Maintain Your Sea-Doo: Change Fuel Filter, How Often?

The Sea-Doo fuel filter is located inside the fuel pump assembly, which is housed within the fuel tank. There are two filters in the fuel pump assembly: a strainer at the bottom of the assembly and a smaller one inside that requires some disassembly to access. While there is no consensus on how often the fuel filter should be changed, some Sea-Doo owners recommend doing so every year or every 100 hours of use, while others suggest that it can be done less frequently, such as every 10 years, if good-quality gas is used.

Fuel filter location

The fuel filter location on a Sea-Doo depends on the model. For a 1996 Sea-Doo Bombardier SPX, the fuel filter can be found by opening the hood, taking out the storage bin, and looking inside—it is mounted on the top of the hull in front of the steering.

For a 2008 Sea-Doo Challenger 180, there are two fuel filters on the fuel pump in the tank.

It is recommended to change the oil on your Sea-Doo annually, and to perform this maintenance at the end of the season.

It is also recommended to change the oil filter every 100 hours or 1 year, whichever comes first.

Fuel pump removal

To remove the fuel pump from a Sea-Doo, follow these steps:

Step 1: Open the hood and remove the storage box.

First, open the hood of your Sea-Doo and remove the storage box to access the fuel pump.

Step 2: Remove the vent tube support bracket.

Locate the vent tube support bracket, which is held in place by two nuts on studs. Remove these nuts and then tap the studs through to remove the vent tube.

Step 3: Remove the glove box.

The glove box is held in place by two clips accessible through the hole for the vent tube. There are also four 1/4" plastic push clips that can be cut off to remove the glove box completely.

Step 4: Disconnect the fuel supply and return lines.

Using a 5/16" fuel/AC disconnecting tool, disconnect the fuel supply and return lines from the bracket inside the hull. Be prepared for fuel to spill out.

Step 5: Remove the fuel pump assembly.

There are nine 8mm nuts holding the fuel pump assembly to the fuel tank. Remove these nuts and then carefully lift the entire assembly out, being mindful of the float arm connected to the assembly. You may need to rotate the assembly to get it out in one piece.

Step 6: Disassemble the fuel pump.

The fuel pump assembly contains two filters: a strainer at the bottom of the assembly and a smaller one inside. To access the internal filter, you may need to drill out and replace the rivets holding the end cap on.

Step 7: Replace the filters.

Install the new filters, making sure to include the thin rubber washer and steel washer in the baseplate. Press the new internal filter into place, replace the rivets, and install the bottom filter.

Step 8: Reassemble the fuel pump.

Once the filters have been replaced, reassemble the fuel pump assembly by following the above steps in reverse.

Step 9: Reinstall the fuel pump assembly.

Finally, reinstall the fuel pump assembly by securing it with the nine retaining nuts and connecting the fuel lines and electrical connectors.

Fuel filter replacement

The fuel filter on your Sea-Doo should be replaced every 10 years or so, according to some Sea-Doo owners. However, it is recommended to inspect and replace the fuel filter if there is any sign of a problem.

• Open the hood and remove the storage box.
• Remove the two nuts from the studs holding the vent tube support bracket to the hull/steering assembly. Tap the studs through and remove the vent tube.
• Remove the glove box. There are two clips holding the glove box itself to the hull, accessible through the hole for the vent tube you just removed. There are also four 1/4" automotive-style plastic push clips that hold the two “wings” of the glove box to the hull. Cut or remove these clips. You’ll also have to remove two screws holding the black plastic reverse lever handle to manoeuvre the glove box wing over it.
• Remove the fuel supply and return lines from the bracket holding them to the inside of the hull. Disconnect them using a 5/16” fuel/AC disconnecting tool. Be prepared for fuel to come out of the lines.
• Remove the nine 8 mm nuts holding the fuel pump assembly to the fuel tank.
• Take out the whole assembly. Remember that there is a float arm connected to the assembly, so you will need to rotate it to get it out in one piece. You may need to pull it out towards the rear (via the glove box) and then back out towards the front.
• There are two filters in the fuel pump assembly: a strainer that you will see on the bottom of the assembly and another smaller one inside that requires some disassembly. The part numbers are Airtex FS220 for the internal strainer and Airtex FS242 for the external one.
• Drill out and replace the two 1/8” rivets holding the end cap on the internal strainer.
• Remove the old internal strainer, making sure not to lose the thin rubber washer and steel washer underneath it.
• Install the new internal filter and replace the rivets.
• Install the bottom external filter.
• Reassemble the fuel pump assembly and reinstall it into the Sea-Doo.

Note: The inline fuel filter on the line to the fuel rail is not designed to be replaced. One option is to cut the fuel line as close to the filter fittings as possible and replace it with a standard metal canister fuel filter.

