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  1. #1

    Angry Engine is in the air BUT still hooked up HELP '03 XLT 800

    I have a "Build" thread over on the Builds Sub-forum...

    So, as you can see by the pictures, motor is on the cherry picker but I am still hooked to electrical box. I have been following the Engine Removal manual that SBT produced for the Yamaha 800 and it has helped but some thing have been very different. Appears previous owner also removed the oil pump which I plan to put back on. The SBT manual claims that all wires have quick connects but mine does not. I have circled the issues, the plug will not pass through the "hole" on the box and I am not sure how to proceed. Do I just remove the flywheel magneto to at least free the engine? Thanks
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  2. #2
    Yamaha artisan Cutlass's Avatar
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    I think that rubber grommet around those wires pops out of the box and stays with the wiring.

  3. #3
    Quote Originally Posted by Cutlass View Post
    I think that rubber grommet around those wires pops out of the box and stays with the wiring.
    I was afraid to yank it out, I pulled on it pretty good and it didn't want to budge. I was afraid even getting the grommet out of the box that the black plug would be too big to come through the box (red circle on the right)

  4. #4
    Tool Bag water worx's Avatar
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    Take front cover off set aside....

  5. #5
    Quote Originally Posted by water worx View Post
    Take front cover off set aside....
    So remove the flywheel cover and that will free the wires from the engine side?

  6. #6
    Dave in DE's Avatar
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    Yes, if you remove the motor front cover the wires all come with it and motor is free.


  7. #7

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    Quote Originally Posted by T0MMY B0NES View Post
    I was afraid to yank it out, I pulled on it pretty good and it didn't want to budge. I was afraid even getting the grommet out of the box that the black plug would be too big to come through the box (red circle on the right)
    Silicone spray is an excellent lube for old rubber parts and is chemically compatible with rubber

  8. #8
    The motor is free and ready to be broken down once I get a workbench built. Removal of the stator housing was the answer to the above post. I did find some oil in the cover of the stator housing, not sure if this is normal or not. Motor mounts appear to be reusable. Any tips on "cleaning" out the hull? Appears hull has some mold as well on the tanks and tank straps.

  9. #9
    I like Boobs. wetwolf's Avatar
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    Make sure those engine shims get put back into the right spots. Label them.

  10. #10
    Quote Originally Posted by wetwolf View Post
    Make sure those engine shims get put back into the right spots. Label them.
    Well damn. They are sitting where they fell off. Not sure if I can find the exact locations or not. Thanks for the heads up.

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