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| | | Forum Newbie
Group: Forum Members
Last Login: 10/14/2007 4:14:14 PM
Posts: 2, Visits: 6 |
| I purchased a used 2003 800 XLT. The previous owner neglected to tell me that it had a motor that was rebuilt by PMC. It was pure junk. The cylinders were honed not bored so they were straight but .003 beyond the service limit. The bottom of the cases still had holes and pieces of the rods imbedded in the aluminum. When the front cylinder piston blew and the engine was torn down these problems looked like they were the cause. The cylinders have been replated and the cases welded and sealed up. Now I'm having problems with the power valves. The front cylinder broke one after just 12 hours of use. Two new ones were installed. After another 10 or twelve hours the front cylinder broke another one. Another power valve was put in and the machine was run for 30 minutes on the lake. Most of this was at full throttle one direction and then turn 180 and run back at full throttle. The engine was pulled back apart and there is wear on the under side and edge of the valve of the front cylinder. Any help or suggestions would be appreciated. Yamaha says they don't have a problem with the power valves. My machinist and mechanics are at wits end. I'm about out of money. $3000 and counting. I did check the distance from the top of the power valve stem to the top of the box. 28/64ths or .4375 on both cylinders. According to Waveaters literature that should be good.
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