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I have resealed every seam on the console panels, gauges, switches, compass, etc. On my boat the drain tubes on the console rod holders run thru the deck under the console and drain directly on top of the fuel tank (I re-plumed them with PVC and added a drain in the side of the console above deck). Here is a bit of history that may help: When the boat is covered, the problem is reduced. Ross indicated Ethanol in his response but I've been using E-Free for some time and still end up with fuel/water contamination issues. S8:28:02 GMT -6 said:Mike, I've had the same reoccurring problem with my 2004 SV2400CC, Yamaha OX66 200. My next step is to drain the tank and have the inside spray sealed.
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I even built my own 12v pump and filter system so I could clear the tank if the boat has not been used in a few weeks. And I reluctantly removed the fuel separator from below deck and installed a large Racor separator with a clear bowl above deck so I can see it. Two different mechanics have indicated a problem with the seal around the sending unit may be the source of the problem and have both said the console would need to be remove for repair (truth? who knows). I also resealed all access ports (a bit of overkill but why not do it all). Mike, I've had the same reoccurring problem with my 2004 SV2400CC, Yamaha OX66 200.