Sea-Doo maintenance

Changing Your Sea-Doo's Fuel Filter

Changing the fuel filter on your Sea-Doo can be a complex process, and it is important to follow the correct steps to ensure a safe and successful procedure. Here is a step-by-step guide to help you through the process:

• Open the hood and remove the storage box and any other necessary components to access the fuel pump assembly.
• Disconnect the fuel supply and return lines from the bracket holding them to the inside of the hull. Be prepared for fuel spillage during this step.
• Remove the nuts holding the fuel pump assembly to the fuel tank, and carefully take out the assembly. Be mindful of the float arm connected to the assembly, as you may need to rotate it to remove it in one piece.
• Locate the fuel filters within the fuel pump assembly. There are typically two filters: a strainer at the bottom of the assembly and a smaller one inside that may require additional disassembly.
• Replace the fuel filters with new ones. Ensure you have the correct part numbers for the internal and external strainers.
• Reassemble the fuel pump assembly and securely tighten all connections.
• Refill the fuel lines and test the engine to ensure there are no leaks.

Changing Your Sea-Doo's Oil

Changing the oil on your Sea-Doo personal watercraft is a necessary maintenance item, and it is recommended to be done annually. Here is a step-by-step guide on how to change the oil:

• Park your Sea-Doo on a level surface and firmly chock the trailer tires.
• Remove the seat and engine access cover to inspect for any signs of coolant or oil leaks.
• Warm up the engine by following the exhaust flushing instructions in your operator's guide. Do not run the engine without supplying water to the exhaust system, and never operate it for more than 2 minutes at a time.
• Run the engine for 10 seconds at 4,000 RPM and then shut it off. This will move the oil from the PTO housing to the oil tank for maximum draining.
• Extract the old engine oil using a manual fluid extractor. Place one end of the extractor hose into the dipstick opening and the other end into a drain pan.
• Remove the dipstick, oil fill cap, and oil filter cover. Carefully remove the old oil filter and inspect the housing for any debris.
• Install a new oil filter and O-ring(s), lightly oiling them with fresh oil to ensure a tight seal. Reinstall the oil filter cover and torque the bolts to the specified tightness.
• Fill the engine with fresh oil and replace the oil fill cap or dipstick.
• Verify the proper oil level by running the engine and checking the RPM. Adjust the oil levels as required.
• Reinstall the engine access cover and seat. Dispose of the old oil and filter properly at designated locations.

By following these maintenance procedures and staying on top of your Sea-Doo's fuel filter and oil changes, you can ensure the optimal performance and longevity of your watercraft.

Fuel filter types

Fuel filters are an essential component of any vehicle's fuel system, trapping contaminants and impurities in the fuel to prevent them from reaching the engine. There are several types of fuel filters, each with its own unique design, mounting style, and functionality. Here is an overview of the different types:

Primary and Secondary Fuel Filters

Primary fuel filters are commonly used in diesel fuel systems and are positioned on the vacuum side of the fuel pump. They are less restrictive and usually precede secondary filters in the fuel system, capturing larger particles, particularly water and wax. Secondary filters, on the other hand, are fitted with tighter media or a higher micron rating to capture finer particles. They are located on the pressure side of the fuel pump, closer to the engine.

Canister and Cartridge Fuel Filters

Canister fuel filters feature a canister-like shell that houses the filtration element. The housing can be made of plastic or metal. Cartridge fuel filters, on the other hand, consist of a cartridge containing the filtration media, structural components, and other essential parts. They are more environmentally friendly as they produce less waste during replacement.

Spin-On, In-Tank, and Inline Fuel Filters

Spin-on fuel filters are easily recognisable by their threaded mounting design. They are typically installed in the engine compartment and are known for their ease of replacement. In-tank fuel filters are mounted inside the fuel tank and can be separate or integrated into the fuel pump assembly. Inline fuel filters are installed along the fuel line between the fuel tank and the engine, usually underneath the vehicle.

Positive and Negative Pressure Main Filters

Main filters can be either positive or negative pressure types. Negative pressure main filters utilise suction pressure created by the feed pump and are placed closer to the fuel tank. Positive pressure main filters, on the other hand, utilise the upthrust pressure from the feed pump and are located closer to the engine. Some vehicles may be equipped with both types of main filters.

Fuel Filter Media Types

Fuel filter media can be natural or synthetic. Natural materials include cellulose, a plant-based fibre that offers minimal restriction to fuel flow. Synthetic materials such as glass fibres, sintered bronze, ceramic, and nylon provide better filtration for finer impurities but have shorter lifespans.

Frequently asked questions