Hey guys first post here.
I bought a 05' XT660X with 18000ks on it about 3 weeks ago was pretty happy with it have ridden it every day with no issues but today it had the weirdest surges during a longer then usual ride at speed, so i pulled over gave it a break had a look at it, checked the fuel all the usual stuff seemed all good so tested it and the surges seemed to be gone so i hit the road again and not 10 minutes down the road without warning it just cut out.
After going right over the bike and trying to start it came to the decision the fuel pump wasnt working so pulled the tank off and pump out only to find what seems to be rusty fuel and a lot of crap in the mesh filter.
Tried the pump on its own out of the tank and found a wire to be faulty (would only switch on while on certain angles) rigged it all up and put it all back together and got it to start again but didnt seem to be able to hold pressure in the fuel lines and would only run for 5 seconds.
Im presuming now i should be replacing the pump but cant find any on the internet to suit an 05' model only this one.
http://www.ebay.com.au/itm/like/1111...=true&lpid=107
Would Yamaha still sell them? or would that pump still suit even tho it says 08' to 12'?
How do i clean out the rust of the tank i can get my hand in quite easily and seems as though the rust is mainly at the top of the tank, all the stuff i can find seems to be for old tanks not much is out there for something this new.

Any help would be greatly appreciated
Cheers Matt.

Firstly...

Welcome to XT660.com

You should be fine with a later pump. The part numbers are the same for all models (5VK-13907-01). In 2009 the last two digits changed to -02, but this only signifies that is an updated/improved version of the same part.

Not sure about the one in the link, doesn't look right to me?

As for cleaning the rust out of your tank, there is a DIY method that costs very little and has worked well for me in the past (although I've only ever done it on bikes with fuel taps which have smaller holes to plug.)

Take out the tank and take off all the fittings, pipe work etc. Seal all the holes (except the filler). Tip in about 500g of brass tacks and about half a litre of diesel. (You can use almost anything - nuts, bolts, screws, some even use sand, just bear in mind you need to get it all out at the end! Brass is good because it's softer than steel, but harder than iron oxide.) Seal the filler hole. Shake/swill in as many directions as you can for as long as you arms can take - the longer the better. Pour out the diesel/tacks and flush with petrol. Repeat if necessary.

To prevent the rust coming back at the top of the tank, always try and keep the tank full particularly during the winter months and in storage. Use a fuel stabliser too for long periods when not in use.

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I always use some STP or similar to try and reduce the amount of rust and muck and stuff that we all get into the tank. I also try to avoid reaching reserve, and I use a Yamaha fuel winter stabiliser when the bike is stored. Good luck!!!! And ps welcome on board.

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(Now sold on, sob) 2011 Blue XT660X with gold wheels, was 26,500 km.
Engine mods: K&N Stage 1 filter, DNA Stage 2 filter, snorkel removed, Kev fuel mod fitted.
Plus: smoked Puig screen, Yam aluminium sump guard, Yamaha / Acerbis handguards, Givi Trekker aluminium side cases, Leo Vince X3 cans plus Kev front fork mod and Fender Xtender. Just fitted Michelin Road Pilot 3 tyres.

SOLD the XTX for a Super Ten 1200. And just bought a Raptor 700 so staying on here for some tips....

Thanks guys.
I went with a rust neutralizer/sealer kit as to stop any rust i may miss in the tank waiting a few more days for it to dry.

I got a quote from yamaha for a new pump and it nearly made me choke on my tounge when they told me.. $770 ! There was no way i was paying that for a 9 year old bike!

So i found one from china for $160 Shipped to aus which was quite reasonable but they had none in stock :| .. so i eventually went with a pump similar to the one i linked in the first post that i actually found at a local auto store while messing round out the back and works a treat!

But a problem still seems to be present. It will start but wont idle or run. Im taking the strainer, the fuel rail and line to work to clean and ill get the injector cleaned and flow tested.

But it seems like a vacuum leak nearly anyone had a similar problem to this?
Thanks Matt.