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  1. #1
    98gsxl951's Avatar
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    going to do oil seals in 03 gp800r, anything else i should tend to while motor is out

    like the title says, my oil seals should be in tomorrow, gonna start pulling motor out via http://www.shopsbt.com/pdfs/y800.pdf, what else should i tend to while the motor is out, check over etc.


  2. #2
    There is no reason to open up the electrical box on the 800 when pulling the engine. Pull the flywheel cover off and leave it in the hull. Take off the postive and negative leads on the starter and the temp sensor at the bottom of the pipe and that all you need electric wise. Pull the PV bracket off at the power valve cover and take the the oil and fuel line off and throttle cable and thats it...

  3. #3
    WATER WOODY's Avatar
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    base gaskets for sure

    its not a bad idea to get all new gaskets: head,intake,ex manifold as well, while you are there. Pressure test kit from Lowell !!!!!
    Also a good time to check the bore and rings.... check pulse lines and fuel lines

  4. #4
    98gsxl951's Avatar
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    base gasket is that where the two cases split? motor is suppose to fairly new, and ski has 120 hours on it, but who knows

  5. #5
    WATER WOODY's Avatar
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    base gaskets are between the cyl's and the case

  6. #6
    98gsxl951's Avatar
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    so i have to split the cylinders from the cases?haven read the write up in detail yet. also are these the correct seals? i am at work and dont have the old ones

  7. #7
    Yes the cases have to be split..

  8. #8
    fenn's Avatar
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    Quote Originally Posted by 98gsxl951 View Post
    so i have to split the cylinders from the cases?haven read the write up in detail yet. also are these the correct seals? i am at work and dont have the old ones
    i only see 2 there. there are 3 seals on the bottom end

  9. #9
    98gsxl951's Avatar
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    the microfiche only showed 2 on the pto side,... havent removed the stator cover so am not sure what that seal looks like.

    also i know i have to split the cases, but i am asking if i can just flip the mover over and split the cases with the cylinders on. or do the cyls have to come off in order to split them?>

  10. #10
    quadzilla's Avatar
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    ??

    Its item #4 on the micro-fiche image you posted..

    also i know i have to split the cases, but i am asking if i can just flip the mover over and split the cases with the cylinders on. or do the cyls have to come off in order to split them?
    Technically NO the top end doesn't need to be split from the top case half..!!

    Is that a good idea or method of replacing crank seals..... NO..!!

    What will need to be removed is both the flywheel and PTO coupler though..

    Gerry

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