Replacing The Fuel Selector Switch In A Sea-Doo Gti

If you're looking to replace the fuel selector switch on your Sea-Doo GTI, you've come to the right place. This is a common issue, and there are a few things you should know before getting started. First, the fuel selector switch is also known as the fuel valve, and it's responsible for switching between the on, off, and reserve positions. It's located near the valve you use to switch between these positions, and you'll need to remove the black plastic nut and the black cap to access it. You can find replacement parts online or at specialty stores, and the process of replacing the fuel selector switch is relatively straightforward. However, it's important to be cautious when working with fuel lines to avoid any leaks or mishaps.

Removing the fuel selector switch

Step 1: Accessing the Fuel Selector Switch

Locate the fuel selector switch, which is usually found near the fuel tank. It is the valve used to switch between "on", "off", and "reserve" positions.

Step 2: Removing the Knob

At the center of the knob, there is a small black cap. Pop it out to expose a Phillips-head screw. Use a suitable screwdriver to remove this screw, and then take off the knob.

Step 3: Detaching the Black Plastic Nut

Underneath the knob, you will find a black plastic ring with a black plastic nut. Remove this nut to free the entire fuel selector valve.

Step 4: Disassembling the Valve

Once the valve is removed, you will see a small screw on the side of the threaded area. Unscrew this to release the plug valve. Use a pair of pliers to pull out the plug for cleaning or replacement.

Step 5: Cleaning and Inspection

Before cleaning or replacing any parts, pay attention to a rubber insert inside the switch body, where the fuel lines connect. This rubber piece is crucial and should not be mistaken for dirt. Clean the valve and its components carefully, ensuring that the rubber parts, including the O-ring, are in good condition.

Step 6: Reassembly and Testing

If you are reassembling the valve after cleaning, make sure to put everything back in the correct order. Test the valve by turning it between its different positions. It should move with some resistance and stop firmly at each end of its travel. If it turns too easily or does not stop precisely, there may be an issue with the valve or the O-ring.

It is important to note that some fuel selector switches may not be serviceable, especially those with 5/16" selectors. These often have pressed-in fittings that can spin, potentially causing air bubbles in the fuel lines. If you encounter this type of selector, consider replacing it entirely for peace of mind.

Additionally, always refer to your Sea-Doo's user manual or seek advice from a qualified technician if you are unsure about any steps in the removal or reassembly process.

Cleaning the fuel selector switch

To clean the fuel selector switch, you will need to first locate the valve which is used to switch between on, off, and reserve. In the centre of the knob, there is a small black cap that will pop out, exposing a Phillips head screw. Remove this screw and take off the knob. Underneath the knob, there is a black plastic nut that needs to be removed as well. Once these parts are off, the entire fuel selector valve can be pulled out.

On the side of the threaded area, there is a small screw that holds the plug valve in place. Remove this screw and then use a pair of pliers to pull out the plug. Now, you can clean the entire assembly. It is important to note that there is a rubber insert inside the switch body that can look like dirt but should not be removed as it is not dirt. Instead, focus on cleaning the other parts and be careful not to damage this rubber piece.

After cleaning, simply reassemble the parts in the reverse order, making sure to include the rubber insert. Additionally, it is recommended to use stainless steel hose clamps and avoid cutting the fuel lines if possible.

Disassembling the fuel selector switch

To disassemble the fuel selector switch, start by locating the valve you use to switch between on, off, and reserve. In the centre of the knob, there is a small black cap that will pop out, exposing a Phillips-head screw. Remove this screw and take off the knob. Underneath the knob, there is a black plastic ring with a black plastic nut that needs to be removed. Once this is done, the entire fuel selector valve can be pulled out.

On the side of the threaded area, there is a small screw that holds the plug valve in place. Remove this screw with a pair of pliers and the plug will come out, allowing you to clean the entire assembly. Be careful not to confuse this small screw with the one holding the plastic nut, as they are different.

It is important to note that not all fuel selector switches can be disassembled in the same way. The process described above is for a 1/4" selector, while a 5/16" selector may not have a screw to disassemble. Additionally, the fittings on a 5/16" selector are pressed in, so be cautious when handling them to avoid introducing air bubbles.

Replacing the fuel selector switch

To replace the fuel selector switch on a Sea-Doo GTI, you'll first need to purchase a replacement fuel selector switch that is compatible with your specific Sea-Doo model. You can find these online or at a marine supply store. Once you have the replacement part, follow these steps:

• Locate the fuel selector switch on your Sea-Doo. It is usually found near the fuel lines or the fuel tank.
• Disconnect the fuel lines from the old fuel selector switch. Be careful not to damage the hoses, as you will be reusing them.
• Remove the old fuel selector switch by unscrewing any screws or bolts holding it in place.
• Install the new fuel selector switch by securing it in place with the appropriate screws or bolts.
• Reconnect the fuel lines to the new fuel selector switch, ensuring that they are securely attached.
• Test the new fuel selector switch by turning it to the "on" position and checking for any leaks.

It is important to note that you should always use stainless steel hose clamps when working with fuel lines, as zinc screws can rust and become difficult to remove. Additionally, it is recommended to replace the plastic nut that secures the fuel selector switch, as these can also break over time.

When purchasing a replacement fuel selector switch, make sure to verify compatibility with your specific Sea-Doo model and year. Some switches are designed for specific models, while others are universal replacements that fit a variety of watercraft brands.

Reattaching the fuel lines

First, you need to identify the fuel selector switch. It is the valve you use to switch between "on", "off", and "reserve". Once you have located it, you will see a small black cap in the center of the knob. Pop this cap out to expose a Phillips-head screw.

Using a suitable screwdriver, unscrew and remove the screw, then take off the knob. Underneath the knob, you will find a black plastic ring with a black plastic nut. Remove this nut, and the entire fuel selector valve can now be pulled out.

At this point, you should see a small screw on the side of the threaded area. This screw holds the plug valve in place, so remove it with a suitable screwdriver. Now, using a pair of pliers, pull firmly on the plug to remove it. You can now clean the entire assembly.

To reassemble the fuel selector switch, simply follow the steps in reverse. First, insert the plug back into the valve and secure it with the small screw. Then, place the black plastic nut and ring back onto the assembly. Finally, screw the knob back into place, and snap the small black cap back into the center of the knob to hide the screw.

When reattaching the fuel lines to the fuel selector switch, take care to avoid crossing the wires. Ensure that each fuel line is connected to the correct port on the switch. You can refer to the Seadoo's wiring diagram or a trusted mechanic if you are unsure about the correct wiring configuration.

Once the fuel lines are properly connected, use zip ties or stainless steel hose clamps to secure them in place. Make sure the connections are tight and secure to prevent fuel leaks.

Finally, inspect the entire fuel system for any signs of damage or wear. Look for cracks, leaks, or corrosion on the fuel lines, connectors, and other components. Replace any damaged parts as needed.

By following these steps, you can confidently reattach the fuel lines to your Seadoo GTI's fuel selector switch, ensuring a safe and proper fuel delivery system for your watercraft.

Frequently asked questions