New to me 2002 800 xlt problems - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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post #1 of 15 (permalink) Old 08-04-2019, 06:36 AM Thread Starter
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New to me 2002 800 xlt problems

Hi I'm not sure if this is in the write spot for this post but I am in need of some assistance to diagnose what happend to my ski. I was riding around the lake for the first time after buying this ski and then all of a sudden I lost all propulsion but the motor still starts and revs. After being towed back to the ramp I loaded it up and went to town ripping the impeller out and jet pump out as well. I'm not quite sure what I'm supposed to look at but I thought maybe something got caught in it causing it to stick but not so much luck. I did notice the impeller was causing grooves in the plastic wear ring. It was also making a really loud metal clanking noise when started out of the water befor I ripped everything out. Now that the drive shaft is out there's no noise. I'd be grateful to anyone with any knowledge for this problem. I'm lost on what to do next. Thanks in advance.
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post #2 of 15 (permalink) Old 08-04-2019, 07:56 AM
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put the impeller back iin and measure the impeller to wear ring clearance and try and giggle the impeller. Sounds like the pump bearings my have gone south. I think your supposed to be around .018, but Dave can verify that for me.
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post #3 of 15 (permalink) Old 08-04-2019, 09:00 AM Thread Starter
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The impeller rubs all the way around but it does have alittle slack when I giggle it around in there.
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post #4 of 15 (permalink) Old 08-04-2019, 10:00 AM
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Quote:
Originally Posted by Branamoia View Post
Hi I'm not sure if this is in the write spot for this post but I am in need of some assistance to diagnose what happend to my ski. I was riding around the lake for the first time after buying this ski and then all of a sudden I lost all propulsion but the motor still starts and revs. After being towed back to the ramp I loaded it up and went to town ripping the impeller out and jet pump out as well. I'm not quite sure what I'm supposed to look at but I thought maybe something got caught in it causing it to stick but not so much luck. I did notice the impeller was causing grooves in the plastic wear ring. It was also making a really loud metal clanking noise when started out of the water befor I ripped everything out. Now that the drive shaft is out there's no noise. I'd be grateful to anyone with any knowledge for this problem. I'm lost on what to do next. Thanks in advance.
Branamoia, yes you posted in the right spot.
Welcome aboard,
Thanks for posting pics, this helps a lot in diagnosing issue. I'm quite curtain your thrust problem is that the splines in your center shaft have failed. Try inserting the pump shaft and turning it. See if it jumps along or turns motor over. Also see how much back and forth play there is in the splines. They should fit snug. Clean the rust and debis from the shaft first. There probably is still quite a bit in the other end as well.
I don't like the cheap plastic wear rings. They fail quickly and need frequent replacement. Check the pump brgs for side and end play by trying to wiggle the shaft in the housing. Also turn the shaft and check for any roughness in the brgs. Should turn smooth as melted butter no catching or grinding feel.
If pump brgs are ok, the shaft splines look good I'd replace the center support brg/shaft and your wear ring. After that Before you put the pump assembly back in measure the clearance of the Impeller to wear ring. It should be under .018" if it's above that you'll also need an Impeller to tighten the clearance or risk cavitation problems.
All your parts can be found at Babbittsonline for a new ring. Part number 6cr-r1312-00-00 or eBay for used.
SBT or wsm for shaft and seals.
Impros for Impeller if needed. Solas Concords work great for your application.

P.S. the metal clanging sound was probably the impeller rattling on the plastic ring.

Last edited by Dave in DE; 08-04-2019 at 10:18 AM.
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post #5 of 15 (permalink) Old 08-04-2019, 10:01 AM
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Rods is ahead of me. I was writing a book.
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post #6 of 15 (permalink) Old 08-04-2019, 10:16 AM
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I suspect you may be facing 2 failures. The center shaft splines and possibly the pump shaft brgs.
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post #7 of 15 (permalink) Old 08-04-2019, 11:58 AM Thread Starter
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So I did what you said about putting it back to see if the pump brgs have play. They seem to be tight and turn smooth as can be. The shaft on the other hand is doesn't turn the motor over. I didn't realize it wasnt supposed to be loose as it is. Befor I thought it was supposed to turn alot but seems like once I turned it about 280 it went and got tight and then all of a sudden got loose again. Is that supposed to be happening or is that the center shaft thing you were talking about befor? Sorry for all the questions. But thanks for helping narrow this down.
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post #8 of 15 (permalink) Old 08-04-2019, 12:47 PM
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Ok. Sounds like pump is fine then and the center shaft support needs replacing. Unfortunately to do so, the motor needs to be moved forward or removed. I'm not sure how much room there is forward of the motor on the xlt. But if you remove the exhaust and motor mounts you can try it. At worst you'll have to lift it out. To take it out though there's a lot more to be removed.
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post #9 of 15 (permalink) Old 08-04-2019, 01:12 PM
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Let me add this so it's not missed. Before you put the new shaft and brg in place put marine grease on the splines. Then also wipe marine grease on the pump shaft before installing it as well.

Last edited by Dave in DE; 08-04-2019 at 01:20 PM.
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post #10 of 15 (permalink) Old 08-04-2019, 01:56 PM Thread Starter
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Ok thanks. I wouldn't have thought about marine grease. There seems like alot of room for moving the engine forward but would there be something in the way of me moving the engine from the center shaft support?
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