After riding last weekend, I figured that I would install my 650 X2 pump in my FX-1. One hitch though, I gotta get it done by Friday morning so I can ride it this weekend. Pretty ambitious seeings how I work 12 hours a day and I require my 8 hr beauty rest. So I am 3 days into it-- here is the play-by-play action.
Sunday Evening:
I disconnected my exhaust tube, battery, water hose from the hull, primer line, plug caps, and removed the bilge (mounted in between tank and engine). I then unscrewed the four motor mount bolts and removed and tagged my shims.I removed the two bolts which hold the coupler shroud and then I then disconnected my grease line to the pillow block.
With most of the stuff out of the way, I slid the engine to where it rested on the battery box and proceeded to loosen the three bolts which secured the intermediate shaft pillow block bearing assembly to the bulkhead.
Next step I made was to remove the stock pump -- pulled the four bolts holding the ride plate, and the four bolts which hold the pump in place.
With the pump out, my next step was to pre-fit the shaft and pump before I do any significant changes to the boat.
I took the 900 zxi shaft and managed to slide it between the carb and the engine, right into the existing shaft hole-- well it wasn't that easy but after wrestling with the engine and all the other stuff I refused to remove, I managed to get it in. I immediately installed the stock Yamaha coupler onto the shaft, repositioned the engine back onto the motor mounts, and hand tightened a couple bolts back into them. I'm done for the day.
Monday:
With the shaft and engine in place, I make sure there is an appropriate gap in the coupler and proceed to take measurements, ensuring that before I do any grinding, everything is going to fit well. So far so good. Next task is to remove the pump shoe. So I un bolt all three intake grate bolts, and unscrew the four pump shoe screws. Now comes the crappy part. Using a very long and thin screw driver and a large hammer, I manage to break a small hole into a crevice in between the pump shoe and hull -- god the adhesive is like epoxy. Once I get the screw driver in, I take a very large screw driver (more like a pry bar with a handle) and proceed to pry -- PING, part of my pump shoe breaks away. Now I am committed to this project. I spend the rest of the evening trying to break the pump shoe free piece by piece. There is a small portion left on the upper most part of the pump.
Tuesday:
I play in a golf league after work on Tuesdays. After golf, there still is some time to press the new bearing and seals into the pillow block. I prefit the bearings and seals onto the shaft and crap, I have the slightest bit of slop between the shaft and the bearing-- its not a nice press fit like the yami shaft-- oh well, it will have to do. Thank god for oil seals. I proceed to pry the oil seal facing the hull and remove the snap ring. I flipped over the pillow block and pop out the other two oil seals and snap ring. using a 20T press and two large sockets, one to fit into the pillow block to press the bearing and the other to support the ring which it mounts into (eliminate any movement by the rubber), I press the bearing out. I mic'd both bearing to make sure they were the same width and diameter. Bingo. I then installed all four parts back into the stock Yamaha intermediate shaft bearing pillow block.
Wednesday:
Today I lifted the engine enough to pull the shaft out and slide it under it. I then slowly slid the bearing assembly onto the shaft while feeding it into the predesignated hole. I reinstalled the bearing housing and hooked back up the grease line. With the engine back in place, I secured it with a couple bolts for positional reasons. I guess its time to start grinding. I took my grinder and started to remove the ribs on the pump. I then tried to stuff it onto the pump cavity-- no go. I repeated this process multiples times in an attempt to not remove too much material from the hull. I removed as about as much aluminum as I think is safe and moved onto the hull. using a pen, I traced where I wanted to sand and used my orbital palm sander to remove paint, gelcoat, then resin and glass. I have repeatedly tried to install the pump, marking with a pen what to remove, sanding. I'm pretty close but still no cigar. I'll finish sanding tomorrow. I also pried up the turf just past the brass inserts so I can effectivly reloacte them.
