96 seadoo xp 787 full rebuild

[@travisdonley8768]

PSA: Before you tighten down the cylinder bolts make sure to bolt on the exhaust manifold temporarily so it aligns both cylinders to the exhaust, otherwise you can have water/exhaust leaks from the manifold gasket from the misalignment. Please consider adding that to the video or description, thanks!

[@ryancarender7971]

About to rebuild my 96 GTX 787 with a blown piston. Could not find any good videos until now. Thank you very much for putting this together. Extremely helpful.

[@fishnski3128]

Ryan Carender good to hear!

[@harryvalsak]

Very well done my friend. Don't stop doing these cool videos. I lack courage to do my own but my garage has seen all kinds of reject toys that I have risen back to life. Thank you!

[@DanBuilds]

I wish I had watched your video before I attempted this myself. I didn't think I'd be able to compress the rings myself so I put them in through the top of the cyl using a ring compressor tool, then put the wrist pins in from underneath... talk about a pain! Lol well, next time I know the right way to do it. Cheers and thanks for the excellent tutorial.

[@fishnski3128]

Dan Builds Things damn that doesn’t sound easy haha

[@DanBuilds]

@@fishnski3128 it was definitely a learning experience. I did another one after that the right way and it was MUCH easier. 😂

[@cruzmonvi4883]

i have a 96 gsx 787 motor one piston is scored do i have to hone out the piston sleeves and is it 82mm stock wsm piston set . thanks nice rebuild video 💪🏻

[@ripptydevibes2581]

How did it go without replacing that front crank seal? Mine was perfect 160psi on both but rapidly ate the rear cylinder walls until it finally wouldnt start. I was supposing a lean condition due to a leak but not positive. My questions are where would I go for proper diagrams AND cyl/piston kits if you have any input?

[@fishnski3128]

Ripptyde Vibes I order on eBay. Just make sure it’s for your model ski/ engine

[@fishnski3128]

Ripptyde Vibes also I had no issues with the crank seals. She runs amazing !

[@Ab-hl1bv]

Hello, good morning from Spain. Congratulations on your video. I would like to ask you a question if you can help me. I just got into this and I bought a 2003 seea doo. The crankshaft doesn't rotate. I have disassembled the cylinders and they are fine. I would recommend that you look at it, please.

[@chrismansker8870]

if you dont have assembly lube i have always used 2 stroke oil to assemble all my 2 stroke engines.

[@fishnski3128]

That does work fine. But if you think the motor may be sitting for a while, the 2 cycle oil will eventually drain to the bottom and you will get a dry start. Assembly lube will stick there for a long time. That’s why I like it

[@mattdilorenzo9572]

At around the 37 minute mark, you put on the two small o-rings on the head. It seems that you didn't put on the o-ring around the perimeter of the head that would seal to the water jacket (Manufacturer Part#420831550). I pulled the water jacket off mine and it didn't have that o-ring. I noticed on one website that it says that part has been discontinued. I would imagine that it is still necessary, right?

[@fishnski3128]

yes it’s needed for sure. I did forget to show it in the video. My fault. But every new kit you buy, comes with all necessary seals and gaskets.

[@aaronjweldaway]

I'm about to tackle this project ony ski. How did you remove the plate behind the flywheel? I can't grab it and hold the motor still at the same time. Did you have a special tool for this?

[@fishnski3128]

Aaron Johnson there is a special socket that threads on to the flywheel and it has a center that tightens down on the crank. It’s a special puller designed for it. U can order online for under $30.

[@aaronjweldaway]

Awesome. Hopefully that makes it much easier. Thanks for your help and the video. Only one I could find on the 787.

[@fishnski3128]

Aaron Johnson the exact reason I made this video is because I could not find a video on it! Glad I could help :)

[@jamiegirard1070]

Heat the hub to break the loctite bond and use a pipe wrench while its still in the machine...pull the head and put a piece of wood between the piston and exhaust port...i cant imagine putting all that money into a engine and not changing the seal....pretty good video but i didnt see ring gap checked or squish

[@polymexdf69]

Hi what was the reason you rebuilt this I bough a Seadoo 1997XP but the people that sold it to us were not very honest but any ways some how we got water in the engine and I took it a part I’m stock because I don’t know if I have to open it all the way to see if it has water in the oil or baton part of the engine any sugestións

[@fishnski3128]

polymexdf69 if u have water in the engine all u have to do is pull the spark plugs out and hold the start button down till the water is done coming out. I had a water leak internally and my pistons and cylinders were scored from the water ingestion.

