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Starting to Revive 2002 GTX DI - New to PWC and See Doo

S

SHardy

New Member
Hi To All - Got a 2002 GTX DI from a friend, who trailered it behind the barn for last 7 years. New to PWC. Have Parts Catalog but not Shop Manual. To start the revival, drained all fluid and cleaned gas tank twice. Blew out all lines. New spark plugs. New battery. It tries to start - almost - so decided to go further. Ordered new fuel pump, new injectors and rebuild kit for air compressor. Jet pump looks good and can't decide whether to rebuild; buy new one; or just try to see if old one will work.

Hoping to get some advice and guidance and if our approach needs to be added to. For example:

*in order to change the air compressor, a video we watched shows to pull the harmonic balancer. Is this correct? Are there cautions regarding reinstall of balancer?

*is it advisable to rebuild a jet pump? Are there tricks to it? Where is best place to get the correct rebuild kit?

*If going to try our luck with the old jet pump, what is minimum required maintenance and repairs needed?

*Seen on other Post that some of these components - fuel pump maybe? - need to pressure tested. Anything else need to be tested? How to test please?

THanks for your time and help.

Steve
 
You should have come here first.
A DI that hasn't run in years is 99.9999% of the time not worth the trouble.

What fuel pump did you buy, hopefully OEM.
 
I would check fuel pressures before messing with the fuel pump or air compressor. You can contact this Gentleman "ajp25564@gmail.com" (Tony) he builds fuel pressure tester adapters for the DI. They work great !! I've done the air compressor rebuild with the engine in the ski and it sure ain't fun but I hate pulling the engine on a DI when I don't have to. Probably just as much work but....

I wouldn't rebuild the jet pump unless I had a reason. If there was oil in the pump the internals are likely in decent shape. You might want to replace the lip seal. Good Luck !!
 
mikidymac said:
You should have come here first.
A DI that hasn't run in years is 99.9999% of the time not worth the trouble.

What fuel pump did you buy, hopefully OEM.
Click to expand...
Miki - On Amazon.. states it's a HFP brand by Quantum Fuel Systems, CA. and claims to be OEM for See Doo GTX DI.
 
etemplet said:
I would check fuel pressures before messing with the fuel pump or air compressor. You can contact this Gentleman "ajp25564@gmail.com" (Tony) he builds fuel pressure tester adapters for the DI. They work great !! I've done the air compressor rebuild with the engine in the ski and it sure ain't fun but I hate pulling the engine on a DI when I don't have to. Probably just as much work but....

I wouldn't rebuild the jet pump unless I had a reason. If there was oil in the pump the internals are likely in decent shape. You might want to replace the lip seal. Good Luck !!
Click to expand...
Thanks for the info.... But have already got air compressor rebuild kit and will pull impalor blades today and do the rebuild. We'll see how it goes. The jet pump was full of oil; no blade damage and spin freely with no apparent bearing squeal, so going to replace the o-ring on cone. What is the 'lip seal' please.
 
SHardy said:
*in order to change the air compressor, a video we watched shows to pull the harmonic balancer. Is this correct? Are there cautions regarding reinstall of balancer?
Click to expand...
I would do that it will make it easier
SHardy said:
*is it advisable to rebuild a jet pump? Are there tricks to it? Where is best place to get the correct rebuild kit?
Click to expand...
Best would be oem but you can get rebuild kits at alot of places. You will need a press to do it.
SHardy said:
*If going to try our luck with the old jet pump, what is minimum required maintenance and repairs needed?
Click to expand...
Oil Change if internals are good. replace the shaft seal and bearings if damaged.
 
IMO, I wouldn't throw new parts at it, take it one step at a time, OEM is the best to have on these skis, so keep it stock as much as you can.. If you buy parts that are electrical or have seals ...go OEM as much as possible. If you cant, check them out well, most aftermarket stuff for this (in the categories I mentioned ) are terrible. I also wouldn't do any upgrades, its a waste of money, these skis are built to (almost) their limit. Upgraded parts are worthless, unless you go full racing mode.
First thing to do is check compression, make sure the bones are good. Then verify gas and spark. Getting new injector or cleaning the one you have is a good move. New battery and spark plugs is a must as well. Check all hoses. I would also take grounds off, clean them and reinstall. Grounds can be an issue with skis.
If you haven't done so get the maintenance manual, it will help with issues, they are free online.

lets us know how it goes.
 
Hey Grim -

Thanks for the info! This thing has set up behind a barn for seven years.

But with just new plugs and fresh gas, this thing almost started! So we just got the old air compressor out and about to install the rebuild one. Waiting on new injectors. New fuel pump delivered tomorrow. New battery. The pump still has all the oil and no sign of water and no blade damage and spins freely with no sound of bearing distress. Going to change the o-ring at cone and seal lip at bulkhead.

Thanks for advice about checking and cleaning all ground wires.

About maintenance manuals... had a real hard time finding manuals. Finally bought a parts catalog manual on EBay, but really need a Shop / Maintenance Manual. Any guidance on where one for a 2002 GTX Bombadier can be found?

