Where do all the pipes go ??

[Pat-UK]

Hi guys

I did introduce myself in the greet forum whgich explains in detail my situation.

I have bought a dismantled 1998 GTX Limited Bombardier, I have now got the engine re-assembled with all it's new bits and am ready to re-fit the engine.

Never having done one of these before and not being the person that took it apart I am not sure where the hose run from.

I have a copy of the workshop manual but this does not show very much.

Is there any photos or information around that will provide details of where all the grey hoses go, I can post photos of the ones I am trying to connect if that will help.

Many Thanks

Pat

 

[custompartsguy]

with mine I left almost every hose in the hull so when I put the motor back in the hoses are in the exact same put in the precut length, they pretty much lay where they will go, maybe yours it not so easy?

 

[ski-d00]

The grey pipes(we call them hoses here in the US) are the fuel/pulse lines, there should be 3 of them at the carbs. The short one that connects directly under the carbs to the motor is the pulse line and connects to the mag carb at the very front of the carb. The other 2 grey lines are the fuel supply and return lines. The return line goes directly to the fuel tank and connects to the top side of the mag carb at a T-fitting near the idle adjustment screw. The supply line goes directly to the filter housing and connects at the carb on the bottom of the mag carb and sometimes is a slightly larger diameter fuel line(can't remember on the 98 gtxl if it is or not).

On a side note, those grey lines are pretty junky, they deteriorate from the inside and should be replaced entirely, is easy to do with the motor out.

Did you go through your carbs and filters in the carbs? This is a must!

Pictures would help people understand your questions better. There are some very knowledgeable people here on this site who can help.

 

[Pat-UK]

Many Thanks for all your help guys,

almost everything had been cable tied up out the way so nothing is sitting in place unfortunatly.

One short grey hose was connected to the bottom crank case near the starter motor on one of 2 connectors see photo below

Does any one know where these connect to ??

hadn't stripped the carbs, but will do tomorrow now

Also is there only the one oil fill plug, does the oil need to fill the bottom of the sump or just the balance shaft, as I seem to remember everything being seperated by seals and don't remember seeing a way for the oil to reach every where from that one tiny hole.

Thanks again

 

[ski-d00]

The short grey hose is hooked up properly but the hose should be routed up between the carbs(there's a hose tie wrap on the inner side of the mag carb) so that it doesn't rub the moving throttle linkage. The other connector goes to the rave solenoid mounted on the wall of the ski near the spark plugs, there should also be a check valve in the small black hose right close to the connector.
Yes, there is only one fill plug for the countershaft, put 40ml of seadoo synthetic pump oil in it. It is only for the cb and is a sealed compartment. don't overfill.

 

[custompartsguy]

The short grey hose is hooked up properly but the hose should be routed up between the carbs(there's a hose tie wrap on the inner side of the mag carb) so that it doesn't rub the moving throttle linkage. The other connector goes to the rave solenoid mounted on the wall of the ski near the spark plugs, there should also be a check valve in the small black hose right close to the connector.
Yes, there is only one fill plug for the countershaft, put 40ml of seadoo synthetic pump oil in it. It is only for the cb and is a sealed compartment. don't overfill.

where is that fill plugs located and how do you drain it to add in new oil?

 

[ski-d00]

it's located just above the cb gear in the center of the motor, only way to drain is to tilt the whole ski practically upside down.

 

[Pat-UK]

This place is just soooo good

Ok just one more question for now, can you also confirm the following and tell me what goes on the other 2.

Carbs are coming back off shortly to be cleaned and repaired if needed.

Thanks

Pat

 

[custompartsguy]

the middle one is correct for that grey hose, the bottom big one is your fuel feed from your gas tank....and the top one I cannot remember... I will go out and look at mine

 

[ski-d00]

the left side in your picture is the return line that goes directly to the fuel tank, the center one is your pulse line(yes, it is the short grey hose that connects directly under the carbs), the right side is the fuel supply line that will connect to the fuel filter housing assembly in the front of the ski and it is slightly larger in diameter.

Reread my first post for a more detailed description.

What's next? Keep the questions coming...:hurray:

Did you reasemble the entire motor? Looks like somebody did a major weld job on your cases. Did you use 3Bond sealant on the case halves and torque properly? Did you align the crank gear and cb gear to the notches? Did you use seadoo synthetic pump oil in the cb gear reservoir? Just checking b/c these are all mistakes first timers make and are all critical.

 

[custompartsguy]

the left side in your picture is the return line that goes directly to the fuel tank, the center one is your pulse line(yes, it is the short grey hose that connects directly under the carbs), the right side is the fuel supply line that will connect to the fuel filter housing assembly in the front of the ski and it is slightly larger in diameter.

Reread my first post for a more detailed description.

What's next? Keep the questions coming...:hurray:

Did you reasemble the entire motor? Looks like somebody did a major weld job on your cases. Did you use 3Bond sealant on the case halves and torque properly? Did you align the crank gear and cb gear to the notches? Did you use seadoo synthetic pump oil in the cb gear reservoir? Just checking b/c these are all mistakes first timers make and are all critical.

thanks, I could not remember where the top hose went to......I was also going to comment on the weld job on the case

 

[Pat-UK]

Many Thanks once again.

Yes rebuilt whole motor myself, never before touched a Ski engine but years ago used to play with bike engines, it is being kept in a car workshop so all tools are on hand.

To seal the cases I used PU sealant, which is what they use here for all sump gaskets and has a proven track record, and is pretty much "everything proof"

Yep bottem case had a nice crack in it, when I was cleaning and cuttinG the V groove for the welder to beable to repair it, I noticed that a part was almost cracked right off, with a tap of a hammer it was off, so sand blasted the whole bottom case to look for further damage and had the whole thing re-welded, inside if perfect and machined back to original, outside I was not too worried as the extra metal would help keep it's strength.

Oil is being delivered tomorrow.

Yep Dot and line on Balance and Crank Shafts all lined up.

All torqued up, in correct pattern, although I was suprised at how low the torque setting for the top end was.

All the rest of the hoses seem to be obvious to where they need to be looking at the engine.

Thanks again for your help, I might even have it running for the weekend

 

[Pat-UK]

Sad and depressed now

Have no spark, checked all fuses and the wiring, turns over but no spark.

Have no trigger signal at the ignition coils, so have put a scope on the trigger coil and the signal is almost nothing, so i'm guessing that the trigger coil is dead, does anyone know what resistance it should have ?? or what the triger coil output voltage should be.

Thanks

 

[Pat-UK]

I have 90 ohms on the trigger coil,

Also on the stator plug I have 6 wires but on the loom I only have 5.

Another thing After speaking to the guy I bought the ski from he insists that NO WORK other than servicing has ever been done on it from new, he bought it brand new.

This is where I am now concerned, I know the ski was stripped at a propper shop and left for a few weeks, I have a horrible feeling that while it was there the better bits were swapped for "not so good" what reinforces my thinking is this.

The date code on the stater plug says 1996, bottom engine case 2000, top case 1998, bores 1998, paint on bottom and top do not match, stater case does not either.

The guy had owned it from new and has every receipt for every bit of work done, and none involves the changing of any major bits.

At the end of the day I bought it boke and knew it was, but still feel a little miffed that it could be possible for this to happen.

and I WILL NOT SAY OR MENTION THE NAME OF THE SHOP THAT STRIPPED IT !!!! EVEN VIA PM.