97 GTI issues

[get_real]

Got my 97 GTI running for the first this season and had several issues.
1st Burnt 5A fuse
2nd Exhaust pipe bolts & nuts falling off
3rd Carbon seal leaking

First no start. Did some troubleshooting and found the solenoid was not working. Didn’t have time to order a new one before Labor Day weekend on Lake Hartwell so installed one from a lawnmower and it started. However I’ve noticed the fuse in the back electric box was a 15A so replaced it with the correct 5A fuse. Got the ski on the water and after about 30 seconds of run time tried to restart it and nothing. While on the water checked the fuse and saw it was burnt. Put a 15A back in and it started and ran fine. Am I going to do damage by leaving that fuse in there, and if so any ideas on how to fix it??

Second, Two bolts and a nut fell off the tuned pipe while running the ski. Bailed the water out, found the two bolts, bought a new nut and put it back together. What is the best method to stop them from vibrating out?

Third, the carbon seal leaks while sitting. During the day the bailers keep it dry, but at night when left in the water it leaks gallons. Didn’t have this problem last year after replacing it a couple of years ago, so do I need to replace again or can it be adjusted?

 

[SIMPLEARKANSAN]

Is your exhaust bushing still in place. two rubber grommets, two washers, and a bolt? If it's missing that's prolly why exhaust bolts are breaking or backing out. Does your VTS work? I'd find out why that fuse was popping. Replace the carbon seal.

 

[mikidymac]

Is your exhaust bushing still in place. two rubber grommets, two washers, and a bolt? If it's missing that's prolly why exhaust bolts are breaking or backing out. Does your VTS work? I'd find out why that fuse was popping. Replace the carbon seal.

GTI doesn't have VTS.

 

[get_real]

Is your exhaust bushing still in place. two rubber grommets, two washers, and a bolt? If it's missing that's prolly why exhaust bolts are breaking or backing out. Does your VTS work? I'd find out why that fuse was popping. Replace the carbon seal.

Yes, exhaust bushing was still in place. Also after I replaced the 2 bolts & nut that fell off I noticed the third bolt had broke off when I got home. Pulled the pipe this week and plan to use Loctite 242 blue per the manual and a stainless lock washer on the nut. Painted it purple like my XP. Original light tan paint had been flaking off after I over-heated last summer as I had forgotten to attach the water supply hose.

Still don’t know how to find what is causing the fuse to pop. Also I have replaced the lawnmower solenoid with an aftermarket Sea-Doo unit from Amazon.

 

[mikidymac]

The rubber bushings being bad are what cause the pipe bolts to break.

 

[get_real]

The rubber bushings being bad are what cause the pipe bolts to break.

Thanks. The bushings look ok, does the rubber get softer with age causing it to fail?

 

[mikidymac]

Yes. I always replace them.

 

[Jtamaro]

You should prob try and work out why it’s blowing the fuse, if you can’t sort it out maybe try a 10a fuse rather than the 15a.

 

[get_real]

Thanks, put a 10A in over the weekend and it worked. I may try either a 7.5 or 5 again and see what happens.

Also after replacing the gasket with a new one on the tuned pipe and using loctite and torquing the bolts to 18 lbs, I noticed some water and been leaking out of the gasket. I checked the torque and they all needed tightening. I'm thinking I'm going to have to remove the bolts and redo the loctite again. Going to order a new rubber bushing before then.