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  1. #1
    Hybrid AWD's Avatar
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    00' GPR To Do List

    So I have now owned my GP1200R for almost 1yr. I rode it all last summer bone stock. I managed to pull out 65.5mph out of it which impressed me.

    So now that it's the winter and the ski is sitting in my garage I want to take care of some little projects on the ski. So I am trying to compile a list of "To Do's" before this season is in full swing and I wanted some opinions/advice.

    (NOTE) I am removing the pump to replace the plastic pump liner. So this may open up a whole world of DIY mods.

    Here is my list, read it, place you opinion and also give me some advice on other things I should look into.


    • Pump Tunnel Reinforcement - I know this isnt a "must do" thing, but it's cheap insurance
    • Catalytic Converter Removal
    • Pump Shoe Insert - I am considering the DIY approach with the 1/4" piece of steel.
    • Premix Setup - I already have the block off plate kit.
    Now onto the questionable "mods"


    • Dual Feed Fuel Supply Lines
    • Fuel Flapper Removal Mod + Clunk Mod
    • Fercho Jetworks Mod - Should I Consider An Aftermarket Bilge Setup?
    • Remove Tamper Evident Caps On The Carbs
    • 2" GPR Extension Upgrade
    • Free Flow Exhaust Mod

    So any opinions, input or even "omg you don't want to do that" tips, please let me know. I'm already pretty excited to get back out on the water.


  2. #2
    Try not to smile on a Jetski... GPRFrank's Avatar
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    Sep 2009
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    to do list

    Some other things i have done and made a huge diff:
    1 Flame Arrestors
    2 Jeting Carbs
    3 Milled stock head 41cc
    4 Solas Prop/Pump cone
    5 Intake Grate
    6 Ride Plate
    7 Free Flow exhaust
    "WAVE EATERS" and Couplers.

    I had after market sponsons but went back to steped stock ones
    I also found it ran better with stock trim tabs
    Cut some holes for more fresh air for motor (Be careful in rough waters)

    *** This is all just a opinion.Trial and error works great***
    Its a blast though Best of luck and have some fun .......

  3. #3
    Its better to burn out than fade away christian79's Avatar
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    Jul 2007
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    Marysville Ohio
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    698

    Things I Thought Were Important

    Items in bold should be considered REQUIRED

    Engine:
    ADA head with 40cc domes *
    Waveeater clips and couplers
    New crank seals (Held 10PSI for 3.5 hours) (Only If you need to split the case or you engine does not hold pressure)

    Exhaust:
    D-plate with sensor chip
    Riva free flow tube (Blue) *
    Hole shot kit (Fercho Style) *
    Hole shot kit relocation * (Check my posts for pics)
    SS hole shot gasket * (This was a GREAT idea)

    Fuel System:
    Complete carburetor rebuild (OEM Only)
    Bores Polished
    Drilled out returns
    90 Jet installed into return fitting on sending unit (Great idea from WFO)
    Choke Removal
    Accelerator Pump Removal
    Prok F/As
    Primer Added
    Rejetted for all mods and adjustments
    Fuel filter replaced
    Fuel Flapper/Screen removal
    Selector switch removal

    Jet Pump:
    Solas impeller 13/19
    Spray removed
    Bilge line removed

    Hull:
    R&D 1200 Intake Grate (ANYTHING other than stock)
    PPK
    Pump shoe Polished
    Pump shoe sealed
    Transom resealed
    Rideplate polished
    Coco's reenforcement kit
    2004+ rideplate and pump shoe brackets
    500 gph rule bilge
    1300R fuel selector plug
    1300R Choke removal plug
    PET-2100DX installed in glove box (Does not need to be a PET but you need to get a decent tach to monitor the ski)

  4. #4
    Its better to burn out than fade away christian79's Avatar
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    Quote Originally Posted by Hybrid AWD View Post

