1996 Seadoo XP - how to fix the gas gauge

[Villeneuve27]

So just when you sort out a few problems another unexpected one rears its head. I've done some research online but as of yet haven't found any information regarding the 96' XP 800. I'm assuming there are other models with similar sending units and setups but I am not familiar with them. I have diagnosed the following.

- Gauge itself seems operational, when you plug the key in you get all the bars lit up and then it settles into an empty display state and the gas light comes on.
- There is gas in it! About half a tank right now.

I have read some things regarding the magnets dropping into the tank or a small fuse that blows and can be fixed by soldering a peice of metal into its spot. I will be tackling this over the next day or two along with my VTS issue but I'd like to know where to start, any links to a how-to guide would be appreciated. At somepoint this thing will hit the water and it will all be worth it, it has a fresh rebuild on the motor and mechanically is mint, electronically...not so much.

Thanks.

 

[LouDoo]

The gas gauge problem, at least in my experience has always been the float usually it gets saturated with gas and doesn't float anymore. Get a new float, the newer style molded type.

Lou

 

[manolocross]

Change the fuel float in the gas baffle...99 percent of the time this is the fix. It's easy to do!

 

[Dr Honda]

It's a slim chance that the fuse is bad. The most likely issue is that the float has sunk. The old floats don't like the new fuels. They are made of foam, and they eventually saturate, and sink. Just order a new style float, and replace it. There really isn't a "How to"... because it's not hard... and every ski is a little different. Basically... remove the big clamp on the sender, and pull it out of the tank. Then... pop the bottom off the sender, and replace the float. (it will fall out) Before putting in the new float... make sure there are 2 magnets on the old float. If there isn't ... look in the sender, because one can be stuck up in there.

Before putting back in the tank... make sure the gauge is working. (tip the sender back and forth)

It's really not that hard... and in all my years of playing with Seadoo's... I've never personally fixed a sender fuse. If it's blown... you would know it because you shorted something... or your gauge is full of water, and it shorted the sender. (but it sounds like your gauge is ok)

 

[Villeneuve27]

Sounds like my night is planned then, thanks everyone. I will report back with my findings for other members to read, any idea where to buy a float if I need one? I am located near Toronto, Ontario.

 

[Thumper3322]

Do you have to take the hoses off to get the baffle out? Would be nice if you don't have to.

I ordered mine from Parker Yamaha.com.
Where in Toronto you at? I'm east end.

 

[LouDoo]

I wasn't going to say anything but Parker Yamaha is by far the cheapest, less than half of anyone else. I would plan on removing the hoses, just mark them with masking tape.

Lou

 

[Seadoobuddy]

Villeneuve - If you have the gray tempo fuel line, they have to be replaced ASAP with black auto lines.

 

[Villeneuve27]

Alright here's where I am at...

- Took out the baffle (didn't have to remove the hoses) and removed the bottom cover on the baffle to allow the float to fall out. The bottom cover on my baffle is shown in the picture and simply snapped off, should also snap back on.
- Both magnets are still in the float properly by the looks of things.
- I attempted to move the float up and down its travel but still couldn't get anything registering on the gauge, gauge remains at empty with the fuel light on.

So, where the heck do I go from here, have I properly diagnosed that the float is in fact fine and something else is causing the miscommunication between the float and the gauge?

 

[Villeneuve27]

Villeneuve - If you have the gray tempo fuel line, they have to be replaced ASAP with black auto lines.

Thank you, I will be doing this soon, do I need 5/8ths or 1/2" line?

 

[Seadoobuddy]

size for a XP...ask Lou I'm not sure if it's 1/4 & 5/16 or some of both. My 787 "800" took only 1/4"

Make sure the "float" floats....put it in a jar with gas and see if it sinks or floats. If it sinks, that's your problem.

 

[Villeneuve27]

size for a XP...ask Lou I'm not sure if it's 1/4 & 5/16 or some of both. My 787 "800" took only 1/4"

Make sure the "float" floats....put it in a jar with gas and see if it sinks or floats. If it sinks, that's your problem.

Would moving it within the baffle register on the fuel gauge? I will check if it floats now...

 

[LouDoo]

You already have the new style float, it's sitting on the gas tank. So your problem is probably the sending unit inside the baffle. There's a thread about fixing it but if involves cutting into the baffle, if it were me I would just order a good used one from minnetonka4me.

Lou

 

[Villeneuve27]

You already have the new style float, it's sitting on the gas tank. So your problem is probably the sending unit inside the baffle. There's a thread about fixing it but if involves cutting into the baffle, if it were me I would just order a good used one from minnetonka4me.

Lou

Was really hoping the problem was with the float, what does a used sending unit run these days? Also the fix you mentioned is that the fix where you replace the circuit boards fuse? Here's the link to that http://rivaforums.com/eve/forums/a/tpc/f/6366050614/m/4411068803

 

[BigTwinLake]

I picked up a used 94 XP at the end of the summer last year and have the fuel float problem, in fact about to tear into it.

My reserve also does not work, anyone have any ideas, I figure I can get a "twofor" if I can solve both problems at once!!!

I can deal with a bad fuel gauge OR a bad reserve, but both of them not working is not good!!!

 

[Villeneuve27]

Just wanted to update this thread. I performed the ballast fix and replaced the F1 fuse that was blown with solder. For now the gauge is working normally, wish I had the cash for a new sending unit but I don't at the moment so this will do and hopefully won't let me down.

 

[LouDoo]

Since you got it fixed you should be good for a long time, maybe it's just me but I never liked cutting into a baffle that had been soaking in gasoline for the last 16 or 17 years.

Lou