1996 HX - restore... well a mild restore

[macedonia64]

That looks like a carb base gasket. Probably not contributing to the oil leak. Try following the large diameter oil lines coming off the oil tank to the crank case. Sometimes the fitting that threads into the block will leak.

 

[AdamXP800]

That is definitely a carb base gasket

 

[Littleboots]

Well after digging and digging, I found out the leak is the oil line under exhaust. How the heck do I get to it? Remove exhaust? Any suggestions? I can't get my hand in there without taking it out. It could also be the fitting / nipple but I can't tighten that with the exhaust on either.

Wish I could shrink myself.

 

[macedonia64]

Thats correct you will probably have to remove the expansion chamber. I would try not to remove the manafold (piece that bolts to engine) or you will need a new gasket.

 

[Littleboots]

Well I removed the entire exhaust. I'll need a new gasket as the other one tore but I just got inpatient. The leak was the oil hose going to nipple behind the exhaust. Apparently the previous owner put a hose clamp on it and tightened it a bit too much and pinched the hose. So I cut the bad piece off and reinstalled it.

Now I'm onto repairing the hole in the gelcoat. I bought the 4 oz kit on ebay and after my first application, I had to add an additional coat.

And the previous owner decided to run a knife across the year stickers.. you know because they are so often stolen. argh.

After my gelcoat patch on yearly registration sticker

After first coat of gelcoat on the hole on the upper side of the hole.

after second application

After first sanding with 180 grit sand paper

This is my first attempt at gelcoat and after watching several youtube videos I'm thinking I can do this. After the 180 I'm thinking 400 grit, 800 grit and then 1200 grit. Then compound and wax, blah blah blah. All this to flip the ski. Well at least this is my practice one before I do the GSX I'm keeping.

Thank you everyone for your help.

 

[Littleboots]

Anyone know if there is a manual or picture by picture walk through on removing the seat and replacing the shock boot?

 

[racerxxx]

Anyone know if there is a manual or picture by picture walk through on removing the seat and replacing the shock boot?

Sent you a PM

 

[Littleboots]

Well it's been a while. I cleaned up the ski. Redid the seat and the grips. Ski fired right up but continued having the oil leak from under the exhaust. Good news is I just sold the ski. $950. Fair price as I only had fuel lines, two spark plugs, gallon of gas, grips and seat material. Under $100 into it. Bought this ski, and a 96 GSX and a galvanized twin trailer for $1500.

Here are some pics on replacing the seat as I had to replace the boot. What a pain in the butt. But I figured it out with some help from racerxxx (thank you) Remove the 6 10mm bolts under the seat and the seat comes off. You then take off the two 10mm bolts on each side up by the front of the seat (knee pads are). Remove the 4 10mm nuts that hold the seat frame onto the rear shock mount. Remove hose clamp on top to remove boot. Unbolt the shock from bottom and take entire unit out. The way I replaced the shock boot was after I got everything off there are two metal round rings inside the boot. They are removable One goes inside boot below the fiberglass. I installed that one inside the boot first. I then slid boot up through bottom of hole and had it dead stop on the ring. I then inserted the top one through the top. With some patience you'll get it in.

Then I slid the shock in through the top and bolted it in.

Here's a few pics of the finished ski.

My fiberglass patch work is almost unnoticeable.

Thank you everyone for your help. I do need help and am restoring the GSX. I'll start a new thread.

 

[racerxxx]

Cool, congrats on the sale. Once you've had the HX apart it's not all that bad, you just need to figure out how to contort your arms to fit in the back.