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  1. #1
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    1996 SL900 rebuild

    Here is my newest project. I was looking for a single place trailer and found this on a nice Karavan aluminum trailer for 400 bucks.
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    It has all kinds of problems. Previous owner said the stator was bad so I started tearing into it. I hit the start button to check compression and the starter just spun. Heres why....

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    Once I needed to get the flywheel off I decided to just pull the motor. I got the motor out and removed the stator. It ohm tested good, and in fact its the updated ignition system. The front crank seal was shot so the whole flywheel housing was full of an oily mess. I pulled the heads off and the mag and center cylinders looked great. Then I pulled the PTO head. ouch!!!!

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    Lost a rod bearing and all the pieces ended up in the cylinder. So now it needs a crank and 1 cylinder.

    Heres what all 3 pistons look like
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    Thank you Urugol for hooking me up with 1 good cylinder and piston and 2 good domes. I will hone and re ring the other 2 cylinders
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  2. #2
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    As you can see in the last attached pic, the hood is completely beat to hell, as is most of the top side of the hull. So I have decided to paint this ski on the top side. I will be removing decals and repainting the deck the same white, and I most likely will do the hood red again. The purple rub rails kind of screw up any different paint color possibilities.
    Last edited by Mr. Matrix; 04-17-2011 at 08:39 PM.

  3. #3
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    Next problem is the electrical box, and this is probably why he thought the ignition was bad.
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    There were terminals that were so rusted they fell off the board. Thanks to Xlint, I have a new board on the way. I will be getting this thing cleaned out this week and hopefully it will all test out ok.

    MFD is good, however it was once replaced because the one thats in it does not have the trim display. So I guess its a cable and the mechanical indicator for this ski too. I am contemplating selling this MFD and installing an MFI that I have here like I installed in my SL650

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    Mfd only shows 19 hours

  4. #4
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    And of course the jet pump was a mess too. Impeller looks as it sucked a nice rock through it, all 5 stator vanes are missing a piece and 1 impeller blade is bent up, not to mention clearance measured .026. So I need an impeller. Drive shaft is junk too. the through hull fitting was bone dry and wore 2 deep grooves on the drive shaft where it rides in the bearings of the through hull fitting. This one will be getting a 6 vein stator anyways, and I will most likely have the impeller re-done by SBT, unless I can find a good used impeller, possibly a nujet 6.0 for this one

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    Last edited by Mr. Matrix; 04-04-2011 at 08:37 PM.

  5. #5
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    Just curious....what causes a bottom bearing to fail on a connecting rod? Rust? lack of oil? I have now bought 2 domestic engine skis and both lost the pto rod bearing, that was the source of their failure

  6. #6
    urugol's Avatar
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    You got some work on your hands there

    I would remove the hood altogether, it will be easier to get in there and do the fuel lines and if you need to repair it you can have it up on a bench.

    PTO Cyl looks bad, I can see why you needed the domes as well

    I thought all oval MFDs had the trim display. Did the 96 900 come with variable trim? I'm thinking it may not have

    If you are looking for an MFI, here's a real cheap one I seen http://cgi.ebay.com/ebaymotors/Polar...rcraftQ5fParts

  7. #7
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    It came with trim. The mfds for the slt 3 seat models did not have a trim display.

  8. #8
    She likes the bike. But the ski gets her wet!!!! xlint89's Avatar
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    Quote Originally Posted by BryanP View Post
    Just curious....what causes a bottom bearing to fail on a connecting rod? Rust? lack of oil? I have now bought 2 domestic engine skis and both lost the pto rod bearing, that was the source of their failure
    Yes and yes.

    Add my SLTX to the PTO connecting rod snapped at the crank.

    ---------- Post added at 11:34 PM ---------- Previous post was at 11:34 PM ----------

    Quote Originally Posted by BryanP View Post
    It came with trim. The mfds for the slt 3 seat models did not have a trim display.
    Correct ^^^^

  9. #9
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    Quote Originally Posted by BryanP View Post
    Next problem is the electrical box,

    MFD is good, however it was once replaced because the one thats in it does not have the trim display. So I guess its a cable and the mechanical indicator for this ski too. I am contemplating selling this MFD and installing an MFI that I have here like I installed in my SL650
    That MFD has the 2 little boats,used for the trim display.The SLT's will not have that. Of course someone could have changed the bezel.

    I've had a few MFD.that did not show any trim setting, until the trim motor/switch was cycled,then the trim indicater worked properly.
    With the condition of the elect box, it's possible the MFD is not getting a signal for trim.

    The part # on the back will tell if it came from an SLT.

  10. #10
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    Got the electrical box all cleaned up. The terminal board I installed was different, it doesn't have the fuse holder for the bilge pump, so I will just buy an inline fuse holder and connect that between the bilge pump and the orange terminal.
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    I think this looks a little bit better. Now I have to make a bracket to hold down the coil and starter relay, since its missing from my electric box. I forgot to mention, this electrical box was missing the large o-ring seal between the case halves.....no wonder it was full of rust.

    I checked part number 3280252 from the MFD and it is the correct display for a 96 SL 900, so I'm betting I will have the trim display when I can actually operate the trim motor.

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