2003 Yamaha XLT 800 66e Projects - Page 15 - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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post #141 of 154 (permalink) Old 09-23-2019, 07:37 AM
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Something is smelling fishy. I can only figure the bore is a tick big and causing the ring gap issues. But your piston clearance is correct at .004. would be nice to know true bore diameter.
I don't like it, but see no alternative but to assemble as is or buy a new top end exchange kit.
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post #142 of 154 (permalink) Old 09-23-2019, 05:48 PM Thread Starter
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I agree and I too would like to know the "true" diameter. Picked up the oil seal today, oil pump gasket should be here tomorrow.
I'm not sure I would trust my measurement if I were to do it. I could call around and ask a small engine repair or machine shop to throw me top, mid, and bottom bore measurements. I am not sure how that would change things moving forward. I guess if it is too big the option to resleeve and bore and hone would be the most affordable route.
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post #143 of 154 (permalink) Old 09-24-2019, 12:56 AM Thread Starter
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Cylinders are marked Y-1 and Y-2. I was placing Y-1 toward the front of the motor where I assume #1 goes and noticed there was dowel in the case and a dowel in the cylinder in the same corresponding hole. This made me question whether y-1 cylinder needed to be at the front of the motor or not. Also, the worst news, I am missing 2 dowels. I did not pull or replace these dowels. I now have to hope someone local has these or wait for shipping once again, per my usual bad luck.

If I were to replace all 4, how in the hell do you pull these suckers out? I dont guess it matters if I booger the old dowels out but I cant pull them. No access to acetylene torch, all I have is a basic propane torch.
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post #144 of 154 (permalink) Old 09-24-2019, 07:17 AM
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Cyl's are both the same. If it fits rear location without pulling dowel put it there. However I would order and replace missing dowels. They keep the cyl's located correctly.

However in future if you need to pull one. use a pair of wire cutters. Grab as low as possible and push down. Use the 15* angle is jaws as your lever. Or vice grips and twist.
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post #145 of 154 (permalink) Old 09-24-2019, 09:45 AM Thread Starter
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10-4 on cylinder locations.

Wirecutters, great idea, I was trying to pull using channel locks. Making some calls when these shops open!
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post #146 of 154 (permalink) Old 10-02-2019, 04:43 PM Thread Starter
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Pins were replaced. Vise grips and twisting worked for me on pin removal, paying close attention to not damage mating surfaces.

Appears the 3rd and 9th bolt holes, through the cylinder head and to the cylinders have become damaged ad stripped the holes. I need to replace these bolts as well as helicoil one hole on each cylinder.

I am under the assumption that the head bolts are coarse M10 x 55, can anyone confirm?

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post #147 of 154 (permalink) Old 10-02-2019, 05:46 PM
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Tommy,
The bolts are 8mm. Look for a set of used on ebay. Or order new. A generic 8mm bolt won't work.
You may also have to search by part number.
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post #148 of 154 (permalink) Old 10-14-2019, 05:42 PM Thread Starter
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M8x55, not sure where I got the 10 from, maybe quantity needed. My original question was what is the threat type/size on these head bolts? I need to order the correct helicoil kit to try and get this baby back together.
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post #149 of 154 (permalink) Old 10-14-2019, 10:23 PM
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Quote:
Originally Posted by T0MMY B0NES View Post
M8x55, not sure where I got the 10 from, maybe quantity needed. My original question was what is the threat type/size on these head bolts? I need to order the correct helicoil kit to try and get this baby back together.
Sorry guess I misunderstood message 😬. To the best of my knowledge without one to check against. They are 8mm x 1.25 pitch. Check one against a nut in the hardware store. The nut box should have the pitch on it. Or find a pitch guage.
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post #150 of 154 (permalink) Old 10-15-2019, 04:21 PM Thread Starter
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Head bolts are M8 x 1.25 x 55mm. Coarse thread.

Ace had a perfect size match but bolt head numbers were different, replacement labeled 8.8, the head bolts are 10.

I ordered a heli-coil kit for M8 x 1.25 and I have 2 replacement head bolts on order.
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