[@polymexdf69]

FishNski312 look at this video

[@polymexdf69]

kzbin.info/www/bejne/d527mntort6dapI

[@polymexdf69]

On the base were you said to clean it with acetone did you put any silicon. and on the cylinder bolts did you use the same ones thanks

[@fishnski3128]

polymexdf69 only sealer u use is between the crankcase halves and the exhaust manifold gasket.. none on the base gasket

[@MrYoungspeeder]

Hello, I really found your video helpful. I am completely new to jetskis and I own a 1997 seadoo 951. Do you have any videos on tuning these engines? I really cant find videos on this subject. I understand its a very important part to completing a rebuild. Cheers

[@fishnski3128]

No videos on the 951, but I did rebuild mine also and it is pretty similar. Just look up the torque specs online. It’s actually easier because it’s a reed valve engine compared to a rotary valve engine.

[@MrYoungspeeder]

My mistake... I own a 787 jetski. I’m learning how to tune it. Really appreciate your video

[@thediplomasta5891]

The compression seals are....o-rings?! 🤯

[@fishnski3128]

Yes. Weird I know. Lol

[@davidcook4160]

What is that fitting for that is right below the rotary on the block

[@fishnski3128]

The oil line for the rotary shaft. If you premix your fuel, u still need oil running to the shaft or it will seize up

[@Millennial1031]

About to do the same thing.

[@jeffdean1473]

Thank you great video !

[@paulschulze3417]

A lot of people are telling me to keep the oil injection system and don't block it off. So that means you're running premix correct?

[@fishnski3128]

Paul Schulze yes premix. The only benefit of the oil pump is u will use less oil compared to premix. But with premix, you have 100% guaranteed lubrication and never have to worry about any oil lines cracking or any failures of that oil injection system. To each their own. But I don’t see the point in risking the entire engine seizing up when you can easily prevent it. Literally any engine I buy that is oil injected, gets deleted and premix. Never had an issue!

[@paulschulze3417]

@@fishnski3128 Thanks! Do you mix 40:1 then?

[@fishnski3128]

Paul Schulze most people run 40:1. Yes

[@TheHomePros6221]

@@fishnski3128 how did u block off the oil inj?

[@fishnski3128]

@@TheHomePros6221 buy the bypass plate on eBay. You will need to remove the stator cover on some engines because the plastic drive inside only comes out from the inside. But you remove the oil pump and lines. And the kit comes with the plate and two caps to cap off the rotary valve nipples. Then premix your fuel 40:1. Always! And keep the big lines connected to the rotary shaft on both sides of the engine!

[@polymexdf69]

Mine won’t star changed the solenoid and it work but then it die now won’t star

[@davidcook4160]

Do I need to set timing on a new motor

[@fishnski3128]

If you do a full rebuild , The crank and counterbalance shaft need to be aligned correctly and also the rotary valve timing needs to be set

[@rimvydaspranulis987]

Hei do you know eny video how to intall tha engine 787 in to tha jetski ?

[@fishnski3128]

Rimvydas Pranulis not too sure on any videos. It’s pretty simple but you need an alignment tool so your impeller shaft is lined up properly. Or else your carbon seal will leak water.

[@negrobrils2747]

Como ago para escuchar el video en español

[@shannonwilliams601]

Man you made a lot of mistakes on this motor 1 you never use a old front seal that thing will leak and if it doesn't right at the start it will start soon after also red Loctite on a aluminum motor you just trashed that motor you definitely have a lot to learn

[@fishnski3128]

Old seals? Everything is new. And the motor still runs 100% lol but ok cool

[@shannonwilliams601]

@@fishnski3128 you said you did not replace the front seal because you could not get the PTO off so if you did not get the PTO off how did you replace the crank seals in the motor and then you put red Loctite on aluminum yeah you have a lot to learn

[@johnnyslivka7395]

When I removed my engine, I forgot to mark where the magneto hub was located on the flywheel. Does anyone know the exact mark?

[@fishnski3128]

Search for the manual for that engine and it will show u the exact position