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  1. #11
    PWCToday.com Is My Home Away From Home WFO Speedracer's Avatar
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    Re: Bringing a 1996 GTI back to life - help

    If it's off you have to have the cover machined or get another one, the machining operation is tricky because you have to remove the same amount in three different places , the face of the cover, the flange of the cover and the groove where the o-ring sits in the cover
    Last edited by WFO Speedracer; 08-04-2022 at 12:31 PM.
    Y'all know me, still the same O.G. but I been low-key
    hated on by most these &^$$@s with no cheese, no deals and no G's, no wheels and no keys, no boats, no snowmobiles, and no skis, mad at me cause I can finally afford to provide my family with groceries

    WWSRD , What would Speed Racer do ?

  2. #12
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    Re: Bringing a 1996 GTI back to life - help

    Followed forum recommendations and first trial run seemed to resolve all issues. Had it running 45mph with no surging, no hesitation for about 30 minutes. Ideal transition from idle to WOT. Gas level was low so we stopped and filled the tank back up to maybe 3/4. Fired back up perfectly but then couldn't get it back up to full rev. Not the same symptoms as before but felt like it was starving. Flipped to res tank and it rode worse (confirmed correct hose connections). Didn't pop off the gas cap. Oil light came on sporadically. We run pre-mix ethanol free 50:1 with XPS synthetic.

    What am I missing

  3. #13
    PWCToday.com Is My Home Away From Home wmazz's Avatar
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    Re: Bringing a 1996 GTI back to life - help

    Quote Originally Posted by fishingfund View Post
    Gas level was low so we stopped and filled the tank back up to maybe 3/4. Fired back up perfectly but then
    couldn't get it back up to full rev. Not the same symptoms as before but felt like it was starving.

    Flipped to res tank and it rode worse (confirmed correct hose connections). Didn't pop off the gas cap.
    Sounds like the starving symptoms occurred immediately? If
    so, I doubt popping the cap would help.

    Inspect easy stuff first.

    Inspect the fuel filter/water separator. Pour the contents on to
    a hard surface and look for water. Also look inside the hull, for
    a brown residue.

    Where did you get the new gasoline at? a different source than
    when you filled up the tank before the ride?

    Look at the spark plugs just to be thorough.


    Bill M.

    How much time in between rides? Engines continue to heat up,
    after you stop the engine.

    Did the engine ever stall after the tank was topped off?

    The RV shaft gears are in a oil bath?
    Last edited by wmazz; 08-15-2022 at 06:22 PM.
    Horsepower == Speed, RPM != Speed



  4. #14
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    Re: Bringing a 1996 GTI back to life - help

    No water in filter and looks full.

    I noticed brown residue on hull near the pressure relief fitting on vent line at water line. There was also oily looking fluid in the vent line when I had taken it off the baffle before. I had blown out the pressure valve just in case but it did seem like it was sticky for a 3-5 psi

    Gas should be OK. I had filled up about 4 x 5 gallon jugs earlier in the week. 15 gallons went into my boat and didn't seem to affect the outboard performance.

    My wife was on the GTI testing it out and I was in my boat doing some PWC test run lifeguarding. I had taken a 5-gal can of premix on the boat just in case and she pulled up to fuel on the water. Engine was shut down for no more than 10 minutes. Engine never stalled except when we choked it while running.

    Checking plugs too.

  5. #15
    PWCToday.com Is My Home Away From Home WFO Speedracer's Avatar
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    Re: Bringing a 1996 GTI back to life - help

    You are not going to want to hear this but here goes anyway, you probably need to pull the gas tank and clean it, then pull everything else and clean it again as well.

    Here is why . on a small percentage I would say maybe 10% of these skis you get a buildup of brown goo in the bottom of the tank. it is what is left of the inside of the stock fuel lines, it clumps together on the bottom of the tank and it just sits there, that is until you put fresh gas in it, ride and stir things up, gas is an excellent solvent, it usually takes about 30 min to an hour.

    Then the goo liquifies and goes all back through the fuel system, what you will probably find is the internal fuel filter is stopped up again causing a fuel restriction and making it bog and not plane out. The only cure is to get the tank spotlessly clean and clean every component of the fuel system again.

    The fuel tank can be cleaned with either Berryman B12, Heet or Castrol Superclean , any of those will dissolve the goo in the tank, just keep sloshing it back and forth and eventually it will all liquify , then wash it out with water and let it dry and reinstall it.
    Last edited by WFO Speedracer; 08-15-2022 at 07:17 PM.
    Y'all know me, still the same O.G. but I been low-key
    hated on by most these &^$$@s with no cheese, no deals and no G's, no wheels and no keys, no boats, no snowmobiles, and no skis, mad at me cause I can finally afford to provide my family with groceries

    WWSRD , What would Speed Racer do ?

  6. #16
    PWCToday.com Is My Home Away From Home wmazz's Avatar
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    Re: Bringing a 1996 GTI back to life - help

    Quote Originally Posted by fishingfund View Post
    Fired back up perfectly but then couldn't get it back up to full rev.
    How much rpm did it loose? Did it loose a few hundred rpm, or a
    few thousand.

    Or did it just loose mph?
    Quote Originally Posted by fishingfund View Post
    Gas should be OK.
    But you stated it was running fine until you add more fuel to
    the tank. Like a lightswitch.

    Sounds like it should be obvious, but maybe the pump sucked
    up something while you were refilling the gas tank.

    Maybe you need to look for weeds, rocks,or rock damage to
    the pump or impeller.

    Does the pump freely rotate?



    Bill M.
    Horsepower == Speed, RPM != Speed



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