Thanks so much!
 
Too many stories of the Quantum pumps not working, I would not bother. They pull too many amps and do not make pressure.
No reason to rebuild the pump if it isn't leaking oil or water contamination.
 
SHardy said:
Thanks for the info.... But have already got air compressor rebuild kit and will pull impalor blades today and do the rebuild. We'll see how it goes. The jet pump was full of oil; no blade damage and spin freely with no apparent bearing squeal, so going to replace the o-ring on cone. What is the 'lip seal' please.
Click to expand...
Lip seal is at the impeller end where the shaft comes out of the pump. It's obviously not leaking but they lose their elasticity as they age. I have them in stock so I can change them pretty quick. I think you're OK leaving it alone.

There is absolutely no reason to mess with the compressor if you have good pressure. It is a total pain in the azz especially if the engine is in the ski. You need to be able to test the fuel pressures. Sometimes it is only an o-ring leaking. Good Luck !!
 
etemplet said:
Lip seal is at the impeller end where the shaft comes out of the pump. It's obviously not leaking but they lose their elasticity as they age. I have them in stock so I can change them pretty quick. I think you're OK leaving it alone.

There is absolutely no reason to mess with the compressor if you have good pressure. It is a total pain in the azz especially if the engine is in the ski. You need to be able to test the fuel pressures. Sometimes it is only an o-ring leaking. Good Luck !!
Click to expand...
Thanks... rebuilt compressor in. Waiting on new injectors but they're way late for delivery. Soaking old injectors in Mineral Spirits and may have to re-install them... just to see if sky gonna go.
 
I agree with etemplet, and why would you mess with the compressor unless needed? Get or make a fuel pressure tester, it is all important. Don't mess with the balancer. If the jet pump is moving freely, don't mess with it until later, just change the oil and move on to your engine issue. You can hardly get OEM fuel pumps for anything reasonable, the after market pumps work , just not as well.

Report
 
To All - IT RUNS!!!!! 2002 Sea Doo that was trailered in the weather behind a barn for seven years. Put it in the water and it goes... just not fast. 20mph top speed. Smokes more that it should so probably a air/fuel mix problem???? Rebuilt air compressor; cleaned fuel pump as best as possible; soaked injectors 2 days. Waiting on new injectors and new fuel pump.

What we haven't done is perform compression test. Haven't tested pressure output on fuel pump or compressor. How do I get or build pressure tested for compressor and fuel pump please?

Thanks everybody for all the advice and guidance so far. These hillbillies on the lake may be really close to having a fully functioning dinasour!
 
Not sure why you won’t listen to the advice given here by people that have been through it and just trying to help you.

But it is what it is.

Please check compression and fuel pressure and report back to help others in the future.
 
Thanks To All - for the time and advice. I've got some responses that seemed surprised at what I'm trying to do in regards to my procedures. And let me say I've never been involved with a WC at all. Never even sat on one. But I live on Toledo Bend lake in East Texas. It's miles across and many miles long, and when I happened on a 2002 See Doo GTX DI for $750, I said 'why not?' Got it from a friend that says it ran when he parked it 7 years ago (behind his barn in a hayfield). Mikidymac told me in one of his first posts to me that 99.9999% probability it would never run, and with that experienced advice, I proceeded slowly. But my approach is based on not wanting my grandkids or some of my friends getting miles from my pier and the thing breaks down. I wasn't interested in testing components to see the pressure output. I was going to rebuild or change all major drive components - just because they're so old - no matter what they tested out at. After I get the major components replaced or re-built, if I start to have problems, at that time I'll have to decide how far I want to go with troubleshooting, followed by repairs and maintenance on such an old piece of equipment

I'm not mechanical, but couple guys I work with helped with rebuilding fuel pump and compressor. With old injectors cleaned, it started in driveway hooked to water hose and motor was fine. We put it in water and were really surprised when it ran! Although in limp mode. Then we rebuilt the compressor and put in new injectors.... and this time it ran @ 55mp through a tank of gas. Unbelievable. We had serviced the jet pump after the first short water test; it had about 1 ounce of oil in it but no water, spun freely without any squeals or grinding, and having sat for 7 years, low oil may be expected. Put in new external seals and oil and all seemed fine. And based on the advice and guidance I got here on this Forum, I decided to try it for a bit, just to make sure everything else on the WC would stay functioning.

But after the 2nd water test where it ran fine at top speed through a tank of gas, the next day there was black oil in bottom of WC. Took the jet pump off and partially disassembled. All the old seals were broke or completely missing. I had initially bought a pump re-build kit, but have learned that it needs to be OEM, which it ain't. And the re-build is a little too much for our limited mechanical abilities.

Well, that's my lengthy story and thanks for your time and considerations. Now at point where I need a jet pump. Have contacted PowerSports for a totally new and assembled pump but not getting very far. Does anyone have any suggestions please?

Steve
 
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