Replacing Fuel Pump In 2005 Seadoo Sportster Di: Step-By-Step Guide

If you're looking to replace the fuel pump in your 2005 Seadoo Sportster DI, there are a few things you should know. Firstly, it's important to note that the fuel pump is located inside the fuel tank, and the process for replacing it can be quite involved. You will need to remove several components, including the front storage compartment, the glove box console, and the air supply tubes. It is also recommended to strap the hood open to prevent it from falling on you while you work. Additionally, you will need specific tools, such as a 5/16 fuel/AC disconnecting tool and an 8mm nut driver, to separate the fuel lines and remove the nuts holding the fuel pump module in place.

When replacing the fuel pump, it is crucial to pay attention to the alignment of the module and the gasket, as the uneven spacing of the mounting studs means they can only be properly aligned in one way. You will also need to be careful when handling the float for the fuel sensor, which is connected to the end of a pivoting metal rod. It may be necessary to remove the rod from the gauge to avoid damaging it.

Another important consideration is the choice of a suitable replacement fuel pump. The original equipment manufacturer (OEM) fuel pump is known to have issues with particulates or water in the fuel, which can cause premature failure. There are aftermarket options available, but it is important to select a pump that can achieve the required fuel pressure and flow rate for your watercraft.

Remove the storage box and vent tube support bracket

To remove the storage box and vent tube support bracket from a 2005 Seadoo Sportster DI, follow these steps:

Open the hood and remove the storage box. There are no screws holding the storage box in place, so it can be lifted out.

Next, remove the two nuts from the studs that hold the vent tube support bracket to the hull/steering assembly. You can use a ratchet with a 10mm socket to remove these nuts. Once the nuts are removed, tap the studs through and remove the vent tube.

Now, you can move on to removing the glove box. There are two clips holding the glove box to the hull, which are accessible through the hole left by the removed vent tube. There are also four 1/4" automotive-style plastic push clips that hold the "wings" of the glove box in place. These can be cut off if needed. Additionally, there are two screws holding the black plastic reverse lever handle; remove these to manoeuvre the glove box wing over it.

With the glove box removed, you will have better access to the fuel supply and return lines. These lines are connected to a bracket on the inside of the hull, so disconnect them using a 5/16" fuel/AC disconnecting tool. Be prepared for fuel to spill from the lines. It is recommended to wrap paper towels around the lines to minimise spillage.

By following these steps, you will have successfully removed the storage box and vent tube support bracket, allowing you to access and replace the fuel pump in your 2005 Seadoo Sportster DI.

Disconnect the fuel supply and return lines

Disconnecting the fuel supply and return lines is a crucial step in replacing or repairing the fuel pump in a 2005 Seadoo Sportster DI. Here is a detailed guide on how to safely and effectively complete this task:

Before beginning, ensure you have the necessary tools, including a 5/16” fuel/AC disconnecting tool. These can be purchased at automotive stores or online. It is also recommended to have paper towels or rags readily available to wipe up any spilled fuel.

To begin, locate the fuel supply and return lines. These lines are connected to a bracket on the inside of the hull. Using the 5/16” disconnecting tool, push the tool firmly into the female side of the connection. With a gentle wiggle, the male side should disconnect. Be prepared for fuel to spill out of the lines. Have paper towels or rags ready to catch the fuel and absorb any spills.

It is important to work carefully and deliberately to avoid any fuel spills or leaks. If you are unsure about the process, it may be helpful to refer to a repair manual or seek assistance from a qualified technician.

Once the lines are disconnected, set them aside, ensuring they do not pose a safety hazard. With the fuel supply and return lines now disconnected, you can proceed to the next steps in the fuel pump replacement or repair process for your 2005 Seadoo Sportster DI. Remember to refer to a reliable source for further instructions on completing the fuel pump replacement safely and effectively.

Remove the glove box

To remove the glove box from a 2005 Seadoo Sportster DI, follow these steps:

First, open the hood and remove the storage box. Then, 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.

Now, you will need to remove the glove box itself. There are two clips holding the glove box to the hull, which are accessible through the hole left by the removed vent tube. There are also four 1/4" automotive-style plastic push clips that hold the two “wings” of the glove box to the hull. You can either cut these off or remove them. Additionally, there are two screws holding the black plastic reverse lever handle; remove these to maneuver the glove box wing.

With the glove box removed, you can now access the fuel pump assembly and continue with the fuel pump replacement procedure.

Remove the fuel pump assembly

To remove the fuel pump assembly from a 2005 Seadoo Sportster DI, follow these steps:

Firstly, open the hood and remove the storage box. Then, 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.

Next, remove the glove box. To do this, you will need to remove the two clips holding the glove box itself to the hull, accessible through the hole for the vent tube. There are also four 1/4" automotive-style plastic push clips that hold the two “wings” of the glove box to the hull. You can cut these off, but remember to also remove the two screws holding the black plastic reverse lever handle so you can maneuver the glove box wing over it.

Now, remove the fuel supply and return lines from the bracket holding them to the inside of the hull. You will need a 5/16” fuel/AC disconnecting tool for this step. Push the tool all the way into the female side of the connection and the male side will disconnect with a little wiggling. Be prepared for fuel to spill out of the lines.

At this point, you will need to remove the nine 8mm nuts holding the fuel pump assembly to the fuel tank. Take the whole assembly out, remembering 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 partially out towards the rear (via the glove box) and then back out towards the front.

Finally, you can now remove the fuel pump assembly from the 2005 Seadoo Sportster DI.

Install the new fuel pump

To install the new fuel pump, you will need to follow these steps:

Firstly, you will need to prepare the new fuel pump by attaching the rubber hose and copper piping. Cut a piece of copper pipe that is slightly less than the length of the installed hose to avoid interference with the pump or barb fitting. Place the hose onto the pump and the brass barb fitting at the other end, then clamp the copper stiffener shells over the hose.

Next, you can begin to reassemble the fuel pump module. Lube the outlet tube and sliding seal lightly, then set the spring on top of the seal carrier. Insert the outlet tube into the sliding seal, ensuring the correct orientation. Clip the three retaining clips of the upper module into the aluminium reservoir. Reattach the electrical connectors to the module top and fuel sensor.

Now, you can slide the module bottom with the pump setup into the aluminium module body and reattach with small metal screws. If the bottom was not removed, lower the pump setup into the module reservoir and insert the inner filter screen into its pocket. Use a long screwdriver to press all four corners of the filter down into the socket, ensuring the foot-valve washers are in place.

Finally, you can replace the rebuilt fuel pump module into the watercraft, following the removal steps in reverse.

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