04 XLT 800 starter "clunks" - Page 2
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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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    Re: 04 XLT 800 starter "clunks"

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

  3. #13
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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
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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

  6. #16
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    Re: 04 XLT 800 starter "clunks"

    OK, so I wound up replacing the piston and the powervalves and I put it back together.
    Even compression and it runs great, except.... there is water shooting out from the head gasket!
    I was careful about the tightening sequence on the head, and used the specified torque (with my craptastic harbor freight torque wrench).
    But I did leave the bolts dry. No loctite or grease.

    Any suggestions on fixing this? Should I just try to tighten it down more? Or do I need to take off the head and start with a new seal?
    Should I have been using copper sealant? Or silicone around the water jacket holes?

  7. #17
    Resident Guru JC-SuperJet's Avatar
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    Re: 04 XLT 800 starter "clunks"

    Sometimes this happens when the Base Gasket is installed upside down...shoots water into the cylinders
    Last edited by JC-SuperJet; 09-10-2018 at 05:55 PM.

  8. #18
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    Re: 04 XLT 800 starter "clunks"

    Quote Originally Posted by JC-SuperJet View Post
    Sometimes this happens when the Base Gasket is installed upside down...shoots water into the cylinders
    That's good to know. I think I was pretty careful on the base gasket orientation, though.
    And I feel like it wouldn't run well if I was getting significant water in the cylinders?

    Should I just start by tightening the head down more?

  9. #19
    PWCToday.com Is My Home Away From Home Grumpy Old Guy's Avatar
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    Re: 04 XLT 800 starter "clunks"

    Quote Originally Posted by JC-SuperJet View Post
    Sometimes this happens when the Base Gasket is installed upside down...shoots water into the cylinders
    Cant happen.

    Please explain.....
    Last edited by Grumpy Old Guy; 09-11-2018 at 06:32 PM.

  10. #20
    Resident Guru JC-SuperJet's Avatar
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    Re: 04 XLT 800 starter "clunks"

    If you look at the upper Crankcase deck, on the Exhaust side, there are two cooling pockets that align with the Cylinder Cooling passages that run behind the Exhaust Port.

    Refer to following photos:

    Yamaha GP800 Crankcase.jpg

    Yamaha GP800 Cylinder Block Cooling Passages to Crankcase.jpg

    If the Base Gasket is installed incorrectly, backwards or is damaged in this area, then water can/will leak into the Crankcase, then travel up the Transfer & Booster Ports into the Combustion Chamber and so forth...

    Please substitute the word "backwards" for "upside down" in my previous post. I apologize for my misleading comment...lol

    Forum history shows that a few Members have installed this gasket backwards before...
    Last edited by JC-SuperJet; 09-11-2018 at 09:28 PM.

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