Page 1 of 6 123 ... LastLast
Results 1 to 10 of 53
  1. #1

    Fixing My 97 GTX - A to Z

    I had a thread in the build section but its not really getting the views or help I was hoping for so I am creating it here instead.

    So I decided to make a build thread not only to document the work but to also be more efficient and have one common place to ask any/all questions or ask advice on task I come across. I have here a beautiful 97 gtx that we have owned since 97. It's in need of some TLC but I am hoping with some time and effort to get her running back like she did on day one. A little background on the ski

    -Purchased brand new in 97 with 0 hours
    -Original motor lasted until aprox 300 hours then the oil pump failed and the cylinder cracked
    -Paid a shop nearly $2000 to install a new engine "sbt". Engine lasted aprox 10 hours and they said the rave valve broke & engine ate itself>huge loss of $$ here

    Purchased a used oem engine with aprox 60 hours on it from a shop on this forum & installed the motor myself. I ran into issues with it after doing the installation myself. Long story short the carb settings were all sorts of wrong but it took 3 shops to find this problem and once I found a shop that knew what they were doing it was fixed in 30 minutes and ran great. Fast forward and I ended up winterizing the ski and putting it in storage for 2 years. I took it out this summer, replaced the battery, replaced the starter "was rusted and siezed" and it started and ran but I am having some issues.

    Notes: I am running pre-mix after the oil pump incident. I dont find adding oil to the gas is an issue and I would prefer to just run-premix in the long run if I can get a few more summers out of this ski.

    Known problems:
    -12v low>this flashes nearly all of the time
    -hard to start>sometimes the ski is hard to start>primarily leading this towards the 12v & having a bad rectifier so the battery is constantly dead
    -idles low "900 rpm idle". Drives fine above 900rpm but it sounds a little ruff trying to idle that low and often dies giving gas if you drop the accelerator instead of easing into it off idle
    -speed/mph dosnt work. It shows 0 mph all the time
    -throttle cable broke. The plastic clip around the cable inside the handle lever broke
    -studders sometimes around 4200 rpm or a hesitation at the least
    -had a decent amount of water inside the ski after the last outing, could not determine if it was just from the amount of rain the ski was in while uncovered or if their is water getting in somewhere else
    -floor mats are coming up
    -cover is faded and torn. I patched what i could but its almost 20 years old, time for a new sea doo cover
    -fuel gauge always shows empty

    Now why fix her up? Well I dont owe and money on it, I am mechanically inclined and have the time now to fix it up. It ran great for a really long time when we first got it and I want to get her back up to par. When she runs its a blast to drive. After a good haul glaze back in the day the speedo would read 61-63 on a smooth evening. I dont want to put a ton of money into her but I feel I should be able to complete this project for $500 or less unless something mechnical/major were to come up.

    I am not a mechanic and carbs were before my time so I will be doing lots of reading and asking questions

    The plan parts wise:
    -replacement rectifier>purchased
    -replacement speed wheel>purchased
    -replacement throttle cable & lever>purchased
    -replacement ski cover>searching
    -replacement floor mats>searching & considering hydro turf in molded diamond black
    -pull/clean or possible rebuild carbs>also check all settings
    -pulled/clean or replace rave valves
    -use wipe/new on all black trim "someone used the wrong type of soap on the ski and it turned all the black trim grey a while back"
    -replace fuel float>purchased

    Some pics of how she sits. For being as old as she is everything still looks great. It will look better when its done and I am able to clay bar and wax her up.









    Here is where someone used the wrong type of soap and it ruined the oem black. I am going to try that wipe new stuff and/or pull them primer & repaint them.





    Original floor mats are starting to bubble up. Time for replacements





  2. #2
    I had a few hours tonight to get started. The good news is I like to work on car's so I have a fair amount of tools. The bad news is I have to drive 30+ minutes to my parents to use them. I moved out a while ago but have not moved my tools into the new place. A little inconvenience but could be worse.


    Gotta stay organized:







    Pulled the carbs:



    Should there be a gasket between the carb & engine itself? There was not









    Pulled the rave valves for inspection and cleaning:






    Pretty sludgy, I am letting them soak in some seafoam overnight before scrubbing them again. I am using a soft bristle style brush as I didnt want to scratch them up using a wirewheel.











    Should there be a gasket on this as well? This faces the carbs and houses the intake filter


  3. #3
    Dirty Motor :\

    I also want to replace that hose shown below once I find the sizing of it. Its clear but its obviously pretty old



    Better Angle:



    You can also see the sbt starter installed there. It works fine but they have the worst customer service I have dealt with. Long story short they sold me the wrong starter and refused to pay return shipping & I still had to order the correct starter and pay $50 for overnight delivery as I was getting the ski running while family was down at the lake. I will avoid them going forward.

    I would also like to replace this line and/filter I presume?




