I would want to know what diameter bearings you have installed in this pump, are they 52mm OD or something unusual? Also what's the measurement between the pump bolts from center to center; is it 124.5mm as on the SJ?
The GP800 144mm pump was made from 1998 to 2000 then went to the larger 155mm size in 2001 to 2005 with the GP800R.
Almost every thing is different on the GP800 144mm pump assembly with the exception of the wear ring.
What parts were you planning on using?
That's close.... I'd order a plain grommet with no holes and move them back a bit.
The solid grommet is Yamaha part number 90480-23M69-00 and around six bucks.
It appears you have an aftermarket stator and cases so it doesn't have the alignment mark tabs.
Here are couple pictures of a normal 61X & 62T stator with the timing advanced two or three degrees.
You should be able to find black pigment almost anywhere including the Home Depot paint section.
http://www.fgci.com/bp_viewproduct.aspx?itemnum=133697&oldItem=133697
Have the exhaust manifold bead blasted to remove all the contaminants before welding and make sure your TIG welder guy knows how to do cast aluminum well.
Wider rails on jet-ski is like riding a bicycle with training wheels; it's good for beginners but you'll eventually want to take them off. It will improve lateral stability at low speeds but it's not going to keep the nose from diving on turns. I would suggest using sponsons up front and leave...
It sure appears like the major challenge for Lee is just to keep the ski from over rotating.
The couchers would just try to impress you with their superman high speed run.
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