for the first time and was told to "Prime the oil Pump". Mine is a 96 GTX with a 787 engine. Did you do this? If so, how? Can't find anything on this in the MX Manual?
Click to expand...

On mine there is a bolt right at the top of the pump you can loosen to let the air out of the feed line. (bleeding it)

If you need to prime the small lines to the carbs you can take the oil pump off and use a drill in reverse. or run the engine at idle but hold the oil pump wide open. or don't prime and just run extra premix until you see the oil lines fill up.
 
hey guys i got my ski up and running today, huge relief to hear it run.. although i have a question about the idle. it starts just fine and runs, but it seems as if the throttle doesnt want to return down to idle when slapping the throttle a few times. the ski sat for a few years without running so we were thinking that maybe the carbs are blocked up, not letting the plates return to flat.. but we were also thinking maybe cause it had something to do with us running it out of the water with no load? any help would be great, thanks!

MP
 
Mp. Look up a few posts I was having that prob. It was just sticking on fuel line clamp.

I will be water testing mine tomorrow BTW. Crossing my fingers...
 
hah well good luck! I will be out on the water later this afternoon as well, hopefully i dont have to swim back to shore.. so which fuel line clamp are we talking about? like it will sit and idle or whatever and then when we give it some gas it will come back down, but then with some more throttle it doesnt come back down, just sits in the same place.. its very responsive, when we slap the throttle it reacts immediately so it doesnt seem gummed up.. thoughts?
 
Oh ya, LOTS of info on the fuel gauge here. just search Fuel Gauge and you will have more info then you ever thought. Basically, usually have a float... that aint float'n no more, or a sending unit that aint sending no more... Those seem to be the most common. Sending units will run from 40 - 150, and floats are 12. Lets hope its your float. :)
 
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