    Found a grey hose to replace. I thought I replaced all grey lines a few years ago but apparently I missed one.



    Flywheel cover off. I really need to dry this thing out and clean up the inside haul a bit. Lots of oil residue floating around down there.



    Rave valve area


  4. #4
    Is it worth upgrading the bellows to the green version?
    Is it worth upgrading to the newer style rave valve exhaust housings?
    Is it recommended to use some band ties on the bellow grommet at the base?

    Do you think my valves below should be replaced? They were filthy but look closely on the one and there is minor pitting.














  5. #5

    Join Date
    Aug 2014
    Location
    Lavallette, NJ
    Posts
    58
    Its nice seeing someone putting so much love into these older two strokes. Go on osdparts.com and order new oil lines from them. 8mm and 10mm, and the oil filters. Their lines are expensive, but top notch. Take some acetone to those rave valves. Go to homedepot and buy some purple power, or heavy duty de-greaser. Pull the motor. (Its not that hard, you are probably half way there) Spray the cleaner in the hull, scrub it around, then powerwash it away. The hull will look like new. A heat gun and lacquer thinner work wonders on those faded plastic pieces.

  6. #6

    Join Date
    Aug 2014
    Location
    Lavallette, NJ
    Posts
    58
    oh! also make sure you change the small injection lines that go from the pump to the cylinders. Clean the injection nozzles on the manifold, and put on new clamps.

  7. #7
    Quote Originally Posted by howardrya View Post
    Its nice seeing someone putting so much love into these older two strokes. Go on osdparts.com and order new oil lines from them. 8mm and 10mm, and the oil filters. Their lines are expensive, but top notch. Take some acetone to those rave valves. Go to homedepot and buy some purple power, or heavy duty de-greaser. Pull the motor. (Its not that hard, you are probably half way there) Spray the cleaner in the hull, scrub it around, then powerwash it away. The hull will look like new. A heat gun and lacquer thinner work wonders on those faded plastic pieces.
    Thanks so much for the info. I am soaking them in sea foam but what's left of the carbon deposit's is tuff stuff! I have some acetone I can try. Do you think they are safe to use? That one has those little scratches and/or almost crack looking details on the backside? Thoughts?

    Yes, I ordered new oil lines & filter as well. The fuel lines are only 2 years old so I was gonna leave them but ill pull them & visually inspect them just to be sure.

    Purple power is awesome, I used that on my car engine just last week. My only concern with pulling the motor is I don't have the alignment tool. I was going to try and clean her up as best I can with the engine in place if possible.

    For the plastic I bought some of that wipe new stuff to try out but if that stinks Ill try the heat gun trick. I have both already available as well.


    Which nozzles are you referring to off hand? I am not sure I know which ones your referring to. Thanks for all the help bud!

  8. #8
    Waterluvr's Avatar
    Join Date
    Mar 2015
    Location
    Northern Indiana
    Posts
    478
    +1
    70
    Quote Originally Posted by howardrya View Post
    oh! also make sure you change the small injection lines that go from the pump to the cylinders. Clean the injection nozzles on the manifold, and put on new clamps.
    You must have missed this, no oil pump connected to supply those 3/32" lines or injectors.

  9. #9

    Join Date
    Aug 2014
    Location
    Lavallette, NJ
    Posts
    58
    oh sorry, didn't realize you went premix. Ignore my 2nd comment about the injection lines. Make sure your rave valves slide easily in and out of the slots. If they don't and you cant clean them any further, you should replace them.

  10. #10
    Quote Originally Posted by howardrya View Post
    oh sorry, didn't realize you went premix. Ignore my 2nd comment about the injection lines. Make sure your rave valves slide easily in and out of the slots. If they don't and you cant clean them any further, you should replace them.
    Ok great, thanks! Do you think its worth upgrading to the new rave valve exhaust housing? Mine are the original version with the holes in them. I am not sure what the pro's/con's are. I'm going to replace the bellows while I am at it as well.

    Thanks, ill post more pics after I get some time on her this week/weekend!

Page 1 of 6 123 ... LastLast

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Similar Threads

  1. Replies: 3
    Last Post: 07-30-2014, 12:08 AM
  2. Just got my 97 XP, what to check?
    By dkurily in forum 2-Stroke Performance
    Replies: 8
    Last Post: 08-10-2013, 07:35 AM
  3. my 97 gtx wont stay running on water
    By provo in forum 2-Stroke Performance
    Replies: 2
    Last Post: 03-01-2011, 09:15 AM
  4. Problem with my 97 sltx wanting to start
    By cowranch 2006 in forum Polaris Open Discussion
    Replies: 1
    Last Post: 06-29-2010, 09:25 AM
  5. Please comment on my 04 GTX SC to do list
    By KEN G in forum 4-Tec Performance
    Replies: 23
    Last Post: 01-13-2007, 10:31 AM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •