How to re-DOO your broken filler neck

[Myself]

Since the filler neck on these old things seems to be made out of recycled milk jugs, mine broke off yesterday about 5 minutes into our ride. Good thing I had the 650sx fueled up too! Anyway, I caught a stick or something in the pump (recent floods pushed crap from the creeks into the lake) lost thrust and fell off. No biggie but as I started getting back on I smelled a strong gas odor, then saw oily film on the surface. That's when I saw my gas cap AND neck threads just gone! And since ANYbody that rides knows SOMEbody with a broken Seadoo sitting around...........might as well use the parts!!

Broken crappy, non UV resistant plastic oem filler neck.

 

[Myself]

The 'Doo neck is slightly larger than the original. Well, so is the gas tank but they managed to make the hose fit that. I used my handy little heat gun to soften up the end then smeared a tiny amount of grease in and shoved the 'Doo filler neck in it. I continued working the neck around to stretch the hose out as it cooled.

 

[Myself]

Since the 'Doo neck is a tiny bit larger, the hole needs opened up. I used a carbide on the die grinder but a dremel would work as well. The black sharpie line is where I opened it up to. I shoved the shop vac hose in there and ran it while I was cutting.

 

[Myself]

The 'Doo filler neck has a couple of these little tabs to locate it in the hull. We don't need them in the way so I just used a cutoff wheel and removed them. A razor knife or hacksaw blade will also work. You can just see some grinding marks in front of my thumb where the tab USED to be.

 

[Myself]

Then shove the neck on in, tighten the large plastic nut on the backside, shove the fill hose on and clamp it. If I can get my real working MAN hands in there and accomplish it........you can too! All done, nice sturdy filler neck.