RESTO 99 seadoo gsx rfi semi restro

[griz400]

spent the day buffing the hull deck and came out nice and glossy with a very slight almond color from age and sun but barely. not enough to go through the sanding process and would have been very time consuming with all the decals sill in place so to me it just wasn't worth it. any one have any tricks of getting the vinyl seat pliable again with out recovering it. the vinyl is stiff and hard but no cracks. ive read that baby oil and left in the warm sun after a good scrubbing works.
your thoughts?

you got that thing lookin real nice, bring it down here in fla and we can get saltwater all over it .......:cheers:

 

[jammin777]

LOL! thanks for the invite but it will never see salt water hehehe.

 

[Jetskigoodies]

You did a great job on the bottom of the hull. As for the color not being perfect, no one will notice but you.

 

[jammin777]

thank you! its really not as bad seeing it with the naked eye, the lighting from the camera really tells all. like the area where i masked the very front of the keel is hardly noticeable just looking at it,
just got my new alignment tool and shims so almost ready to drop the engine in.

 

[PGHMAN]

jamming-you stated that you replaced the fuel pump and screens. I am uncertain on how to test my FP to see if it might be faulty. Any guidance on how to test? Thanks.

 

[jammin777]

jamming-you stated that you replaced the fuel pump and screens. I am uncertain on how to test my FP to see if it might be faulty. Any guidance on how to test? Thanks.

i didn't test the old one, i just replaced it for preventive maint. before i pulled the ski apart i could hear the pump come on when i plug the dess lanyard in and the ski ran but for a short time as it kept fuel fouling the plugs because the pistons were in backwards according to ses who rebuild the engine. the service manual i downloaded has a diagram of what is needed to test the fuel pump which is an inline quick disconnect Tee with the fuel pump test gauge connector. you can make your own which is what i'm going to do.

 

[PGHMAN]

gotcha. I may go that route and replace the fp to avoid issues later on....$36 for the pump plus screen is cheap insurance. Have you ordered a new rectifier? BTW, your hull cleaned up very nice.

 

[jammin777]

thanks, haven't ordered a rectifier yet but leaning towards the 4 tec one from osd as i want a good heavy duty one and not sure of the one griz mentioned if it's heavier duty or not. I'll let you know what i decide when i get it.

 

[PGHMAN]

Kevin - I just order the HD rectifier from OSD......on sale for $99! It's been $129 for ever. Score!!!
Rob

 

[jammin777]

Kevin - I just order the HD rectifier from OSD......on sale for $99! It's been $129 for ever. Score!!!
Rob

thanks man! very coo!l OSD here i come.

just ordered one, the last one.:cheers:

 

[jammin777]

just received my rectifier from osd yesterday, as some of you know the ft notes on osd web page states that a little mod may be needed to get it to mount up. the existing bolts are too short, so i pulled the mounting plate out and all i had to do is pound the threaded studs off of the plate and bought a couple of longer 6mm stainless 6mm bolts. the mounting holes on the 4 tec rectifier is at mid level which leaves room for some nuts under the rectifier so that i can bull the bolts from the back side of the mounting plate with nuts to tighten it to the plate, then mount the rectifier. this allows for easy replacement without having to remove the plate again. that's it! easy and should have a bullet proof charging system now.

 

[jammin777]

i painted my exhaust today using high gloss hi temp black.
ordered my fuel injectors, maybe next weekend ill get to install the engine.:thumbsup:

 

[PGHMAN]

Coming along quite nicely. I received my OSD rectifier as well and mounted over the weekend. I used 1/4" x 1 1/2" galvanized lag bolts to mount to the top off the electrical box - fit the existing holes well.
May order the fuel pump this week to do the rebuild.

 

[jammin777]

finally

feels great to finally have the engine installed. got to use my new alignment tool as i had to shim it just a bit and got it perfect. torqued the mounts and all is good. the hardest part was remembering where some of the cooling a oil hoses go but got it sorted thanks to another thread. still need to install the electrical box, exhaust pipe and all. should be a lot easier if there's a next time as I've learned a lot with this ski as well as hanging out with this great forum of seadoo fanatics.:thumbsup: now i hope it all works when done! lol!

 

[PGHMAN]

Coming along quite well. Curious, what set-up did you use to attached the come-along? Appears that you have two 2x4s. With the help of my wife and daughter I lowered mine manually.....wasn't too bad.

 

[jammin777]

thanks. I screwed a 2x4 on the ceiling floor joist and used the verticals (wedged floor to 2x4 on ceiling for support.

 

[Ruskeyjdm]

Looks good jammin! Painted exhaust turned out really nice.
It's a great feeling to get the motor in and hear it run for the first time.

 

[jammin777]

thanks, at first i tried painting the exhaust original silver to match the engine but it was doing weird things so i decided on black and turns out i like it better. yep soon i will be experiencing that great feeling of firing it up.

 

[jammin777]

took me 4 hours but finally filled the empty space on my rfi gauge cluster and installed a speedo and quite happy with the results. as most of you know the gsx rfi only has the info center. i pulled the info center measured the mounting hole and made a template. remeasured several times to make sure it was perfect as i didnt want to screw it up as it was quite scary!
cut the hole with a 2 3/4" hole saw and used a dremel with a barrel sander to finish it off to 3 1/2".
not so scary after all! lol! now to wire it up. i have a old non working info center off a 97 gsx that has the plugs for the speedo as the rfi one doesn't, going to rob the plugs from the extra info center and tap into the one for the rfi
should be very easy. color coated wires are the same.

while trying to figure out how to get the pump seal out out of frustration i gave it a break and decided to hook the battery up to see if the analog speedo that i installed actually works, well it does indeed work! yay! blew a little compressed air and i'm a happy camper.
hopefully this will be of help to someone.
all i really have left to do is install the seal on the pump (which is a pita by the way as i'm trying to find find a make shift tool to get it out. any ideas would be appreciated.) install the drive shaft, pump, ( bought a stb rebuild stock impeller) and nozzle.
need to get to the stealer to buy some injection oil and then gas. been really busy these days but it is close. should be on the water in a few weeks.

 

[jammin777]

during my first ride, i found that my oil tank had a small leak at the seam so i found a very clean one piece tank from a 96 gtx on fleabay and bought and installed. hopefully will be on the water tomorrow to continue the painful break-in. lol!

 

[Littleboots]

Where did you get the yellow gel coat? I have a 96 I'm trying to match the yellow.

 

[jammin777]

Where did you get the yellow gel coat? I have a 96 I'm trying to match the yellow.

http://www.gelcoat.ca/index.php?p=catalog&parent=2&pg=1