Need help replacing fuel selector on 96 GSX

[grusnak1001]

When I remove bucket to view fuel selector from the underside, I can not even see it (let alone remove and replace). Can anybody give me some clues how to go about replacing the fuel selector??

 

[POPPS]

Yes,,,we can help you,,,please post a poc of the position of the selector,,,whether it is on the top,,,or side,,,and then we can guide you through it.

 

[grusnak1001]

Thanks a bunch.. It is on the top.

 

[POPPS]

Remove things in the way...fuel/water separator
...inlet hose for the tank...etc,,,i am talking in generalities,,,the goal is to remove the selector with the hoses attached,,,,disconnect the inline to the carb so thst it remains attached to the water separator,,,,,you want to be able to lay the whole unit on a table,,,label your hoses carefully,,,replace one at a time,,,take lots of pics,,,
On top of the ski,,,remove the rubber cosmetic rubber plug,,,underneath it is a small phillips screw,,,use the correct screwdriver,,,pry the black selector knob upwards,,,don't lose the little phillips screw,,,and the tiny washer,,,loosen the black plastic hex nut,,,with your hand under neath,,,you can pull the selector down and out,,,please take note of the orientation of the selector,,,hose orientation,,,etc...so you can put it back without stress,,
once again,,at the beginning,,, remove or pull to the side any hoses in your way,,,
if a hose won't come off the barbed fitting,,,cut it with a knife,
Let us know.

 

[grusnak1001]

Remove things in the way...fuel/water separator
...inlet hose for the tank...etc,,,i am talking in generalities,,,the goal is to remove the selector with the hoses attached,,,,disconnect the inline to the carb so thst it remains attached to the water separator,,,,,you want to be able to lay the whole unit on a table,,,label your hoses carefully,,,replace one at a time,,,take lots of pics,,,
On top of the ski,,,remove the rubber cosmetic rubber plug,,,underneath it is a small phillips screw,,,use the correct screwdriver,,,pry the black selector knob upwards,,,don't lose the little phillips screw,,,and the tiny washer,,,loosen the black plastic hex nut,,,with your hand under neath,,,you can pull the selector down and out,,,please take note of the orientation of the selector,,,hose orientation,,,etc...so you can put it back without stress,,
once again,,at the beginning,,, remove or pull to the side any hoses in your way,,,
if a hose won't come off the barbed fitting,,,cut it with a knife,
Let us know.

Thanks for replying Popps, I'll try this and hope for the best. By fuel/water seperator, do tou mean the fuel filter assembly? And by the inlet hose, do you mean the thick hose running from the place you pour the gas in? If so, now I can see why I could not see anything. I'll keep you updated.

 

[POPPS]

Yes,,,there are 2 8mm clamps on it...i loosen the bottom then wrench it to the side,,,it is very stiff,,,you just need to be ruff with it,,,the water separator has a specific orientation,i like to remove the 10mm nylock nut on the top and drop it for convience,,,don't lose the nut,,,

 

[grusnak1001]

Thanks for replying Popps, I'll try this and hope for the best. By fuel/water seperator, do tou mean the fuel filter assembly? And by the inlet hose, do you mean the thick hose running from the place you pour the gas in? If so, now I can see why I could not see anything. I'll keep you updated.

 

[grusnak1001]

Update...as I was beginning to explore what is involved in replacing fuel selector, I thought I would check the fuel/water seperator. The first thing I noticed was the threads were stripped and would not tighten. The second thing I noticed, when I took a look inside, the rubber o-ring was stretched and could not fit properly. (backing up a bit), the reason for wanting to replace selector, is that the boat would shut down at higher speeds. When I put it back, she started right up but died and would not start so I'm guessing this might be the problem.For now, I am going to replace the fuel/water assembly to see if this solves my problem. I found one on ebay (brand new) for $20. If you have any thoughts or recommendations, I would appreciate hearing from you. Thanks again!

