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  1. #1

    96 XP build from Australia

    Hey guys,
    I'm Jacob and I'm from Western Australia, I've just bought my first pwc it's a 1996 XP 787, it's in need of a lot of tlc but that's what i wanted, the plan is to have it up and running in about a month.

    The engine is currently out and stripped down because of a balance shaft bearing failure causing it to smash apart the cases, while it's apart I'm going to give it a rebuild, clean it all up, and do a few mods too, basically i want to be able to keen up with the newer ski's, i would like it to be fairly reliable and it will be run on pump fuel, 98ron (93-94 aki)


    This is the list of stuff to do so far, if anyone has any recommendations or answers to my questions I'm all ears, I am yet to get any parts for it so if anyone has some of this stuff for a decent price let me know:

    Engine:
    replace engine cases (apparently RFI cases fit and have extra cooling?)
    replace balance shaft
    get new oversize piston kit (apparently .5mm over is the max before the combustion chamber needs machining out?)
    mill the head (not sure how far to go? .020"?)
    maybe port the intake around the rotary valve to give more duration?
    replace stator and pickup
    get aftermarket flame arrestor kit (not sure which one to get?)
    get aftermarket pipe (can get a coffman rec pipe for a decent price, any good?)
    get some kind of rev limit raiser?
    maybe modify the stock waterbox for more flow and slightly more noise?

    Hull/etc:
    replace fuel lines
    replace start/stop and vts buttons
    maybe replace the speedo and vts gauge
    replace the wiring from the vts unit to the front of the hull (has been cut at the motor and thrown)
    replace seat cover with aftermarket one
    clean the hull inside and out and buff it
    maybe get a different impeller?
    maybe get different grate? or even remove the stocker?
    get new lanyard as it didn't come with one (not sure if dess?)
    get flusher kit
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  2. #2
    More pictures, yes the piston is broken but it looks to have been done after the engine was pulled apart as there is no signs of damage from it
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  3. #3
    Addicted Member 5001craig's Avatar
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    Welcome to the forum!

    Looks like you've got your hands full.

  4. #4
    I got a bit of spare time today so i stripped down the bottom end, all that's left of the balance shaft bearing is the inner race, no sign of the outer or the balls!

    Good news is the crank looks reusable, the big ends are fine as i already checked them before buying, the main bearings have minimal play but some have a little muck in them which should clean out

    Also tossed up whether to leave the stock graphics on or rip them off, seen some pics of other ski's with them off and it looks alot cleaner, so i started pulling mine off using a heat gun and cleaned the little spots of residue with thinners, I'm hoping you won't be able to notice the colour difference once its all buffed though
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