Replacing Ski-Doo Fuel Tank Grommets: A Step-By-Step Guide

If you're looking to replace the fuel tank grommet on your Ski-Doo, you've come to the right place. This is a common issue that many Ski-Doo owners face, especially with older models. The fuel tank grommet can become brittle and crack over time, leading to fuel leaks. In this guide, we'll walk you through the process of replacing the fuel tank grommet, so you can get back to enjoying your Ski-Doo safely and efficiently. We'll cover the tools and parts you'll need, as well as step-by-step instructions on how to complete the replacement.

Troubleshooting a leaking fuel tank grommet

Identifying the Leak

Firstly, it's crucial to confirm that the grommet is the source of the leak. Conduct a visual inspection for fuel dripping from the area around the fuel tank, especially near the fuel lines and their connection points. A strong gasoline odour near the tank is also a clear indication of a leak. Carefully follow the fuel lines from the tank to the engine, looking for any signs of damage, cracks, or loose connections. If the grommet is the culprit, you will likely see fuel leaking from where the fuel lines connect to the tank.

Understanding the Causes

Fuel tank grommets are made of rubber, which can deteriorate over time due to various factors. Here are some common causes of a leaking fuel tank grommet:

• Age and Wear: Rubber grommets can become brittle and cracked with age, especially if exposed to harsh weather conditions.
• Chemical Exposure: Gasoline and other chemicals can weaken the rubber, leading to cracks and leaks.
• Overtightening: Excessive tightening of fuel lines can put too much pressure on the grommet, causing it to stretch and fail.
• Extreme Temperatures: Heat and cold can affect the rubber, making it brittle or soft, leading to leaks.

Step-by-Step Troubleshooting Guide

Step 1: Prepare Your Vehicle

Park your vehicle on a level surface to ensure stability and prevent fuel spills. Turn off the engine and disconnect the battery to prevent potential ignition. Release any remaining fuel line pressure by starting the engine and letting it run until it stalls.

Step 2: Disconnect the Fuel Lines

Locate the fuel lines connected to the fuel tank. Use a fuel line disconnect tool to carefully disconnect them. Gently pull the fuel lines away from the tank.

Step 3: Inspect the Grommet

Remove the old grommet from the tank carefully. Clean the area around the fuel tank opening and the new grommet using a clean rag. Inspect the old grommet for signs of damage or degradation.

Step 4: Replace the Grommet

Insert the new grommet, ensuring it is specifically designed for your vehicle's make and model. The new grommet should sit flush and securely in the fuel tank opening.

Step 5: Reconnect the Fuel Lines

Carefully align the fuel lines with the grommet and tank openings. Use a fuel line wrench to tighten the connections, but avoid overtightening.

Step 6: Test for Leaks

Reconnect the battery terminal and start the engine. Let it run for a few minutes, then carefully inspect for any fuel leaks around the fuel lines and the tank. If leaks persist, tighten the connections further or consider replacing the grommet again.

Preventative Measures

To prevent future leaks, it is recommended to take proactive steps:

• Regular Inspections: Periodically inspect the grommets for signs of wear, cracks, or brittleness.
• Avoid Overtightening: Always tighten fuel line connections according to the manufacturer's specifications.
• Protect from Chemicals: Keep the grommets away from harsh chemicals like gasoline, solvents, and cleaning agents.
• Proper Storage: If your vehicle is stored for extended periods, use a fuel stabilizer to prevent fuel degradation and protect the grommet.

Using a socket to push the grommet in place

To replace the fuel tank grommet on a Ski-Doo, you'll need to first purchase a new grommet that fits your specific Ski-Doo model. You can find these at your local dealer or online. Once you have the new grommet, follow these steps:

• Remove the fuel line and pop the fuel tank out of the sled. This will give you access to the grommet.
• If the old grommet is still in place, remove it. You may need to use a tool to pop it out, such as a flat-head screwdriver. Be careful not to damage the fuel tank.
• Take your new grommet and lubricate it lightly. This will help it slide into place more easily.
• Using a socket that has a slightly smaller circumference than the grommet, push the grommet into place. The socket will distribute the force more evenly, making it easier to pop the grommet into place.
• Ensure the grommet is seated securely and level with the surface of the fuel tank.
• Reattach the fuel line to the new grommet.
• Refit the fuel tank into the sled, securing it in place.

It is important to take your time and be careful when performing these steps to avoid damaging the fuel tank or any other components. If you are unsure about any part of the process, it is always best to consult a professional or seek further advice.

Converting the in-tank fuel strainer to a dual pickup

To convert the in-tank fuel strainer to a dual pickup, you can follow these steps:

• Remove the fuel tank from the sled.
• Take out the old fuel strainer by pulling it out through the fuel cap opening or the front of the fuel tank. This may require some creativity and manipulation with a bent coat hanger, especially for XP chassis tanks.
• Install a new fuel strainer with a dual pickup. You can source this part from an older sled or a local BRP parts counter. Ensure the hose is pliable and pointed downwards to prevent it from curling up and always sitting at the bottom of the tank.
• Consider adding a small piece of steel line or a barbed brass fitting (which won't rust) inside the end of the hose at the rear of the tank to weigh it down.
• Reinstall the fuel tank and connect the fuel lines.

Remember to always use genuine Ski-Doo OEM parts for the best fit, form, and function.

Testing the stator output

To test the stator output, you can begin by checking the resistance between any two pins in the connector. The specification states that the reading should be 0.1-1 OHM (pins 1-2, 2-3, 1-3). After this, perform a stator insulation test. To do this, touch any yellow wire with the chassis ground. You should have OL Ohm.

Next, start the sled and check the voltage output at idle. This should be a reading of between 25 Vac and pins 1-2, 2-3, 1-3. If you are unable to reach the stator, you may need to remove the muffler.

Checking the voltage

To check the voltage of your Ski-Doo snowmobile, you will need a voltmeter. Here is a step-by-step guide:

• Place the snowmobile on a stand to ensure it cannot touch the ground.
• Set the voltmeter to the 25-volt AC scale.
• Connect one of the voltmeter leads to a good ground.
• Connect the other voltmeter lead to the voltage regulator yellow wire.
• Start the engine without increasing the engine speed more than necessary.
• Slowly increase the engine RPM and observe the voltmeter reading.

If the voltmeter indicates less than 12.5 volts or more than 15 volts, the voltage regulator may need to be replaced. This method should work for Ski-Doo models from 1990 to 1995, including the Formula MX's, Plus's, SS, ST, STX, Mach 1's, and Grand Tourings.

Another way to check for voltage issues is to observe the headlights. If you are experiencing blown bulbs or dim lights, this could indicate a problem with the voltage regulator. Lift the rear of the sled and rev the engine to between 4000-5000 RPM. Check the voltage at the headlight, battery, or any accessory wire. If the voltage is over 16 volts, it is likely that the voltage regulator needs to be replaced.

It is important to note that voltage issues can also be caused by factors other than the voltage regulator, such as dirty or oxidized connections. Ensure that all contacts and grounds are clean before replacing any parts.

Additionally, if you are experiencing issues with your fuel tank grommet, you may need to replace it. This process involves removing the fuel tank and installing a new grommet, connector, and hose. There are also videos available online that demonstrate how to replace the fuel tank grommet in a 1985 Ski-Doo Formula MX.

Frequently asked questions