Replacing Fuel Lines: 1996 Sea-Doo Gti Guide

If you own a 1996 Seadoo GTI, you may have heard about issues with the grey fuel lines. These lines are known to deteriorate over time, causing performance issues and even safety hazards. It is recommended to replace them with new fuel lines, and this process will be the focus of this discussion. We will cover the necessary materials, steps, and potential challenges to help you successfully complete this maintenance task.

The correct length of fuel line required for a 1996 Seadoo GTI

For a 1996 Seadoo XP, you will need 20 feet of 1/4" fuel line and about 20 1/4" hose clamps. The 5/16" line is for 951 carb setups.

For a 1996 Seadoo GSX, you can use all 1/4" fuel line.

For a 1996 Seadoo GTX, you will need about 18 feet of 1/4" fuel line.

It is important to note that the original grey fuel lines were manufactured by Tempo. While it is possible to use regular black automotive fuel tubing, it is recommended to use fuel injection-rated lines or marine-grade hose to ensure safety and compliance with federal standards.

The correct diameter of fuel line for a 1996 Seadoo GTI

If you own a 1996 Seadoo GTI, it is likely that you have a 787 engine. This means that you will need 20 feet of 1/4" fuel line to replace the existing fuel lines.

The 1/4" fuel line is also suitable for the 96 GSX. However, some models also use 5/16" fuel line on the delivery side, so it is worth checking the parts manual for your specific model.

When replacing the fuel lines, it is recommended to also replace the fuel valve and the internal fuel filter inside the carbs. It is also important to be careful when working with the fuel system, as fuel leaking inside a PWC hull can be dangerous.

The best type of fuel line to use for a 1996 Seadoo GTI

When replacing the fuel lines on a 1996 Seadoo GTI, it is recommended to use 1/4-inch marine-grade fuel line. You will need around 20 to 25 feet of this fuel line, which can be purchased at any auto parts store. In addition, you will require approximately 20 stainless steel clamps to secure the fuel line in place. Some people also recommend replacing the grey vent lines, as they can become clogged with green goo from the tempo lines and new gas.

It is important to take your time during this process and work on one hose at a time. Mark the hoses with masking tape or take pictures to ensure you reconnect them correctly. The fuel lines connect to the fuel tank, fuel valve, and fuel filter. The fuel valve is marked with "Res to reserve" and "On to on." The return line comes from the carburettor and is the upper hose. The remaining spot on the fuel valve connects to the fuel filter, with the arrow pointing in, and the arrow on the fuel filter pointing out goes to the bottom fitting on the carburettor.

It is also recommended to clean or replace the fuel selector valve, as well as the internal fuel filters inside the carburettors. These filters are tiny and can easily get clogged, so it is important to clean them with Super Kleen or Purple Power (avoid using carb cleaner as it may melt them). Additionally, consider adding an inline fuel filter for extra protection.

Some people choose to use black automotive fuel tubing, but it is important to ensure that it can withstand the heat and not burn. It is always best to consult with a professional or a mechanic to ensure you are using the correct parts and following the proper procedures for your specific model.

How to attach the fuel lines to the fuel tank

To attach the fuel lines to the fuel tank of your 1996 Sea-Doo GTI, follow these steps:

Firstly, ensure you have the correct materials. You will need about 20 feet of 1/4-inch fuel line hose, which can be purchased from auto parts stores such as AutoZone or Napa. Additionally, you will require around 20 stainless steel hose clamps of the same width to secure the fuel lines. It is important to use stainless steel clamps as they are more reliable and safer than other fastening methods such as zip ties.

Next, locate the fuel tank. The fuel tank is typically found at the rear of the watercraft, and it is where the fuel lines will connect to draw fuel. Before attaching the new fuel lines, it is recommended to clean the fuel tank and ensure there is no debris or residue that could contaminate the fuel system.

Now, you can begin attaching the fuel lines. Cut the fuel line hose to the appropriate length, ensuring there is enough hose to reach from the fuel tank to the carburetors or fuel injectors. Secure one end of the fuel line to the fuel tank using the stainless steel hose clamps. Tighten the clamps securely, but be careful not to overtighten to avoid damaging the hose.

Repeat this process for each of the fuel lines, ensuring that you connect them to the correct ports on the fuel tank. The fuel tank should have markings or labels indicating which line connects where. If you are unsure, refer to the Sea-Doo GTI manual or seek advice from a qualified technician.

Once all the fuel lines are securely attached to the fuel tank, inspect your work for any signs of leaks or loose connections. Double-check that all clamps are tight and that the hoses are securely seated in the appropriate ports.

Finally, refill the fuel tank and carefully inspect for any signs of leaks. Start the engine and observe the fuel lines for any leaks or issues. If everything appears secure and there are no leaks, you have successfully attached the fuel lines to the fuel tank.

How to bleed the fuel lines

Bleeding the fuel lines on your 1996 Seadoo GTI is a crucial step to ensure the engine receives the necessary fuel for proper operation. Here is a detailed guide on how to bleed the fuel lines:

Before Beginning:

• Ensure you have replaced the grey fuel lines with new fuel lines of the appropriate size and secured them with suitable clamps.
• Check that the fuel tank is full and the fuel valve is in the "ON" position.
• Inspect the fuel bowl and ensure it is not cross-threaded or missing its O-ring, as this can cause air leaks.

Step 1: Crank the Engine:

• Turn the engine over several times without starting it. This action will create a vacuum and prime the fuel system, drawing fuel into the lines and towards the carburetors.
• Crank the engine for approximately 10 seconds.

Step 2: Check for Fuel Flow:

• Observe the water separator/filter bowl. It should begin to fill with fuel within a few seconds of cranking the engine.
• If the bowl does not fill, there may be an issue with the fuel selector valve or a clogged fuel filter.

Step 3: Address Potential Issues:

• If you suspect a problem with the fuel selector valve, switch it to the reserve position and observe if that makes a difference in fuel flow.
• Ensure the pulse line from the engine case to the carburetor is connected. This line is responsible for drawing fuel through the system.

Step 4: Clean the Carburetors:

• If the above steps do not resolve the issue, it is recommended to clean or replace the fuel filters inside the carburetors.
• Use a recommended cleaning solution such as Super Kleen or Purple Power, as carburetor cleaner may damage the filters.

Note: These steps are based on the assumption that the fuel lines were replaced one at a time to ensure correct connections. If there are still issues with fuel delivery, it may be necessary to recheck all connections and ensure the lines are not crossed or incorrectly installed.

Additionally, if you are comfortable with mechanical work and want to further improve fuel delivery, you can consider replacing the fuel valve and the internal O-ring, as these are known to degrade over time.

By carefully following these steps, you should be able to successfully bleed the fuel lines on your 1996 Seadoo GTI and restore proper fuel flow to the engine.

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