I also managed to pry the rest of the shoe out-- word of advice, USE HEAT!!! After grinding on it, I found the adhesive to be soft and plyable, it also peels away from the gel coat nicely. Wish I would've figured out that sooner rather than destroy my aluminum pump shoe and pump cavity trying to break the adhesive free.
Sunday Evening:
I disconnected my exhaust tube, battery, water hose from the hull, primer line, plug caps, and removed the bilge (mounted in between tank and engine). I then unscrewed the four motor mount bolts and removed and tagged my shims.I removed the two bolts which hold the coupler shroud and then I then disconnected my grease line to the pillow block.
With most of the stuff out of the way, I slid the engine to where it rested on the battery box and proceeded to loosen the three bolts which secured the intermediate shaft pillow block bearing assembly to the bulkhead.
Next step I made was to remove the stock pump -- pulled the four bolts holding the ride plate, and the four bolts which hold the pump in place.
With the pump out, my next step was to pre-fit the shaft and pump before I do any significant changes to the boat.
I took the 900 zxi shaft and managed to slide it between the carb and the engine, right into the existing shaft hole-- well it wasn't that easy but after wrestling with the engine and all the other stuff I refused to remove, I managed to get it in. I immediately installed the stock Yamaha coupler onto the shaft, repositioned the engine back onto the motor mounts, and hand tightened a couple bolts back into them. I'm done for the day.
Monday:
With the shaft and engine in place, I make sure there is an appropriate gap in the coupler and proceed to take measurements, ensuring that before I do any grinding, everything is going to fit well. So far so good. Next task is to remove the pump shoe. So I un bolt all three intake grate bolts, and unscrew the four pump shoe screws. Now comes the crappy part. Using a very long and thin screw driver and a large hammer, I manage to break a small hole into a crevice in between the pump shoe and hull -- god the adhesive is like epoxy. Once I get the screw driver in, I take a very large screw driver (more like a pry bar with a handle) and proceed to pry -- PING, part of my pump shoe breaks away. Now I am committed to this project. I spend the rest of the evening trying to break the pump shoe free piece by piece. There is a small portion left on the upper most part of the pump.
Tuesday:
I play in a golf league after work on Tuesdays. After golf, there still is some time to press the new bearing and seals into the pillow block. I prefit the bearings and seals onto the shaft and crap, I have the slightest bit of slop between the shaft and the bearing-- its not a nice press fit like the yami shaft-- oh well, it will have to do. Thank god for oil seals. I proceed to pry the oil seal facing the hull and remove the snap ring. I flipped over the pillow block and pop out the other two oil seals and snap ring. using a 20T press and two large sockets, one to fit into the pillow block to press the bearing and the other to support the ring which it mounts into (eliminate any movement by the rubber), I press the bearing out. I mic'd both bearing to make sure they were the same width and diameter. Bingo. I then installed all four parts back into the stock Yamaha intermediate shaft bearing pillow block.
Wednesday:
Today I lifted the engine enough to pull the shaft out and slide it under it. I then slowly slid the bearing assembly onto the shaft while feeding it into the predesignated hole. I reinstalled the bearing housing and hooked back up the grease line. With the engine back in place, I secured it with a couple bolts for positional reasons. I guess its time to start grinding. I took my grinder and started to remove the ribs on the pump. I then tried to stuff it onto the pump cavity-- no go. I repeated this process multiples times in an attempt to not remove too much material from the hull. I removed as about as much aluminum as I think is safe and moved onto the hull. using a pen, I traced where I wanted to sand and used my orbital palm sander to remove paint, gelcoat, then resin and glass. I have repeatedly tried to install the pump, marking with a pen what to remove, sanding. I'm pretty close but still no cigar. I'll finish sanding tomorrow. I also pried up the turf just past the brass inserts so I can effectivly reloacte them.
I also managed to pry the rest of the shoe out-- word of advice, USE HEAT!!! After grinding on it, I found the adhesive to be soft and plyable, it also peels away from the gel coat nicely. Wish I would've figured out that sooner rather than destroy my aluminum pump shoe and pump cavity trying to break the adhesive free.
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