2003 Yamaha XLT 800 66e Projects - Page 6 - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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post #51 of 93 (permalink) Old 08-11-2019, 03:03 PM Thread Starter
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Took the used dip back to AZ, they wouldn't allow a refund so I was fine with an exchange, though the replacement is just as dark just without the metal shavings, oh well.

Drove up to Louisville on Saturday and met with Big John at his house. He has a machine shop in his garage and he was nice enough to bore and hone both jugs while I waited and tried to stay out of his way. $40 for each cylinder and from what I can tell does a great job. He did give me permission to post his contact info if that is allowed. While visiting Louisville I had to stop for some Skyline Chili!

Piston picture shows the +1mm piston fitting in the newly bored cylinders. I brought my PIA of a crankshaft up and BJ was nice enough to help me out. He had to break out the acetylene torch on the flywheel and PTO as they were both heavily coated with what appeared to be loctite. FINALLY!
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post #52 of 93 (permalink) Old 08-11-2019, 03:29 PM
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Something just came to mind looking at your pics. And that is with oversized bore you may need to take a bit off the end of your power valves.
The bores look good. Nice crosshatch pattern. Don't see any boring marks.
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post #53 of 93 (permalink) Old 08-11-2019, 03:39 PM Thread Starter
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All good Dave! You are 100% correct. The WSM overbore kit came with a reminder that I would need to take off .005 off the powervalves to avoid snagging the piston rings or piston. Big John also "rounded" all of the sharp edges on the ports in the cylinder sleeve. We were going to reuse the old powervalves but found one valve was pretty nicked up from what I assume was part of the old piston making it's way out.

Also on topic of the overbore, will this affect carb settings or jets?

Carbs are taking a dip today for around an hour now that I have them separated and all the lines removed, will power rinse and blow dry afterwards.
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post #54 of 93 (permalink) Old 08-12-2019, 05:01 AM
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Nice job, and 40 is cheap. Go ahead and post his contact info if you want. I don't see a issue with it.
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post #55 of 93 (permalink) Old 08-12-2019, 07:34 AM
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I don't think you have anything to worry about as far as jetting goes. Just back your high/low screws out a bit. Say 3/8 turn on low and 1/2 on high.
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post #56 of 93 (permalink) Old 08-12-2019, 02:34 PM Thread Starter
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Big John

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Originally Posted by rodsatheart View Post
Nice job, and 40 is cheap. Go ahead and post his contact info if you want. I don't see a issue with it.
Awesome, thanks Rod.

Big John
Louisville, KY
Cell: (502) 693-4717

Big John does not like to text, call him. He will bore and hone cylinders for $40. If you drive up to his house he will perform the work while you wait and might even make you help. He can also re-sleeve if needed. Here is a link to his Craigslist ad if needed.
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post #57 of 93 (permalink) Old 08-12-2019, 02:45 PM Thread Starter
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Rebuilding the carbs today but I'll have to wait on my Oetiker kit to come in. Also going to replace all of the oil lines with tygon tubing. I noticed 3 different sized lines when tearing down the carbs. What size ID is required for replacing all of the oil lines?
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post #58 of 93 (permalink) Old 08-12-2019, 03:18 PM
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1/8" is what I used. But factory stuff is metric
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post #59 of 93 (permalink) Old 08-12-2019, 03:59 PM Thread Starter
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1/8" is what I used. But factory stuff is metric
Can I use 1/8" ID everywhere? Seems like the carbs had 2-3 different size lines on them.
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post #60 of 93 (permalink) Old 08-12-2019, 05:48 PM Thread Starter
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Reading up on these carbs, while I have them out, should I perform OsideBill's mods while I have the carbs out? The pressure return mod and the accelerator delete mod? I also have a primer kit to install.
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