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Chasing Oil Leaks

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JPX

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This pertains primarily to pre-1998 models, but the principles are similar across any motorized vehicle (most of my experienced is based on cars).

Injection oil leaks commonly result in a hull full of oil.

The number one source of a leak is at the grommet (part#293720008) below the reservoir tank. It swells or hardens over time and becomes ineffective of sealing the bottom of the tank. It is super easy to replace - just pop off the fitting, replace and pop back on......might need to replace a few zipties as well.

For reference, I had to do this on my 1996 HX, a 1996 GTX, and a 1996 GSX this year.

Another source is a split oil reservoir tank. It may be cracked either across the bottom at the molding seam, or along the mid-height seam (top and bottom halves). Possible solutions include resealing the tank, replacing the tank, or simply not filling the tank beyond the half-way mark (below seam). You should also check the filler hose and the clamp. The corrugated hose may have a hidden split in it. I have not run across this yet, but I can very easily imagine it.

In my case, I had already complete the above checks on a 1996 GSX and it still emptied a quart of oil into the hull again.

I had to remove the stock airbox to get to the oil fitting on the starboard side. The hose was already hardened and ready to split (although it hadn't started leaking yet).


For the port side oil fitting, the hose had completely hardened and turned out to be the source of my leak........lots of fun trying to get a gallon of oil out of the hull.:mad:

The picture below is the port side fitting with a NEW hose clamped on.




I will leave descriptions of "worse" leaks to the experts. These types of leaks are related to the crankcase itself or driveline.

Once you find the source of the leak, be sure to clean up the bilge! Here is a link with some useful tips to clean up the mess->http://www.seadooforum.com/showthread.php?t=498
 
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Excellent Post!

I just want to add that if you are using the Oil Injection system, I highly suggest switching to premix.
 
Phantom oil leaks..............

After testing a recently "saved" GSX, I cleaned up the bilge with oil eater degreaser and made things nice and tidy. But a small amount of oil kept accumulating in the bilge.

Go figure on this picture:


Appears to be oil seeping out the the zip tie mount. I presume that the hull was saturated with oil in the laminate between the outer hull and inner hull. I don't even know how to deal with this one. Maybe have to put up with it until it eventually stops coming out?
 
Another source of a mystery leak can be worn rotary shaft seals and it will make an engine smoke upon first cranking/firing. The oil bath for the rotary gear will leak into the intake cover area.
I've also seen a worn rotary cover o-ring leak can cause a lean condition, or drip oil from a leaky rotary shaft leak.

Oil tank leak grommets are common too.

Loose hose clamps under the motor and side of block for the rotary gear supply and return can become loose also.

PArt number 9 will leak the oil in the intake area
Parts number 20 and 30 will have the loose hose clamps
 
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