1996 GSX project with few questions

[JuliusCaesar]

Couple things…..:
Picked up a free 1996 gsx that has been sitting in a field for probably 12 years with no key. It’s a mess but I like to restore so it’s my new project. PO said it ran when parked and they had issues with it fouling plugs. Sometimes it was mag plugs and sometimes pto plugs. Local dealer at the time couldn’t figure out what was wrong. So they parked it.
Engine has never been opened that can tell. Pulled carbs off and while some green on the choke and throttle plates, The insides where surprisingly good as jets where clean but seats were not holding pressure and just leaked by. So I’ll need new OSD kits. Must have been non ethanol fuel back then.
Rear electrical box was badly corroded. No resistance on the fuses so that is shot and I have a completely new box with electronics in the way.
Pulled one rave valve and much to my disappointment the engine is full of water. Pistons are seized to jugs. I guess engine is coming out. Pulled pipe and water poured out.
Can I pull the crank out with the Pto flywheel still attached? It’s seized on there I’d buy a crank and Pto flywheel for replacement just wondering if there would be anything in the way?
Intake grate is broken off. Ride plate is still there and pump came out easily. Screws must have come out of the grate and it just broke off. Still a small piece left that’s attached to the ride plate. Does that just come off and can I just insert another one there.
Not sure how many hours are on this as I can’t get display to light up. Maybe because of the shitty rear box. Hate to throw a grand into this and not have it start. Anyways. Hope to have it on the water by July.

 

[mikidymac]

Yes cases can be split with PTO still on.

 

[burtshaver2021]

Well, I have some experience although it is fairly limited but to try and answer your question about throwing a grand into it and not having it run. I think you’re probably best to leave this one alone, not only is it a non runner which is fine but it’s been sitting for possibly 12 years with the crankcase full of water. I would say at best you’re looking in the neighborhood of 1400.00 to get this back on the water. Just rough estimates but say 300.00 for new pistons and rings, 800.00 for new crank, 170.00 for carb rebuild, 200.00 for machining of the cylinders, new fuel lines? 30.00, new fuel selector valve 50.00, have you checked the prop and wear ring? Does it give you 2 beeps with the key inserted? Or does it at least attempt to crank? Like a thud from the starter? I would have a real good look at the cylinders and cases before putting a dime into it, to see if they have froze and cracked, even if they aren’t cracked, I’m revising my estimate to 1600.00 minimum to get on the water. Is the hull in fantastic condition? If it is, might be worth it to keep it laying around and look for another GSX 787 that may have a rougher hull. You could probably buy a running one for the same or less than your going to put in this. If you do decide to restore this, I would like I mentioned check the cylinders and cases for damage, and at least get power to the starter to verify electronics are any good. I have the same one, mine has no spark, good compression. I’m pretty sure this model year was known to have trigger coil bracket that broke causing no spark.

 

[JuliusCaesar]

i would not want to put a TON into the unit. With the water in the engine, i know the crank is shot, but i can find a "used good one" on eBay for a couple hundred, flywheel for $50 and then new pistons for a few hundred. Probably into it for under a G is possible. I would surmise the jugs can be salvaged if it's just the rings stuck. It wouldn't be used very much....maybe 10-15 hours a summer if that. I have a 93 XP that runs well that i rebuilt. just wanted something a bit faster than 43mph. I have a 1997 tigershark daytona that runs about 55 with some mods, but it's not really a great ride if you know what i mean. I'll see how it goes.

Does the intake that goes into the ride shoe just pull out?

