Intro and new to me 96 XP, with a few questions

[KayakNFly]

Hey all,
I'm new to the forums, been doing research here for the last few months on getting a seadoo. After searching for a while I picked up a 1996 XP. It's in pretty good condition, original engine, unknown hours, good gel coat, some fading on seat, hood and handle bar pad. Trim works, gauges do not. Will try and fix those this fall. Has a r&d ride plate (assuming 3 degrees), westcoast grate, and an unknown AM impeller. Read all the info on cleaning it up, lots of good info on this site. Engine has 148/153 compression. Excited to get it on the water but going through and replacing the fuel and oil lines, and all the general MTC items, also added a inline fuel filter. Haven't had it on the water yet, waiting till all the above is done. Just in case.

All has gone well with everything except the carb.
I had a few questions on the carb.
1. I was unable to take the screws out of the MAG carb for accesing the carb filter, 2 of the 4 are stuck and the heads are stripping. Any good ways to take them out besides an easy out and new screws? Also where can I find new screws for other than $9.99 off sdw.com if I do have to destroy them?
2. When torquing the MAG carb back to RV cover the throttle sticks. It's fine when not on tight, but as soon as I tighten it it sticks. I don't think it's the cable or spring, both look good and have been lubed. Only sticks when torqued, when I move the throttle. Out of ideas on what to do with it. If I loosen the main carb to RV bolts it frees up. It's not binding on the gasket, took it off to verify. Any thoughts?
3. The nut and washer (http://fiche.seadoowarehouse.com/se...=seadoopwc&a=269&b=14&c=0&d=-CARBURETOR)(part 6 and 7), on the MAG carb are rusted big time. Nothing else is rusted in the entire engine bay, so I think it may have been a none SS nut and washer. The end of the butterfly threading looks to also be worn. I don't want to play with it to much for fear of destroying butterfly valve threading. Any ideas? Works fine as is but worried about it in the future.

Other than that all is well so far. Hope to enjoy the ski.
Thanks for the great forum and the help!

 

[Dr Honda]

1) EZ-out's don't work on stuck screws. They are hardened tools, and they will break. IF... you brake a screw extractor... all you can do is throw away the part.

Put the carb on a wood block, and give the screws a good whack with a hammer. That will break the corrosion. THEN... use a hand impact to get them out. BUT... if you already damaged the screws... it may be too late.

2) I know you said it's not the gasket... but it probably is. OR... the flange on the manifold is badly warped, and when you tighten the carb, it's putting a twist into it.

3) The original parts would have been stainless, or brass. SO... someone obviously put on the wrong nut and washer. And... it sounds like they forced on the wrong parts.

I would chase the threads, and put on a new, proper nut ans washer.

 

[68ragtop]

I wonder if someone over tightened the fuel pump side screws. I have always been able to get them loose with a large flat blade. Shouldn't those screws have both philips & flat? I have found some of the internal valve body philips screws harder to get out.
I have had great success setting the carbs in my hydraulic press, with the press holding a screwdriver down on the screw. Not using the press for its force, but rather using it to prevent the screwdriver from moving up & slipping on the screw head. It works very well.

 

[Jetskigoodies]

http://www.seadooforum.com/showthread.php?59699-New-Hardware-update-kits-for-carbs

I have complete carb screw replacements with an allen head socket style screw.

Use an impact driver to remove the old screws. They are only $8 at harbor frieght. Also when installing new screws use anti sieze

 

[KayakNFly]

Thanks for the replies!
I'll be sending jetskigoodies a pm for one of those kits. And asking around for a new nut and washer.
As for the throttle sticking it was a combination of weak spring on throttle return and also one of the hose clamps I had on the carb fuel lines was catching the paint, causing extra pressure. All is fixed now and working well.
Thanks again for the assistance.