2003 Yamaha XLT 800 66e Projects - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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post #1 of 151 (permalink) Old 07-12-2019, 12:51 AM Thread Starter
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Post 2003 Yamaha XLT 800 66e Projects

It is a build thread, filled with pictures, my random questions, and hopefully some decent answers, tip, recommendations. I am a newbie to the PWC scene but somewhat of a wrench-turner. Purchased 2x 2003 Yamaha XLT 800's to rebuild as a project. I'll be building the thread as I go, just wanted to get it started tonight.

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post #2 of 151 (permalink) Old 07-12-2019, 08:53 AM
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Welcome aboard, Tommy.
That's pair of nice looking skis. Do they both run? Any problems with them? How many hrs on them?
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post #3 of 151 (permalink) Old 07-12-2019, 12:44 PM Thread Starter
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It's a start!

Both were running at time of purchase. Unfortunately I had not done my homework before purchase. Skis both had about 130 hours. I bought them on Saturday and was on the lake Sunday, ski #1 ran great until something broke with the impeller, ski revs but doesn't move. Ski #2 ran ok until it would not start without constant manipulation of the choke. Ski#1 is on the trailer while I work on ski#2 as it was more of a major issue though I plan on rebuilding both engine. I was unaware that both oil pumps had been removed so I plan on reinstalling the pumps with rebuilt lines and going back to stock. The pumps don't fail, its the hoses and zip ties that fail. I don't want the hassle of premix.

Picked up a cherry picker from HF, a sling, and built some redneck rollers for the garage. Couple pics below.

Dave in DE, you are one of the reasons I came to this forum to post. Your knowledge and willingness to help on the Yamaha forum is undeniable. Thank you for posts, past, present, and future.
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post #4 of 151 (permalink) Old 07-12-2019, 02:35 PM
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Thanks for the kind words
The use of wire ties for the oil lines is ok but you must use a wire tie gun to get them tight enough to hold. The pumps are great and are veriable ratio. At Idle it's around 200/1 saving oil and fouled plugs all the way up to 30/1 at full throttle.
I have 2, GP800r's an 01/02 the 800is a very strong motor with a nice power band. I have done my research on them and my Two will carry max load at 56 mph. Stock motor, and blueprinted pump solas impeller.
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post #5 of 151 (permalink) Old 07-12-2019, 03:11 PM Thread Starter
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Engine Breakdown

For rebuilding, I am leaning towards Oetiker clamps when replacing the oil lines. I have the motor out of the hull with the head and carbs off. I was posting on a different forum but hadn't received much help. Apparently no one likes discussing the older smaller 2 cyl 800's.
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post #6 of 151 (permalink) Old 07-12-2019, 05:07 PM
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The Oetiker clamps are nice and work well. I've never used them though. The last 2 weeks I've been enjoying my vac lake house in upstate NY. On the finger lakes. Pic is me and my daughter enjoying the afternoon at the park with my cousin and his daughter. This is 02 it has all of 47hrs on it and all original except for impeller.
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post #7 of 151 (permalink) Old 07-12-2019, 05:16 PM
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Can you tell if the cyl's are nikasil still or sleeved? When you rebuild get a set of sbt valves and linkages. That will eliminate the valve problem with them
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post #8 of 151 (permalink) Old 07-12-2019, 05:48 PM
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Tommy, where you located at? What lake?
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post #9 of 151 (permalink) Old 07-12-2019, 06:40 PM Thread Starter
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Quote:
Originally Posted by Dave in DE View Post
The Oetiker clamps are nice and work well. I've never used them though. The last 2 weeks I've been enjoying my vac lake house in upstate NY. On the finger lakes. Pic is me and my daughter enjoying the afternoon at the park with my cousin and his daughter. This is 02 it has all of 47hrs on it and all original except for impeller.
Nice! That pic looks oddly familiar to a spot here at Old Hickory Lake in Middle Tennessee us locals call Two Foot, names pretty obvious. I am trying to get these skis torn apart and back together before Summer 2020, ha! In all seriousness, before the end of July I hope.
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post #10 of 151 (permalink) Old 07-12-2019, 06:46 PM Thread Starter
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Originally Posted by Dave in DE View Post
Can you tell if the cyl's are nikasil still or sleeved? When you rebuild get a set of sbt valves and linkages. That will eliminate the valve problem with them
Total newbie to PWC world, how can I tell about the cylinders? Cleaned up close up needed?
As for the Power Valves, I picked up an updated set by WSM.
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