In canada, we have some higher prices for used units. The US is the place to grab deals, but with the tariffs and crap, not worth the trip

 

[JuliusCaesar]

Well, I have some experience although it is fairly limited but to try and answer your question about throwing a grand into it and not having it run. I think you’re probably best to leave this one alone, not only is it a non runner which is fine but it’s been sitting for possibly 12 years with the crankcase full of water. I would say at best you’re looking in the neighborhood of 1400.00 to get this back on the water. Just rough estimates but say 300.00 for new pistons and rings, 800.00 for new crank, 170.00 for carb rebuild, 200.00 for machining of the cylinders, new fuel lines? 30.00, new fuel selector valve 50.00, have you checked the prop and wear ring? Does it give you 2 beeps with the key inserted? Or does it at least attempt to crank? Like a thud from the starter? I would have a real good look at the cylinders and cases before putting a dime into it, to see if they have froze and cracked, even if they aren’t cracked, I’m revising my estimate to 1600.00 minimum to get on the water. Is the hull in fantastic condition? If it is, might be worth it to keep it laying around and look for another GSX 787 that may have a rougher hull. You could probably buy a running one for the same or less than your going to put in this. If you do decide to restore this, I would like I mentioned check the cylinders and cases for damage, and at least get power to the starter to verify electronics are any good. I have the same one, mine has no spark, good compression. I’m pretty sure this model year was known to have trigger coil bracket that broke causing no spark.

i've never dealt with DESS so i'm wondering how i can tell whether it get good power to the unit or at least have the dash light up so i can see if electronics work?

i guess i could ohm out the MPEM and see, but there should be an easier way?

 

[burtshaver2021]

i would not want to put a TON into the unit. With the water in the engine, i know the crank is shot, but i can find a "used good one" on eBay for a couple hundred, flywheel for $50 and then new pistons for a few hundred. Probably into it for under a G is possible. I would surmise the jugs can be salvaged if it's just the rings stuck. It wouldn't be used very much....maybe 10-15 hours a summer if that. I have a 93 XP that runs well that i rebuilt. just wanted something a bit faster than 43mph. I have a 1997 tigershark daytona that runs about 55 with some mods, but it's not really a great ride if you know what i mean. I'll see how it goes.

Does the intake that goes into the ride shoe just pull out?

In canada, we have some higher prices for used units. The US is the place to grab deals, but with the tariffs and crap, not worth the trip

I’m not sure about the intake grate, I’ve only ever had the intake grate off of a Tigershark. I would think it would very easily come off.

 

[burtshaver2021]

i've never dealt with DESS so i'm wondering how i can tell whether it get good power to the unit or at least have the dash light up so i can see if electronics work?

i guess i could ohm out the MPEM and see, but there should be an easier way?

Sorry, not overly familiar at all with testing electronics. I’m just as much the helped as I am the helper. I do believe I recall seeing some test procedures for the DESS post in the manual. When I first got my HX as a non runner with no DESS Key, the first thing I did was take the whole machine to my Local BRP dealer and had them program a new key into my MPEM. I think it cost me 150.00 CDN. At that time. If you look around you can find people that do this. West side Powersports is one. Not much you’re going to be able to do without a key, so that will be your first step. I’m interested to see how this plays out, so please let me know how you make out

 

[JuliusCaesar]

Sorry, not overly familiar at all with testing electronics. I’m just as much the helped as I am the helper. I do believe I recall seeing some test procedures for the DESS post in the manual. When I first got my HX as a non runner with no DESS Key, the first thing I did was take the whole machine to my Local BRP dealer and had them program a new key into my MPEM. I think it cost me 150.00 CDN. At that time. If you look around you can find people that do this. West side Powersports is one. Not much you’re going to be able to do without a key, so that will be your first step. I’m interested to see how this plays out, so please let me know how you make out

for sure, i'll keep you posted as a fellow Canuck. FWIW, the PWC in Canada always seems to have a higher price point for skis. In the US they are a dime a dozen hence the reason i'd like to toss a G in this project and see where it goes.

 

[burtshaver2021]

for sure, i'll keep you posted as a fellow Canuck. FWIW, the PWC in Canada always seems to have a higher price point for skis. In the US they are a dime a dozen hence the reason i'd like to toss a G in this project and see where it goes.

I find they are a little less up Muskoka way, but I agree, more here than most places in states

 

[mikidymac]

With water in the engine you are going to have rust and pitting in the cylinders. You are going to need to have them bored oversized with new pistons and rings. Just new rings aren’t going to cut it.

With a good battery pushing the start button repeatedly should wake up the gauges even without a coded DESS key.

Intake grate is just bolted on and sealed with RTV silicone.