87 X2 Resurrection

Joined
Jul 8, 2015
Likes
19
Location
Michigan
#5
The bottom hood hinge was broken when I bought it. I bought the wrong one on ebay, and then I couldn't find any. So, it was the Harbor Freight mini mill to the rescue. I pressed the pin out of the old hinge and pressed it into the new one. I also made the base a little thicker, which is where the old one broke.

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Joined
Jul 8, 2015
Likes
19
Location
Michigan
#6
After testing the cooling system on the garden hose, there was water spraying out of the exhaust header pipe. It had a big crack in it. The PO had tried to fix it with JB weld, and that wasn't working. I tried to TIG weld it. But, since I'm not a good welder, and it's an aluminum casting, that didn't work out. So I bought another one off ebay.

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Joined
Jul 8, 2015
Likes
19
Location
Michigan
#8
Took it for a ride and it ran pretty good. Charging system is not charging. The stator is not putting out any a/c voltage. And as much as I need to run the bilge pump, I need a charging system. Looks like the flywheel will have to come off to inspect that. Might be a good winter project.
 
Joined
Jul 8, 2015
Likes
19
Location
Michigan
#9
I fabbed up a hook shaped engine lift bracket. My back isn't going to take lifting this thing out by hand. Worked really good.

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Joined
Jul 8, 2015
Likes
19
Location
Michigan
#10
I can tell when I rotate the engine by hand that the crankcase drain valve is leaking. It makes an air "goose honk" sound as it leaks. It seems like most people just take it off and install a block off plate. Hardly any other jet ski engine has this, so I don't see why it's necessary. Is that what I should do?
 
Joined
Dec 29, 2013
Likes
50
Location
Argo, Al
#11
I laughed at "goose honk" because I can hear it in my head. The only thing it's good for is an air leak so yes, block it off. When I had Kawasaki stuff, I would just epoxy the holes but that was when I had the cases apart.
 
Joined
Jul 8, 2015
Likes
19
Location
Michigan
#15
I got the charging system fixed. The problem was the two yellow wires coming from the charging coil to the reg/rec box. The wires looked fine on the outside, but they were both corroded so badly that they were dead electrically. It seems weird that both of these wires were bad, but the ignition system wires were fine. Has anyone had this happen?

 
Joined
Jul 8, 2015
Likes
19
Location
Michigan
#16
I was really happy with the price and quality of this block-off plate. When the crankcase drain valve was still on, it was leaking so badly that I couldn't even do a leak down test. When I tried pressurizing the crankcase, air was rushing past the valve so quickly that the pressure gauge wouldn't even register. Not good!

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Joined
Jul 8, 2015
Likes
19
Location
Michigan
#17
The other thing I wanted to correct while the engine was out was the bilge pump hose routing. When we would ride this thing, it would take on huge amounts of water. If I would just let it sit by the shore, it wouldn't take on any water. This is how the hose was routed, with no hose clamps (and no check valve). It's supposed to go to the highest point inside the hull, then back down to the hull fitting. I replaced this hose with a much longer one. Apparently, whoever installed this bilge pump just created a need for a bilge pump.

Everything's fixed, just have to wait for summer.

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