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  1. #11
    PWCToday Newbie
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    Re: 04 XLT 800 starter "clunks"

    Quote Originally Posted by Myself View Post
    As i suspected. Time for a teardown. Could have broke a piston skirt and the debris is binding it up, or a bearing. We can guess at causes after you tear down and post pics. That is......if you dont find an oil line popped loose.
    If the oil line popped loose I will be upset. I used the forum approved Oetiker clamps and tygon line

    I will get going on the teardown and then post pics.

  2. #12
    PWCToday.com Is My Home Away From Home Grumpy Old Guy's Avatar
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    Dec 2003
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    Re: 04 XLT 800 starter "clunks"

    Pull the head off I bet you have a broken powervalve......

  3. #13
    PWCToday Newbie
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    Re: 04 XLT 800 starter "clunks"

    Quote Originally Posted by Grumpy Old Guy View Post
    Pull the head off I bet you have a broken powervalve......
    Grumpy Old Guy wins the prize (thanks for the suggestion -- otherwise I might have pulled the engine before looking under the head).
    So... obviously I need new powervalves. What else should be done? The lip of the piston is a little dinged up. Do I need to replace that?

    IMG_0845.JPGIMG_0849.JPG

  4. #14
    PWCToday.com Is My Home Away From Home Grumpy Old Guy's Avatar
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    Re: 04 XLT 800 starter "clunks"

    From that # on the piston it has already been apart & has WSM pistons....

    I would take the clys off & inspect & also see if it has nickasil cyls or if they have been sleeved. There are aftermarket power valves but IMO are inferior to the OEM ones but they OEM ones are $$$

  5. #15
    PWCToday Newbie
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    Re: 04 XLT 800 starter "clunks"

    Quote Originally Posted by Grumpy Old Guy View Post
    From that # on the piston it has already been apart & has WSM pistons....

    I would take the clys off & inspect & also see if it has nickasil cyls or if they have been sleeved. There are aftermarket power valves but IMO are inferior to the OEM ones but they OEM ones are $$$
    Definitely no nikasil here. I originally bought the ski with a blown engine and sent it off to be rebuilt (not at a place that replates). Not very many hours on the since the rebuild (<20). I think everything should be good except for damage caused by the starter banging the piston against that powervalve. The cylinder seems fine, but you can see in the picture the lip of the piston has suffered a little bit of damage. I guess mainly I was wondering if that piston damage is within operating tolerances, or if I should replace it.

    piston.jpg

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