2003 Yamaha XLT 800 66e Projects - Page 14 - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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post #131 of 154 (permalink) Old 09-13-2019, 02:25 PM Thread Starter
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So you're saying I should be able to blow them open with my mouth? I was able to open them with compressed air but it was a bit more than a few pounds. Even after blowing them out and cleaning with carb clean, I still could not blow through them myself. Five bad check valves seems highly unlikely but possible I guess. I'll go back with my regulator I used on my pop off valves and measure when it opens.

Even worse news, the replacement rings showed up today. I am still getting the same piston ring gap measure of 0.024". The manual calls for 0.012"-0.018" so I am 0.006" too big. So close yet so far.

What is my next option? Trying to find the next size up and filing down rings? How much would 6 thousandths of an inch REALLY affect the motor?
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post #132 of 154 (permalink) Old 09-13-2019, 04:52 PM
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No you won't be able to blow through by mouth. So long as air only goes in the direction of the arrow your good.
I'd call wsm and talk to a costomer service representative. Explain the issue. See if they can help.
Are you using a piston to push the ring in square to a point it's not over any ports. And making your measurements?

Last edited by Dave in DE; 09-13-2019 at 04:58 PM.
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post #133 of 154 (permalink) Old 09-13-2019, 05:25 PM Thread Starter
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Quote:
Originally Posted by Dave in DE View Post
Are you using a piston to push the ring in square to a point it's not over any ports. And making your measurements?
Yeah, I have triple checked everything. Measuring towards the bottom of the cylinder, using the new piston to push it on square. Not over any ports. The ONLY thing I can think of is maybe a shitty set of feeler gauges?

10-4 on the check valves.
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post #134 of 154 (permalink) Old 09-13-2019, 06:10 PM
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I'd call wsm's customer service then.
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post #135 of 154 (permalink) Old 09-13-2019, 08:44 PM
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How much would 6 thousandths of an inch REALLY affect the motor?

.006 would cause it to have very low compression and a lot of blowby. once they wore in a season or two you'd be doing a new set of rings again.
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post #136 of 154 (permalink) Old 09-17-2019, 05:03 PM Thread Starter
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WSM has confirmed I received the correct set of rings. So what are my options moving forward? I assume resleeving the cylinders is the easiest option, then have them bored and honed again.

Last edited by T0MMY B0NES; 09-17-2019 at 05:37 PM. Reason: Options
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post #137 of 154 (permalink) Old 09-17-2019, 06:45 PM Thread Starter
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I sent Big John an email, he bored and hones the cylinders for me. 30+ years as a boat mechanic. I let him know what was going and he fired me back a promising email:

"Donít worry about the ring being a little big. I see it often and have been asked this question many times. It will run fine this way. Call me if you like."

He doesn't seem to worried about the larger ring gap. I trust his knowledge but at the same time, he's not paying for repairs! Any thoughts, concerns, or opinions?
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post #138 of 154 (permalink) Old 09-17-2019, 08:42 PM
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What type end is on the rings? A blunt end or a stepped end?

Thinking it may be best to order next up ring size and file. But if there a step type end it's difficult. But not impossible 😉.
A Dremel tool, a steady hand to rough cut then a fine file to clean up and fine tune. Just need to keep it clean and square, no burrs.
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post #139 of 154 (permalink) Old 09-17-2019, 09:31 PM Thread Starter
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I believe it is a stepped end, it has a "step end" not blunt. Ill grab a picture. Bay Area Powersports and WSM knew of no such "bigger" rings. I inquired about exactly what you mentioned.
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Last edited by T0MMY B0NES; 09-18-2019 at 02:40 AM. Reason: photo
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post #140 of 154 (permalink) Old 09-22-2019, 08:18 PM Thread Starter
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Having to replace a PV oil seal and had to buy oil pump gasket. Parts come in first of this/next week depending where your week starts. Its going to be 98 degrees in Nashville on October 1st, I got plenty of time to get back on the water for testing before winterizing.
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