Pressurizing Fuel Tanks: Sea-Doo Gti Maintenance Guide

If you own a Sea-Doo GTI, you may need to pressurize your fuel tank to ensure optimal performance. The Sea-Doo GTI is a personal watercraft that features a Rotax 4-TEC three-cylinder engine with multi-port fuel injection. While the GTI fuel filter does not require regular maintenance, Sea-Doo recommends replacing it if it becomes clogged or damaged, or if other issues such as low fuel pressure are noticed. To replace the fuel filter, you will need to relieve the fuel pressure in the system, disconnect the inlet hose, and remove the fuel pump retaining nuts. After installing a new fuel filter, you will need to pressurize the fuel system and perform a leak test. Additionally, the Sea-Doo baffle (fuel pickup) may require attention if the fuel gauge is malfunctioning. This procedure involves disconnecting the battery cables, removing the fuel tank, and replacing the fuel float. It is important to perform a fuel system pressurization test after any type of repair or disconnection of fuel system components. This test ensures that there are no leaks in the system and that the engine can be started safely.

Replacing a clogged or damaged fuel filter

To replace a clogged or damaged fuel filter on a Sea-Doo GTI personal watercraft, you'll first need to relieve the fuel pressure in the system and disconnect the inlet hose from the fuel pump. Here is a step-by-step guide:

Step 1: Accessing the Fuel Tank and Pump

• 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.

Step 2: Removing the Fuel Pump and Old Fuel Filter

• Relieve the fuel pressure in the system.
• Disconnect the inlet hose from the fuel pump.
• Remove the nine fuel pump retaining nuts.
• Lift the fuel pump out of the fuel tank through the glove box opening.
• Turn the fuel pump over and use a screwdriver to gently pry up the inner plastic ring of the fuel filter to remove it.

Step 3: Installing the New Fuel Filter

• Install the new fuel filter by pressing it onto the bottom of the fuel pump by hand, ensuring it is correctly seated for proper filtration.
• Align the tab on the fuel pump gasket with the fuel tank's neck, and 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 Sea-Doo service manual.
• Connect the electrical connector and replace the vent tube on the fuel pump.
• Reconnect the inlet hose and tighten it.

Step 4: Final Checks

• Pressurize the fuel system and perform a leak test.
• Reinstall the access panel.

Note: When removing and installing the fuel pump, be careful not to bend the fuel sensor float arm attached to the body of the fuel pump.

Disconnecting the battery cables

To disconnect the battery cables on your Sea-Doo GTI, follow these steps:

First, locate the battery. It is important to work in a well-ventilated area when performing any type of maintenance on your watercraft, as fuel is flammable and explosive under certain conditions. Ensure that there is no smoking or open flames nearby.

Once you have located the battery, the next step is to identify the cables. You will see that there are two cables connected to the battery, one BLACK negative cable and one RED positive cable. It is crucial to always disconnect the battery cables in the correct order to ensure safety.

Using the appropriate tools, start by disconnecting the BLACK negative cable first. This is very important as electrolyte or fuel vapors may be present in the engine compartment, and a spark could ignite them, leading to potential personal injuries. Once the negative cable is safely disconnected, you can then proceed to disconnect the RED positive cable.

By following these steps in the specified order, you can safely disconnect the battery cables on your Sea-Doo GTI, reducing the risk of any accidents or injuries. Remember to always exercise caution when working with any electrical components on your watercraft.

Removing the storage basket

To remove the storage basket from your Sea-Doo GTI, you'll need to follow these steps:

Firstly, open the front storage cover. This will give you access to the basket. If your model has a handle on the shift lever, you'll need to remove it. Now, unscrew any retaining screws and remove the side pan.

Next, you'll need to locate the vent tube bracket and unscrew the nut that holds the vent tube in place. With the nut removed, you can now reach into the engine compartment through the vent tube hole. Find the glove box lock tabs and press them to release the glove box.

At this point, you should be able to lift the storage basket out. Ensure you handle it with care as it may be heavy or awkwardly shaped.

Once the basket is removed, you can proceed with the next steps to pressurize your fuel tank. Remember to follow all safety precautions when working with fuel systems and always refer to your Sea-Doo service manual for detailed instructions and safety information.

Disconnecting the filler neck hose

To disconnect the filler neck hose from the fuel tank of your Sea-Doo GTI, you will need to follow these steps carefully:

Firstly, ensure that you are working in a well-ventilated area. This is crucial, as fuel is flammable and explosive under certain conditions. Do not smoke, and avoid any open flames or sparks during this process.

Now, let's begin with the procedure:

• Disconnect the battery cables: Start by disconnecting the BLACK negative cable first, followed by the RED positive cable. This specific order is essential for safety. If you disconnect in the wrong order, electrolyte or fuel vapors in the engine compartment could ignite, leading to potential injury.
• Remove the storage basket: This step is straightforward. Simply remove the storage basket from your watercraft.
• Remove the vent tube and fuel filter (for GTS and GTI models): This step is model-specific, so ensure you have the correct Sea-Doo model before proceeding.
• Disconnect the filler neck hose: You are now ready to disconnect the filler neck hose from the fuel tank. This is the critical step in the process of pressurizing your fuel tank.
• Remove retaining straps and move the fuel tank forward: Once the filler neck hose is disconnected, you will need to remove the retaining straps that hold the fuel tank in place. This will allow you to access the fuel tank and move it forward for easier handling.

By following these steps, you will have successfully disconnected the filler neck hose from your Sea-Doo GTI's fuel tank. Remember to exercise caution and adhere to safety guidelines when working with any fuel system.

Performing a Fuel System Pressurization Test

Before starting, ensure that any repair work has been carried out on your watercraft or any components of the fuel system have been disconnected. Check fuel line ends for damage and cut or repair any that are damaged.

Firstly, fill up the fuel tank. Then, disconnect the air inlet hose of the fuel tank from the body. Install a hose pincher (P/N 295-000-076) on the fuel tank vent hose. Now, connect a pump gauge tester (P/N 295-000-085) to the air inlet hose.

Turn the fuel valve to the OFF position and pressurize the fuel system to 34 kPa (5 PSI). If no leaks are found, turn the fuel valve to the ON position and pressurize once more. If the pressure is not maintained, locate the leak, and repair or replace the component that is leaking. To make this easier, you can spray a solution of soapy water on the components, as bubbles will indicate the location of the leak.

The system must maintain a pressure of 34 kPa (5 PSI) for 10 minutes. Never pressurize over 34 kPa (5 PSI). If a leak is found, do not start the engine and wipe off any fuel leakage. Do not use electric-powered tools on the watercraft unless the system has passed the pressure test.

Before removing the hose pincher, block the outlet hole with your finger to feel if air is coming out when removing the hose pincher. This will indicate that the pressure relief valve and the outlet fitting are not blocked. Finally, remove the hose pincher from the fuel tank vent hose.

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