How To Rebuild A 1996 Seadoo GTI Carb

Knowing how to rebuild a 1996 Seadoo GTI carb can be time consuming but worth every effort. Rebuilding the carburetor may solve issues like longer starting and most running problems. Sea Doo GTI has dual carb which requires rebuilding in time, and this will guide you to completely rebuild the carburetor.

What you need:

  • Carburetor Rebuild Kit (BN 38)

  • 4 pieces Screws (30 mm, 2 washers each)

  • Screwdrivers

  • Pump tester

  • Gauge tester

  • Plastic tubing

  • Loctite

  • Ruler

  • Pop off tester (gauge range 0-60 PSI)

  • Lube

  1. Remove the Seadoo GTI carb from the engine. Disconnect fuel supply and return line followed by all the cables. Unscrew the carburettor.

  2. Check and replace damaged pieces of the carburetor. Also, check the needle valve if worn. The replacement should be together with the needle seat. Screws should be inspected for any grooved signs.

  3. Pump the diaphragm for any leaks. Connect the pump gauge tester to the pulse nipple and pump the tester until 4 PSI. The diaphragm should be able to endure the pressure for around ten seconds; if not, then it must be replaced.

  4. Check the fuel pump valve. Connect the plastic tubing to the inlet nipple and blow for pressure and suction for vacuum using the mouth. Be careful not to swallow fuel during the procedure since some fuel may be present. The inlet valve should let go with pressure, and do the opposite with vacuum. Perform this step for the outlet nipple but the effect on the outlet valve is reversed.

  5. Inspect the fuel filter. Unscrew pump cover, gasket, diaphragm, the pump body and the other diaphragm. Remove and clean filter, then check its condition. Replace it if needed.

  6. To check the fuel accelerator pump, disconnect the hoses and both the inlet and outlet accelerator pump nipples. Connect the pump gauge tester to the inlet nipple. Clog the outlet with your finger and start pumping tester until 4 PSI. The accelerator pump diaphragm should withstand the pressure for about ten seconds and should be replaced if not. Check the accelerator pump and valve condition following the fuel pump valve check procedure in step 4.

  7. Check the injector by connecting the pump tester to the injector hose and pump tester until 3 PSI. The check valve should open when 3 PSI is reached. Too low acquired pressure means leakage; if it’s too high, it may result in engine problems due to minimal fuel being carried through.

  8. Assemble the pump properly. Ensure the throttle plate is closed and centered into the carburetor when installing onto the shaft. Apply loctite on the screw threads, then tighten screws.

  9. Ensure the needle valve lever is flush with the metering chamber floor. Place the end of a ruler over the lever for the adjustment check. Adjust by slightly bending the lever avoiding any damage to the valve seat and needle.

  10. Perform pop-off pressure test. Connect the gauge tester to the carburetor fuel inlet nipple and pump tester while covering the fuel return nipple until pressure abruptly drops. Repeat the test thrice to achieve an accurate reading. Adjust the lever or replace the spring if needed to get result within specs.

  11. Leak test the needle valve. Needle valve must stand ten PSI pressure for around 30 seconds. If not, turn the carburetor upside down and pour oil over the needle valve and administer pressure. Inspect for any bubbles. Tighten seat and O-ring if bubbles come out from the seat. If leaking still occurs, replace the O-ring. Replace the needle, along with the seat, if bubbles come out from the needle.

  12. Remove check valve housing to inspect both the pilot jet and main jet. Refer to the spark plug tip condition to check the carb mixture setting for proper jet adjustment.

  13. Inspect check valve assembly. The check valve prevents fuel to flow back into the carburetor’s lower part.



Apply some lube when installing O-rings for both low and high speed screws and on the roller shaft. Lubricate accelerator pump with synthetic grease.

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