2004 Waverunner 800XLT
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  1. #1
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    2004 Waverunner 800XLT

    Hi, just had the engine rebuilt. Everything checks out. Now having trouble getting the Ski running. I can start it with Starting Fluid but can't keep it going. Any ideas? Thanks.

  2. #2
    PWCToday.com Is My Home Away From Home wmazz's Avatar
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    Re: 2004 Waverunner 800XLT

    Bad things happen when you start messing around with starting fluid
    and a ski that doesn't want to start. Things go BOOM!

    If a ski is loaded up, and you use starting fluid, and the engine backfires,
    the water box becomes a bomb.

    Quote Originally Posted by dlane123 View Post
    Now having trouble getting the Ski running.

    I can start it with Starting Fluid but can't keep it going. Any ideas? Thanks.
    So, it runs on starting fluid, but doesn't keep running?

    That sounds like the needle and seats are not opening.

    Were the carbs overhualed, and were some of the intake gaskets replaced,
    or reused?


    Bill M.
    Horsepower == Speed, RPM != Speed



  3. #3
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    Re: 2004 Waverunner 800XLT

    Thanks Bill M. I do appreciate your BOOM comment on starting fluid. I have seen it happen. As to carburetor rebuild, I have not done anything to the previously working carburetor. I am still trouble shooting and may have to rebuild the carburetor. Thanks again. Dave

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    PWCToday.com Is My Home Away From Home wmazz's Avatar
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    Re: 2004 Waverunner 800XLT

    Keep in mind, the most likely problem is the needle & seats are not
    opening. That could be caused by stiff float diaphragms. But Yamaha's
    are the worst for vacuum leaks. Followed by Sea Doo, and Kawasaki.

    The intake manifold/adapter plate is a great place to start. The carb
    base gaskets and the long adapter plate. I used to flat sand all the
    gaskets surface on hard starting skis and carb overhauls. But it is much
    easier to make your own thick gaskets from Fel Pro 1/16" (or 1/32")
    rubberized felt gasket material from a Napa auto parts.

    Hard starting from a vacuum leak (needle & seats not opening) occurs
    on all types of engines with float diaphragm carbs from lawn & garden
    2 stroke weed whackers to watercraft.


    Bill M.
    Horsepower == Speed, RPM != Speed



  5. #5
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    Re: 2004 Waverunner 800XLT

    Easy answer for most but perplexing to me. Just overhauled my Yamaha 2004 XLT 800. Ready to install the carb, but: How can you tell the Feed and Return (pulse and fuel lines) gas lines apart? Thanks

  6. #6
    PWCToday.com Is My Home Away From Home wmazz's Avatar
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    Re: 2004 Waverunner 800XLT

    If you were holding it in your hand, the lowest connector is
    the fuel in, and the highest connector is the return line.

    Pulse is usually in the middle, and attached to a fuel pump.


    Bill M.
    Last edited by wmazz; 08-21-2021 at 01:53 AM.
    Horsepower == Speed, RPM != Speed



  7. #7
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    Re: 2004 Waverunner 800XLT

    Thanks Bill M. That is what I thought, but wasn't sure. Dave

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