 

[POPPS]

Also...when you are putting clamps on the selector,,,take note if the clamps prevent the selector from sitting flush with the top deck,,,that happens to me often,,,

 

[grusnak1001]

Update...as I was beginning to explore what is involved in replacing fuel selector, I thought I would check the fuel/water seperator. The first thing I noticed was the threads were stripped and would not tighten. The second thing I noticed, when I took a look inside, the rubber o-ring was stretched and could not fit properly. (backing up a bit), the reason for wanting to replace selector, is that the boat would shut down at higher speeds. When I put it back, she started right up but died and would not start so I'm guessing this might be the problem.For now, I am going to replace the fuel/water assembly to see if this solves my problem. I found one on ebay (brand new) for $20. If you have any thoughts or recommendations, I would appreciate hearing from you. Thanks again!

Also...when you are putting clamps on the selector,,,take note if the clamps prevent the selector from sitting flush with the top deck,,,that happens to me often,,,

Well, I'm hoping the F/W assembly will fix my problem, but I'll keep that in mind if it comes to replacing selector....By the way, do you have an opinion on a plastic v.s. aluminum selector? I heard arguments on both sides.

 

[POPPS]

If you are able to find an aluminum one,,,I would get it,,the chinese knock offs sometimes have the selector being out if phase 90 degrees ,,,that is,,,reserve does not point to reserve,,,etc...

 

[bermuda]

If you are able to find an aluminum one,,,I would get it,,the chinese knock offs sometimes have the selector being out if phase 90 degrees ,,,that is,,,reserve does not point to reserve,,,etc...

Good info pops ! Now I know the the one on my ski is probably Chinese - is definitely out of phase.

 

[POPPS]

Happy to help...

 

[grusnak1001]

Update...as I was beginning to explore what is involved in replacing fuel selector, I thought I would check the fuel/water seperator. The first thing I noticed was the threads were stripped and would not tighten. The second thing I noticed, when I took a look inside, the rubber o-ring was stretched and could not fit properly. (backing up a bit), the reason for wanting to replace selector, is that the boat would shut down at higher speeds. When I put it back, she started right up but died and would not start so I'm guessing this might be the problem.For now, I am going to replace the fuel/water assembly to see if this solves my problem. I found one on ebay (brand new) for $20. If you have any thoughts or recommendations, I would appreciate hearing from you. Thanks again!

Ok, I replaced fuel/water separator, and it would not start (it turned over though). I thought it was because I forgot to fill fuel/water separator with gas, but when I unscrewed the cup, it was full. Any idea what's going on here Popps?

 

[POPPS]

Heres my current question,,,why were you replacing the selector in the 1st place?

 

[grusnak1001]

So...another update. Today It started and ran. (Yippie!)To answer your question, I was considering replacing the fuel selector because at higher speeds, it just dies. Typically, it runs just fine up until 4000 rpm, then I give it gas and it takes off like a bat out of you know what for about 1 to 2 seconds and then dies. There is no one around here that works on these things and I'm 66 years old, so working on it myself isn't easy. My question is....based on what I described, does it sound like clogged carb(s) or selector? Are there any easy tests other than replacing selector and rebuilding carbs?

 

[POPPS]

Your issue is either a plugged selector,,,clogged micro filters in the carb,,,however...could be electrical as well,,,if you havent done the selector,,,bypass it and run straight from the separator to the carb,,,and see what happens,,,and will save you lots of work,,,pull the carbs and check the microfilters,,,often its carburation fuel delivery

 

[grusnak1001]

Really great advice Popps...Since I can't reach the fuel lines (attached to the selector) without tearing apart half the tubes to get to it, I would just want to splice the fuel lines, however I don't know what I am looking for.. I guess I would take the fuel line FROM the fuel/water separator (with the arrow pointing outward) and attach it to the fuel line going INTO the fuel/water separator (with the arrow pointing inward). Does this make sense?

 

[grusnak1001]

Wait...that makes no sense..I understand taking fuel line from the fuel/water seperator, but i don't know which line to splice it with ( nor where to locate it)