2003 Yamaha XLT 800 66e Projects - Page 9 - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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post #81 of 154 (permalink) Old 08-18-2019, 11:57 PM Thread Starter
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Oil and fuel tanks have both been siphoned empty as best as possible. Oil tank has been removed from hull, trying to figure out the trick for removing the fuel tank. It appears the front body cover will need to be loosened up enough to allow the tank to squeeze by. The manual claims I need to remove handle bars, choke cable, fuel cable, and throttle cable, please tell me there is an easier way.
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post #82 of 154 (permalink) Old 08-19-2019, 05:25 AM
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Have you tried working it up out of it as is? My gpr manual said the same thing. But I worked it around and got it out.
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post #83 of 154 (permalink) Old 08-19-2019, 01:10 PM Thread Starter
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I feel like I have tried turning and twisting every which way but it still gets caught on the "tail" (red rectangle) of the front cover. Instead of messing with it, I figured loosening the cover up would work but that appears to entail a lot more work.
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post #84 of 154 (permalink) Old 08-19-2019, 03:00 PM
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Looking on Babbittsonline at the exploded views. Yes. You have a lot to pull off. Mine are two piece to your one. If you can't get the tank out you'll have to remove it though. Yours over hangs the opening further than the gpr.

Maybe if you take cover loose it can be lifted enough to allow the tank to come out.

Last edited by Dave in DE; 08-19-2019 at 03:02 PM.
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post #85 of 154 (permalink) Old 08-19-2019, 03:23 PM Thread Starter
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This was almost as bad as the loctite flywheel on the crankshaft. I have a service manual printed off in a binder with the exploded views, they just didn't help worth a damn when it came to this. I finally have the fuel tank removed, I was taking nuts and bolts off of everything that I could see might be binding up the cover. Appears I finally got her loose enough for the tank to squeeze by the overhang with minimal sounds of cracking and twisting, though the sounds were still present.

Oil tank, fuel tank, front bin, back bin, and inside of hull have all been sprayed and pressure washer with Super Clean (purple jug). I am off to the convenience center to dispose off the old fuel and oil. We will let everything drip dry on the driveway then come back and blow dry it with the compressor and then start assembly I hope.

Side note: Is there a company this still manufacture the weather stripping for the bins? Mine are pretty rotten but I don't have replacements on hand so I did not remove them.
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post #86 of 154 (permalink) Old 08-19-2019, 04:33 PM
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"Babbittsonline" or "Partszilla" you can still get packing for front bin. You'll also need to get the packing for the oil tank filter/sending unit to tank. The under seat locker the lower seal is available but upper is not. Try searching the part number on eBay as "Yamaha then the part #" sometimes you'll find one someone has.

Correction, only the lower packing is available for both compartments.

Last edited by Dave in DE; 08-19-2019 at 04:37 PM.
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post #87 of 154 (permalink) Old 08-19-2019, 04:41 PM Thread Starter
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Quote:
Originally Posted by Dave in DE View Post
You'll also need to get the packing for the oil tank filter/sending unit to tank.
Help me out with this one. I am not exactly sure what you are referring to...

I think I will hold off on replacing weatherstripping unless its a must to get back on the water. Ill bring some watertight bags with me to keep stuff dry.
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post #88 of 154 (permalink) Old 08-19-2019, 05:21 PM
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Quote:
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Quote:
Originally Posted by Dave in DE View Post
You'll also need to get the packing for the oil tank filter/sending unit to tank.
Help me out with this one. I am not exactly sure what you are referring to...

I think I will hold off on replacing weatherstripping unless its a must to get back on the water. Ill bring some watertight bags with me to keep stuff dry.
When you reinstall the sending unit you'll need packing #8. This seals the tank so all oil goes through the screen filter as it exits to the pump. The old one may be stuck in the tank if not on sending unit.
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post #89 of 154 (permalink) Old 08-19-2019, 06:53 PM Thread Starter
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Got the fuel tank back in the hull. Now to start buttoning everything back up that I took loose to remove the tank.

I have the unit sitting in an empty cup. I will have to see if I can find the packing/seal, I guess it is advised to not reuse #8? This ski was transitioned to premix but I am reverting back to oil injection.

Found some random pieces in the hull when I cleaned it out. The black plastic piece appears to be from the battery, the random nuts, washer and bot appears to be pretty rusted and may have been in the bottom of the hull for quite sometime.

The other piece is from a motor mount, not sure if this means it shot or if it will bolt back down. Also located a 4th shim that had fallen off. Now I am not completely sure of the shims' original locations. I will need to measure thickness to see if they differ much.

Also random piece "fell" from somewhere, hammer is for scale. Almost looks like an engine shim but much larger, could have possibly fallen out of the throttle cable, reverse cable mount inside of the hull.
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post #90 of 154 (permalink) Old 08-20-2019, 12:11 AM Thread Starter
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And I was either shorted a check valve or it got lost somewhere. It being clear plastic, it is virtually impossible to find if you drop it. I opened both of my kits in ziploc baggies to not lose anything but I cannot find the 4th check valve. And I threw away my old ones.

Last edited by T0MMY B0NES; 08-20-2019 at 12:43 AM.
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