1996 HX exhaust blues - pinhole leak

[JPX]

My 1996 HX has been getting sidelined due to my recent access to both a 96 GTX and a 96 GSX which are much more family oriented. The HX failed to operate correctly on a recent vacation with poor idle and no RPMs when gassed.

I did notice water coming from somewhere on the exhaust pipe by the engine. But only today got to take a closer look.......and I don't like what I have found. (click picture to enlarge)


Ugh - going to need a new one I guess. Or weld it.
http://www.boatangel.org/seadoo/thread.htm
http://www.sea-doo.net/board/thread.asp?threadid=52855#489766

More to come as I get around to working on it.

 

[JPX]

Today I took off the exhaust pipe from the HX.

Started with a fully assembled motor.


Dosconnected the water line - the corrosion is on the outer part of the flange. Inside the head looked fine and there was no debris in the hose.

 

[JPX]

Once the pipe was off, I was relieved to see that the mating surfaces were fine. The gasket was doing it's job and no evidence of cooling water crossing through the exhaust.


And I got a good look at the leak - the pinhole on the flat round spot where the plug to the water jacket is welded on.


I'll spend some time grinding the paint off and seeing about getting a welder to check it out.

 

[JPX]

BACK FROM THE DEAD.....and yet still not quite alive.:leaving:

I got a used exhaust pipe but simply did not have the time to install it for ....what, 9 months?

So I got the new pipe back on. Nice thing about stock to stock is everything just plugs right back in. I kept the "holey" pipe just in case I stumble across anyone that could weld it......although I suppose it is not beneath me to JB weld it shut.

I decided to take apart the forward side of each carb to clean out the internal filters. Since I didn't have a carb rebuild kit or pop off gauge handy, I just did this portion of the "clean".




Well, sure enough the filters were clogged.




So I soaked them in soapy water and then gently brushed out the junk. Linty cloths should not be used, and also harsh solvents like carb cleaner should be avoided.


Unfortunately after all this, the ski still doesn't run quite right. I have high revs out of the water. But in the water, I can't get high revs and the motor simply doesn't crank out enough to go over 20mph. Since electrical is checking out okay, and the carbs have never been touched, a carb rebuild is seeming appropriate.

Sooooooo, the next steps are as follows (my wife is already dreading all this time I'm going to burn on this boat):
1. Pulls carbs completely for a full rebuild.....still need to improvise pop-off measurement (and stay cheap).
2. Replace the grey fuel line with new black automotive fuel injection hose.
3. Buy a huge number of hose clamps for said fuel hose.

I'm looking to sell the HX since I am running out of space to house it. Plus I have unlimited access to a GTX more conducive to my current lifestyle with kids. But it is a bit tough to sell a boat that runs badly. Besides, after the carb work, I might just use it one last time for a houseboat trip this summer......stay tuned!

 

[jsun3701]

Where did you pull those filters from? I have a 95 HX do I have them?

 

[timmyboy76]

jsun....yep, in the carb/s.

 

[robin savell lloyd]

BACK FROM THE DEAD.....and yet still not quite alive.:leaving:

I got a used exhaust pipe but simply did not have the time to install it for ....what, 9 months?

So I got the new pipe back on. Nice thing about stock to stock is everything just plugs right back in. I kept the "holey" pipe just in case I stumble across anyone that could weld it......although I suppose it is not beneath me to JB weld it shut.

I decided to take apart the forward side of each carb to clean out the internal filters. Since I didn't have a carb rebuild kit or pop off gauge handy, I just did this portion of the "clean".




Well, sure enough the filters were clogged.




So I soaked them in soapy water and then gently brushed out the junk. Linty cloths should not be used, and also harsh solvents like carb cleaner should be avoided.


Unfortunately after all this, the ski still doesn't run quite right. I have high revs out of the water. But in the water, I can't get high revs and the motor simply doesn't crank out enough to go over 20mph. Since electrical is checking out okay, and the carbs have never been touched, a carb rebuild is seeming appropriate.

Sooooooo, the next steps are as follows (my wife is already dreading all this time I'm going to burn on this boat):
1. Pulls carbs completely for a full rebuild.....still need to improvise pop-off measurement (and stay cheap).
2. Replace the grey fuel line with new black automotive fuel injection hose.
3. Buy a huge number of hose clamps for said fuel hose.

I'm looking to sell the HX since I am running out of space to house it. Plus I have unlimited access to a GTX more conducive to my current lifestyle with kids. But it is a bit tough to sell a boat that runs badly. Besides, after the carb work, I might just use it one last time for a houseboat trip this summer......stay tuned!

Very good post. Thank you for taken the time to show us all. :cheers:

 

[JPX]

The adventures of working on this HX continue here->http://seadooforum.com/showthread.php?t=4809

 

[jsun3701]

Thanks do they just pull out or do I have to take the carbs apart?