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95 XP rebuild: Hope you enjoy!

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newfiedoo

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So, in early August, I decided I should pick up an older Seadoo for the nieces and nephews. I figured I'd get something in rough shape, and take the winter to restore it. It came together much faster than I anticipated! I've never tackled anything like this before, but figured with forums like this, I could learn.

Within days, a 95XP came available for $1000 Cdn without a trailer. Exterior was in great shape; rod bearing was gone. He had taken the head off, enough to diagnose the issue. I saw a hull full of parts with two pistons sticking out.

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The ski had been through the Fort McMurray forest fire a couple of year back, and had smoke damage. Insurance paid him to redo the exterior. He changed the colour from purple to black, added new graphics and seat cover, and created a one-of-a-kind. We agreed on $900 including the trailer, and took it home.

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Got the engine out without any trouble.

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Picked it down to the crank.

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Happily, there's a local guy who has been rebuilding Rotax engines for decades. Brought it to him, and he redid the crank, bored the cylinders, and installed new pistons. I cleaned it up, and gave it a new paint job to match the new colours

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Replaced all the gas lines, and the two small oil lines (both were cracked and leaking. Would this cause the rod bearing to go?)
Cleaned the hull with Super Clean. Cleaned or replaced the gas selector, oil filter, and gas filter.
Back in she goes!

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Along the way, could not figure out what this mysterious box was attached by silicone to the upper hull! Seadoo forum to the rescue. A 451 relay for the VTS carefully sealed in a tupperware container! I've now seen it all.

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Sorted that out, new tupperware installed! Did an exterior polish, and replaced a couple of switches:

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Gauges all look really good, but only the RPM works. Multi only shows low gas, and VTS gauge is dead. Might need help with this shortly.

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Engine back in, hooked up, and ready for the water test!

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First rides today, and lots of smiles!

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Starts first click when she's cold. When she's warm, we have to feather the throttle to get it running. After it starts, smooth as a 2 stroke can be! Any idea what's causing the need for throttle when warm?
 
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