If you have a Sea Doo with the gray-colored Tempo fuel lines, the fuel lines should NEED TO be replaced. There have been very many instances where the Tempo fuel lines begin to deteriorate and will gum up the carbuerators. This can lead to the engine running lean equalling out to SERIOUS engine damage. Spending about $20-$25 to change the fuel lines is much better than spending about $1200, or more, for a new engine.
I bought this Sea Doo without an engine, so I emptied all of the gas out of the tank before doing anything else with it. Now I know I will be using fresh gas and it will be easier to change the fuel lines, since they are empty.
The existing fuel lines are metric (8mm and 6.4mm). They can be replaced with 5/16" and 1/4" fuel line. It is recommended that you use the 5/16" and 1/4" and not just one size for everything. It was designed that way for a reason!
Download the SeaDoo shop manual for reference
Items Needed:
Step 1:
Disconnect the fuel line which goes to the input of the fuel filter. The fuel line will fit into a pump-type siphon thing (as shown below).
Step 2:
Turn the fuel selector knob to RESERVE and start pumping until all the gas is out of the tank.
Still more to go
Step 3:
To access the fuel baffle, the seat should be moved out of the way. To disconnect the seat, remove the 2 ring-looking things which are attached to the seat at the front of the ski. The seat can then be rotated out of the way (No need to completely remove the seat).
Underneath the seat is the access to the fuel baffle. It is covered with a rubber top, which can easily be removed with the assistance of a screwdriver.
The clamps on the fuel lines can be removed with the 1/4" socket, since it would be difficult to get a flat head screwdriving in that small space.
Step 4:
While you are at it, you might as well remove the fuel selector and make sure it is not gummed up.
Remove the knob by taking out the little rubber stopper to access the phillips head screw. Remove the phillips head screw and wiggle the knob off.
Beneath the knob is a plastic nut. I used a pliers to get it off. Be careful not to break it, it's only plastic.
Step 5:
The fuel selector can then be removed. I took it out through the fuel baffle access hole.
Clean the fuel selector with carb cleaner and make sure it is not clogged.
Step 6:
Remove the old fuel lines one at a time.
As you remove each line, label each end so you know where they came from.
Step 7:
Line up the new hoses with the old hoses and cut them to the same length. (I did all of the 5/16" hose first)
Step 8:
The 5/16" fuel line can be installed onto the fuel selector switch.
Step 9:
The fuel selector switch can be installed and the lines can be connected to the fuel baffle.
(RESERVE on the left (front of ski) and ON on the right (rear))
Step 10:
The vent lines can now be removed and replaced with the 1/4" hoses
Notice the loop in the line.
Step 11:
Here is the 1/4" line installed on the Y connector for the vent lines.
Step 12:
Insert the vent tube setup as shown. Keep the loop and use zip ties.
The clamps on the top are junk. When you replace the lines, use the worm-type clamps shown below.
Picture of the vent tube next to the coolant pisser
Step 13:
Replace the dirty fuel filter.........
With a new fuel filter
There are also Tempo fuel lines on the carbuerator
Step 14:
Remove the clamps by pinching the clasping part with pliers or pair of dikes
Step 15:
Insert a screwdriver under the clamp to pry the top part off
Step 16:
Cut a piece of 1/4" fuel line to the size of the one which was on the carb.
Step 17:
Insert the fuel line onto the carb.
Step 18:
Fasten the fuel line onto the carb by using either worm-type clamps or zip ties.
See my other page, where I show how to build a 951 engine from the bottom up