New to me 2001xp tons of questions

[Jaiello]

I just bought a project 2001 seadoo xp. Long story short. Got the jetski for a a few hundred bucks. This is my second time owning seadoos. The other two I had I had zero issues with. This one I bought as a project to work on. It has the 951 engine. The previous owner said it had low compression on one cylinder and it would surge up and down. He rode it back to the dock and left it. He said it needed a top end. I said what the hell I am handy and have had and I own a boat and have worked on many engines. Well that was a load of you know what. The true story once I cracked open the engine was a disaster. One of the pistons looked burned. After looking more into it. The piston rod is bent and all the pins for the Bering where on the bottom of the crankcase. The piston rod moved up and down and wiggled. I have no idea how he can say he rode it back bs. Anyway, ordered and installed a new crank with new pistons, and all new seals. I am waiting for the cylinders to come back from the machine shop to finish and get it in the water. I had to go .5 over on the bore and pistons. My questions are as follows:
1-Do I have to trim the rave valve with only .5 over ?
Some say I do others I don’t.
2-Anything I need to do besides premix the first start up?
3-Also anyone knows where I can get the rubber that goes around the gauges ? Mine are trashed being as he left it out in his yard (I had to sand it down 800,1000,2000 then rubbing compound then polish then wax. It looks new what a pain
4-Any suggestions on draining the gas tank without removal? Gas is at least 8 months to a year old.
5-Also what should I do about the carbs? I really do not want to rebuild them since it never turns out right. At least everytime I have tried on every engine it makes a mess of getting things tuned right.

Any suggestions are welcomed this type of forums are invaluable to people that work on their own stuff. It wouldn’t be fun unless you can tinker with your toys

 

[Jaiello]

More pics

 

[Sportster-2001-951C-Stock]

You have to rebuild the carburetors, that's probably part of the reason the cylinder was destroyed. That and too many hours are the thing that does them in.

Don't go hog wild replacing parts in the carbs, they just need a thorough deep cleaning, concentrate on the smallest passages the most or buy new carbs. Use mikuni parts, re-use the original springs, and replace the metering needle for sure. Make sure the accelerator pump works and both accelerator pump nozzles aren't clogged, carb cleaner will get the goo out of them. The thimble filters inside the carbs will be full of junk some of it is from the Tempo fuel lines.

Make sure there are no inward air leaks in the fuel lines, a low pressure test to confirm this is the ticket.

Replace the grey Tempo fuel lines, they're carb cloggers.

 

[Sportster-2001-951C-Stock]

You have to siphon the stale fuel out, might be a good idea to clean inside tank if there's trash in there.

The service manual gives good advice on how to measure the RAVE valves by dropping them in while the head is off and measuring.

Does the machine shop know how to chamfer the port edges so the rings don't snag in the ports? This need to be done correctly.

 

[Jaiello]

The machine shop does know he has done these before. I will make sure so it doesn’t snag a ring.

Also thanks for the advice I will order the mikuni carb rebuild kit. I will reuse the original springs. I don’t have the grey lines looks like someone has replaced them. Also if someone can direct me to a good rebuild thread and tuning the carbs after I rebuild them. Having two seems it would be tricky.

 

[mikidymac]

Give the machine shop the RAVES and have them clearance them.
Send the carbs to PWC Muscle if you don’t want to do them yourself. Replace strainer, selector and run API-TC full synthetic oil.

Did you rebuild the balancer shaft?

Make sure you align the engine with the proper tool, very important on your ski.

 

[Jaiello]

Counter balance bearings and sprocket where perfect. I did give my machine shop the rave valves. I been watching videos and reading the carb disassembly I think I can handle it. I am going to order the mikuni carb rebuild and tackle it seems simple. Any suggestions on tuning the carb after I get it all back together ? Thanks for the help

 

[Jaiello]

As far as the alignment the countershaft and camshaft have a mark I aligned that mark. The engine turns over smooth as silk now.

 

[mikidymac]

Check out my carb rebuild thread.

I’m talking aligning the engine in the hull. Not the crank and balancer.

 

[Sportster-2001-951C-Stock]

It's like mine, the 951 with Mikuni SBN 46i, correct? Set and forget the mixture screw position on these, idle mixture screw 1.5 turns open from the seat and this factory recommended position is dead nuts. High speed mixture adjuster is zero turns open from seat.

You might need to adjust idle speed. Make sure accelerator pump is working. And it's good advice, the engine must be aligned to the pump using the alignment fixture tool.

 

[Jaiello]

Thanks you guys have answered a lot of my questions.