Changing Fuel Filter On A 1996 Sea-Doo Jet Ski: Step-By-Step Guide

If you're looking to change the fuel filter on your 96 Seadoo Jetski, you've come to the right place. This guide will take you through the process step-by-step, ensuring you're able to get back out on the water in no time. The Sea-Doo GTI personal watercraft is equipped with a Rotax 4-TEC three-cylinder engine and multi-port fuel injection. While the GTI fuel filter doesn't require regular maintenance, Sea-Doo recommends replacing it if it becomes clogged, damaged, or if there are signs of malfunction, such as low fuel pressure. So, without further ado, let's dive into the process of changing your fuel filter.

Locating the fuel filter

The fuel filter on a 96 Seadoo Jetski is typically mounted on the fuel pump, which is installed inside the fuel tank. To locate the fuel tank, look for it behind the steering column. It is usually located under the hull, in front of the steering. The fuel tank is where you will find the fuel pump, and consequently, the fuel filter.

It is important to note that the fuel filter may not look like a traditional fuel filter found in boats or cars. Instead, it is often integrated into the fuel/water separator assembly. This assembly may appear as a bulb-like structure, which can be unscrewed and cleaned.

In some older Seadoo models, the fuel filter is located within the fuel pump itself. To access this type of fuel filter, you will need to remove the fuel pump from the fuel tank. This can be done by disconnecting the electrical connector and vent tube from the fuel pump, relieving the fuel pressure, and then removing the fuel pump retaining nuts to lift it out.

Once you have located the fuel filter, whether it is mounted on the fuel pump or integrated into the fuel/water separator, you can proceed with the necessary maintenance or replacement.

Removing the fuel filter

To remove the fuel filter from a 96 Seadoo Jetski, first open the front storage compartment and remove the access panel to the fuel tank. Remove the two vent tubes. Disconnect the electrical connector and the vent tube from the fuel pump.

Next, relieve the fuel pressure in the system and disconnect the inlet hose from the fuel pump. Remove the nine fuel pump retaining nuts and carefully lift the fuel pump from the gas tank, taking it out through the glove box opening. Be careful not to bend the fuel sensor float arm attached to the body of the fuel pump.

Now turn the fuel pump over. Using a screwdriver, gently pry up the inner plastic ring of the fuel filter to remove it.

Cleaning the fuel filter

To clean the fuel filter on your 96 Seadoo Jetski, you will first need to locate it. Open the front hood and remove the storage bin/tray. The fuel filter should be behind this, mounted on the top of the hull in front of the steering.

Once located, you can begin the cleaning process. First, relieve the fuel pressure in the system. Then, unscrew the bulb underneath the steering and clean it out. Do not use compressed air to clean the filter, as this can damage the screen. Instead, spray it down with a suitable carb cleaner and let it air dry.

In addition to cleaning the main fuel filter, it is also recommended to clean the internal fuel filters in the carbs. These can be accessed by removing the pump cover and the carbs. Clean these filters with a water-based solvent, such as Purple Power or Super Clean. Avoid using carb cleaner on these filters, as it can melt the mesh.

Installing a new fuel filter

To install a new fuel filter on a 96 Seadoo Jetski, you will need to first locate the fuel filter. On a 96 Seadoo SPX, the fuel filter is located inside the hull, mounted on the top of the hull in front of the steering.

Once you have located the fuel filter, follow these steps:

• Open the front storage compartment and remove the access panel to the fuel tank.
• Remove the two vent tubes.
• Disconnect the electrical connector and the vent tube from the fuel pump.
• Relieve the fuel pressure in the system and disconnect the inlet hose from the fuel pump.
• Remove the nine fuel pump retaining nuts and lift the fuel pump out of the gas tank.
• Turn the fuel pump over and use a screwdriver to gently pry up the inner plastic ring of the old fuel filter.
• Install the new fuel filter by pressing it onto the bottom of the fuel pump by hand. Ensure that it is correctly seated for proper filtration.
• Align the tab on the fuel pump gasket with the neck of the fuel tank.
• Align the molded arrow on the fuel pump with the tab.
• Tighten the nine fuel pump retaining nuts in the correct sequence, as specified in the Seadoo service manual.
• Connect the electrical connector and replace the vent tube on the fuel pump.
• Reconnect the inlet hose and tighten it.
• Pressurize the fuel system and perform a leak test.
• Reinstall the access panel.

It is important to note that you should be careful not to bend the fuel sensor float arm attached to the body of the fuel pump when removing it from the fuel tank.

Reattaching the fuel pump

To reattach the fuel pump of a 96 Seadoo Jetski, follow these steps:

Firstly, ensure that the new fuel filter is correctly seated at the bottom of the fuel pump. This is essential for proper filtration. Next, align the tab on the fuel pump gasket with the neck of the fuel tank. There is also a moulded arrow on the fuel pump; this should be aligned with the tab.

Now, tighten the nine fuel pump retaining nuts, following the correct sequence and torque specified in the Seadoo service manual. It is important to refer to the manual to ensure this is done correctly and in the right order. Once the retaining nuts are tightened, reconnect the electrical connector and replace the vent tube on the fuel pump.

Finally, reconnect the inlet hose and tighten it. Now, pressurize the fuel system and conduct a leak test to ensure there are no issues. Reinstall the access panel, and the process is complete.

It is important to note that when removing and reattaching the fuel pump, care should be taken not to bend the fuel sensor float arm, which is attached to the body of the fuel pump.

Frequently asked questions