    • Pump Tunnel Reinforcement - I know this isnt a "must do" thing, but it's cheap insurance This is REQUIRED
    • Catalytic Converter Removal This is REQUIRED
    • Pump Shoe Insert - I am considering the DIY approach with the 1/4" piece of steel. This is REQUIRED Just get the updated brackets
    • Premix Setup - I already have the block off plate kit. This is REQUIRED unless you want to replace the oil lines and INSURE they never come off
    • Dual Feed Fuel Supply Lines This is NOT REQUIRED for a stock application
    • Fuel Flapper Removal Mod This is REQUIRED + Clunk Mod This is a good idea if you do alot of wave jumping
    • Fercho Jetworks Mod - Should I Consider An Aftermarket Bilge Setup? Hell YES
    • Remove Tamper Evident Caps On The Carbs This is REQUIRED to adjust the circuits after all the other mods you are going to do
    • 2" GPR Extension Upgrade This is not REQUIRED but is best done in conjunction with a 2005+ pump
    • Free Flow Exhaust Mod This is not REQUIRED and may cause you to lose RPMS. However it sound great

  5. #5
    Greenhulk Grasshopah (DRC) HallPass's Avatar
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    if you ever have time check out my build thread from my gp1200r.. theres a lot of good info cause i installed all this stuff you are doing plus more.. oh yeah i was age 13-14 literally when i did it.. so that should be inspiration that you can do it and get it done!

    http://www.greenhulk.net/forums/show...light=hallpass

    I also have some left over parts like the stinger exhaust for the Gp1200r with the jetworks mod done and I have all the jetworks valves and stealth mod just laying around if you are interested.. then you'd just need to swap stingers and be done.. updated gasket as well. no leaks!

  6. #6
    Hybrid AWD's Avatar
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    Im in the process of removing the pump right now.... wait let me rephrase.

    I am in the process of getting my ass kicked by the pump. It's not coming out. I've pryed both side and it moves out about 1" and does nothing. I figured it would have a "pop" point, but I am putting in some serious force.

    Any other advice to remove this burden lol.

  7. #7
    zx11rider's Avatar
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    Quote Originally Posted by Hybrid AWD View Post
    Im in the process of removing the pump right now.... wait let me rephrase.

    I am in the process of getting my ass kicked by the pump. It's not coming out. I've pryed both side and it moves out about 1" and does nothing. I figured it would have a "pop" point, but I am putting in some serious force.

    Any other advice to remove this burden lol.
    do a search this thread and many others will come up to try and give you ideas http://www.greenhulk.net/forums/show...ght=stuck+pump good luck Ron

  8. #8
    Hybrid AWD's Avatar
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    Quote Originally Posted by zx11rider View Post
    do a search this thread and many others will come up to try and give you ideas http://www.greenhulk.net/forums/show...ght=stuck+pump good luck Ron
    Yeah I think I am just going to cut it.... and then that will be my rational reason as to "why I must do the 2" extension" mod

    I'm not sure if I should use the smiley or

  9. #9

    Join Date
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    Quote Originally Posted by Hybrid AWD View Post
    Im in the process of removing the pump right now.... wait let me rephrase.

    I am in the process of getting my ass kicked by the pump. It's not coming out. I've pryed both side and it moves out about 1" and does nothing. I figured it would have a "pop" point, but I am putting in some serious force.

    Any other advice to remove this burden lol.

    Drop the tongue on the trailer so that the pump on the boat is the highest point on the boat. Remove the intake grate and spray WD-40 or any superior penetrateing/lubricant that works on rust and corrosion on to the shaft as close to where the shaft inserts into the intermediate shaft. Let it sit for about an hour.

    You said that the shaft pulled out about an inch. Use a brass or rubber hammer, and tap the pump back into place then try once again to remove it. If you do not have a rubber hammer, then retighten the mounting bolts back into the pump, then try to pry the pump back out by putting the screwdriver between the pump ears. Do this a few times, and it will break itself loose.

    I've done this on 2 different boats and it works well.

  10. #10
    Hybrid AWD's Avatar
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    Quote Originally Posted by salty View Post
    Drop the tongue on the trailer so that the pump on the boat is the highest point on the boat. Remove the intake grate and spray WD-40 or any superior penetrateing/lubricant that works on rust and corrosion on to the shaft as close to where the shaft inserts into the intermediate shaft. Let it sit for about an hour.

    You said that the shaft pulled out about an inch. Use a brass or rubber hammer, and tap the pump back into place then try once again to remove it. If you do not have a rubber hammer, then retighten the mounting bolts back into the pump, then try to pry the pump back out by putting the screwdriver between the pump ears. Do this a few times, and it will break itself loose.

    I've done this on 2 different boats and it works well.
    They are on stands right now in the garage but I'll definitely take a shot at the rust penetrant. Thanks for the advice.

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