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RESTO My semi resto 96 XP project

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Did I miss something? Why would he need to remove the whole engine? Why cant he just remove the R/V cover and drill it?

Just gave another option so he didn't have to buy an RV O-ring, but more labor. Also just trying to stress the point that I would do what ever it takes to not do it in the hull and not run the risk of making another mistake. So, by suggesting to remove the engine, the easier option is to remove the RV cover, I guess my point was missed.

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I think the longer bolt option would work. It's just stripped at the top of the bolt holes
Didn't realize how shallow the bolt went into the cover. Trying an epoxy type thread repair fist since it's cheap and easy. Also since this is a low torque item it should be good. Helicoil is absolute last resort at this moment.
 
Ahh nice. So your going to try a longer bolt then? And using the epoxy repair as well? I have never heard of the epoxy repair, hope it works!
 
Yup. Helping a buddy move right now
Then going to lowes to get a longer bolt. There's almost .5" of threads down in there. The epoxy is essentially like jb weld you thread in and it makes the thread of the bolt.
 
Cool Cool, it probably wouldnt hurt to add a little blue locktite to keep that bolt in there, since the amount of threads you will be grabbing now will be less
 
If your going to use a longer bolt that's fine, do not use red loctite, you'll be pissed if you need to take it back off later. Use the blue, it's removable, and it's available at Home Depot for sure and probably Lowes. I know I've preached this before on other threads but as durable and rugged these engines are you really need to treat them like fine china, the aluminum they use is VERY soft.
 
Can't sat I was aware they were that fragile. Good to know in the future. I'll grab some loctite as well.
 
Welp got a longer bolt. Felt it was too long and didn't feel like going back to the store. So tried the old bolt. Held fine. I didn't crank down on them this time. Hand tight then a full turn. That seemed pretty snug. I'll most likely replace that bolt with a slightly longer one. Should have taken the bolt in with me, but by the third hardware store was sure they wouldn't have it.
 
Carbs are now on and secure. Gave them hell putting the hoses and clamps on. They didn't budge so I'd say we're good. Didn't do much else other than clean up my garage and put the ski back in the corner. It's going to get into the 20's at night and want to get the wife's car back in the garage. I'm quite the neat freak so it was driving me nuts to have my garage a complete mess. Not much to take pics of. Just plugging away getting stuff done here or there. I'll be detailing a car next week so I won't be touching the ski likely for another week or so.

Hopefully I'm done doing stupid stuff.
 
You should really be using a torque wrench, takes the guess work out of it. I try and use it wherever I can. That way you don't have to worry about under or overtightening and damaging the threads.
 
You should really be using a torque wrench, takes the guess work out of it. I try and use it wherever I can. That way you don't have to worry about under or overtightening and damaging the threads.

the use of a torque wrench is what got me in trouble. lol Granted I guesstimated the wrong ft lbs from in lbs.
 
WOW! So converted the 88 in lbs into ft lbs......it's 7.3333 ft lbs! That's barely past hand tight.
 
Just get an inch lbs wrench. They are not that expensive. Good to have especially if you have more jet ski projects to work on.
 
Just get an inch lbs wrench. They are not that expensive. Good to have especially if you have more jet ski projects to work on.

Yeah I will. Most of my tools are from my days of working on jeeps. So everything is 100+ ft lbs.
 
really ? y'all don't use red ? case, cyl, head, mag cover ?

Yeah I bought the red loctite as it seemed to be popular in the parts diagrams. May have been just the ones I was looking at. Either way when I used it I only put a tiny dot at the end of the bolts.
 
really ? y'all don't use red ? case, cyl, head, mag cover ?

Yeah I bought the red loctite as it seemed to be popular in the parts diagrams. May have been just the ones I was looking at. Either way when I used it I only put a tiny dot at the end of the bolts.
 
I believe the only place it calls for red loctite is for the impeller, everywhere else just use blue. Red loctite is considered permanent when used on small fasteners and can only be removed with heat.
 
really ? y'all don't use red ? case, cyl, head, mag cover ?

That is anaerobic sealant(gasket maker), not thread locker. There are many many many different versions of loctite. Seadoo uses the red to seal the cases and seal the threads on hardware but on the screws I guess it would double as a thread locker but technically it's a sealant. As far as the case halves, Threebond 1211, loctite blows in this application.

They all have their correct application.
 
There's one other thing that is driving me nuts. For the life of me I can't find anything in the manual about the rear electrical box by the battery. I hooked up the wires to the best of my recollection to the starter, but can't find anything to confirm the wires I hooked up are right. Anyone have a diagram or possibly a pic of which of those wires goes to the starter and which to the battery? As fragile as the electrical systems are on these buggers I want to get it right.

Especially after my bone head move this weekend.
 
The lead with the two small red wires is the one that goes to the battery and the other, well you can guess where that goes.
 
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