2003 Yamaha XLT 800 66e Projects - Page 5 - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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post #41 of 93 (permalink) Old 07-31-2019, 04:02 PM Thread Starter
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Dave:

Any issues with proceeding with the tear down with the flywheel and PTO still on the crankshaft? Will this make it harder to remove these parts if crank is removed?
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post #42 of 93 (permalink) Old 07-31-2019, 06:27 PM
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Originally Posted by T0MMY B0NES View Post
Dave:

Any issues with proceeding with the tear down with the flywheel and PTO still on the crankshaft? Will this make it harder to remove these parts if crank is removed?
No, you can proceed, but can't replace seals till they are removed.
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post #43 of 93 (permalink) Old 08-06-2019, 06:40 PM Thread Starter
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I finally got the cylinders removed and the case separated though the flywheel and PTO are still connected to crankshaft. I was hoping it would "lift" out of the bottom but it has not. I am in the process of locating a machine shop that can bore and hone my sleeved cylinders to +1mm and clean the jugs up as will as have the crankcase cleaned, I am told I need to look for a shop that has vapor degreaser. I have a pressure washer and a cherry pick I could hang it from, just not sure the neighbors would be ok with me spraying carb cleaner and degreaser down the street.
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post #44 of 93 (permalink) Old 08-06-2019, 09:04 PM
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Just clean it all up in mineral spirits. Just remember to put lot 2stroke oil on/in all the crank brgs. Then wrap it up in a garbage bag
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post #45 of 93 (permalink) Old 08-08-2019, 11:17 PM Thread Starter
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Crankshaft pooped loose from lower case when I was messing with PTO. Case has been pressure washed with plain water, blown dry with air compressor, rubbed down with oil and bagged. Now I am looking for someone local to bore cylinders if not, making the drive to Louisville to Big John.
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post #46 of 93 (permalink) Old 08-09-2019, 01:54 AM
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Any cycle shop should be able to do it I would think.
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post #47 of 93 (permalink) Old 08-09-2019, 03:55 PM Thread Starter
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I have called several around Nashville and no one wants to work on an older 2 cycle. Driving up to Louisville will be my excuse to enjoy some Skyline Chili, headed up tomorrow morning and he will perform work while I eat lunch.

I was prepping all the parts when I noticed one of the older pistons had damage on it, didn't find any metal in the case so I guess it blew it out the exhaust.

I was getting ready to dive into my carbs when I opened my Berryman Chemdip can and found that it was extremely dark brown with what appears to be metal shavings, can someone confirm this is normal? I feel like someone used it and returned it to the store and I was lucky enough to buy it.
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post #48 of 93 (permalink) Old 08-10-2019, 10:52 PM Thread Starter
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Done! Pics to come.

Anyone have any opinions on the Berryman Cleaner? Does it look used?
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post #49 of 93 (permalink) Old 08-11-2019, 05:47 AM
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Parts dip looks used to me, but just my opinion. No need to dip the carbs. Just clean outside with carb or brake cleaner, open them up, spray clean with carb or brake cleaner, blow dry, assemble, check pop off, done.
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post #50 of 93 (permalink) Old 08-11-2019, 06:31 AM
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Ya, that chem dip is used. The color is fairly clear. Fluid level should be about an inch down from top. There should also be a part basket in the can and be clean on the bottom. That's how my 2 cans were when I got them.

As Rods said you don't have to dip. I dip mine and get them clean inside and out. Then after full assembly I tape off hose connections and openings and repaint.

Put marine grease on the high low adjusting screws threads and spring. Keeps them from seizing in place from corrosion.
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