1998 TS1000 rebuild project

RENTAL33 · 02-22-2010, 10:48 PM

Hello everyone..I am attempting to do a rebuild on a 1998 TS1000L. I started the teardown today and cannot seem to get the #1 cylinder jug loose from the case after removing the 4 nuts. Tried tapping the jug with a hammer but dont want to damage it. The two others came off fine, Any suggestions? I also found a nickle size hole it the lower case under the middle piston. Hoping to have it repaired or find another lower case, any ideas? I will continue the tear down and post my findings with the hopes of getting some advice on doing this project since it is my first rebuild. Get in there yogi!!! Thanks.........

engr146 · 02-23-2010, 12:14 PM

See ongoing post 770 wristpin might help!!

lownrangr · 02-25-2010, 01:52 AM

there's only 4 bolts per cylinder so if you have all of them off, tap harder with a rubber mallet or rotate the impeller shaft by hand a bit to see if that will free it up.

RENTAL33 · 02-25-2010, 08:18 AM

Well I finally got the jug off last nite, actually had to pry it off with two screwdrivers being careful not to damage anything. The gasket just would not let go. I am going to split the case this week and look at the crank, any suggestions on what to look for? Where can I buy a oil pump block-off kit? I did have one piston broken, the center one, I'm thinking lack of oil. The piston must have broke right through the lower case, hence the hole in it. I will keep all posted as I progress...thanks for the help it is greatly appreciated!!!!

lownrangr · 02-25-2010, 01:36 PM

the block off plate you can get from SBT at the bottom of the page.

RENTAL33 · 02-25-2010, 06:10 PM

Ok, casings are split and crank is removed. Middle cylinder portion of the crank has some surface rust. The rest of the crank looks fine, no discoloring or broken parts. Seems to turn fine and tight. I'm going to take it to a shop this weekend to have someone look at it since I really dont know what to check for. If everything works out I should only need 1 piston and a lower case unless they can weld this one. I will post my findings.....

attnondeck · 02-25-2010, 06:45 PM

make sure you check out your crank seals

RENTAL33 · 02-25-2010, 07:14 PM

Thanks...will do...

engr146 · 02-25-2010, 07:22 PM

I just ordered my 98 770 TSL parts , WSM .50 mm piston $78 topend kit $86 oil block off kit $10 $6.00 for shipping all, I shopped around and he had the best prices on ebay, and other online jetski parts stores http://test.jetskimechanic.com/home/...shop/index.php

dank · 02-25-2010, 07:41 PM

If you end up needing a gasket set I have one left for the 900/1000 engine I would sell for less than retail.