I took off my exhuast y pipe and looking at one of my pistons on REV 800 noticed a vertical scratch on one of them. I could feel the scratch with my finger. Should this require new pistons or should I just run it?
Piston Scratch
- Thread starter KTG151
- Start date
What year REV. 04 and 05 had bad rings and pistons. Pull them out and put in new. If you already have the y pipe off, you have done the worst part of the top end job. The entire job took me around 6 hrs. The damn y pipe took 2 hours. Get yourself some ball end allen wrenches. I didn't have any.
I just did my 05, only had 1600 miles. Rings were falling apart, pistons scuffed from pieces of ring coming out.
My buddies 03 had the same ring problems, pieces of ring got into his lower rod bearing and grenaded his crank and case.
Dodge a bullet and change them out. Save some $$ in the long run.
Crasher
I just did my 05, only had 1600 miles. Rings were falling apart, pistons scuffed from pieces of ring coming out.
My buddies 03 had the same ring problems, pieces of ring got into his lower rod bearing and grenaded his crank and case.
Dodge a bullet and change them out. Save some $$ in the long run.
Crasher
Ya better to do the top end now before it gets really expensive.... hopefully your cylinders are still good???
I ran my finger around the top of the wall and it seemed ok. I'm good with doing this although I'm unsure about the pulling the pistons (tools involved). If any tips or steps input would be greatly appreciated.
if your going to replace the pistons and rings you might as well go this route for better performance!
http://www.2strokeheads.com/Ski_Doo_800_Replacement_Dual_Ring_Piston.htm
it's easy. did mine out in the parking lot. the only tool you might need is the thing that holds your wrist pin together. (they are cageless). i used mine again but some people say by new ones that have a cage. getting the cir clips back on the pistons is tough but can be done. get a torx every thing to spec
Nothing overly special required to do the job. but if i were you i would pop the engine out of the chassis and do it on the bench. Its much easier to tinker on and inspect things. though, ive done a few in-chassis but your pretty much screwed if you drop a wrist pin bearing!
No special tools needed. I did mine with open end, box end wrenches. Socket set and 5 mm allen wrench. Good pair of needle nose pliers for the snap rings.
Heat the piston with a head gun to push the pin out. Make sure you put rags under the pistons so the needles don't fall into the crank case. Count them to make sure one is not somewhere it is not suppose to be. 28 for each piston.
Install caged bearings. Way easier. New pistons with new pins, may as well change bearings anyhow, buy caged.
Warm the pistons with heat gun, oil the pin and slip it right in. Pre-oil the bearing w/ 2 stroke oil.
Rings are tapered. Taper goes up.
Do not hone cylinder with rigid hone. Use a berry bush hone, lightly. Better yet, just wash and wipe with solvent.
Mine has some scratchs down the sides of the pistons also, no damage to cylinders. Just cleaned them up and installed new pistons and rings. Started up first pull and runs good.
Check the base gasket. Make sure you install the same thickness.
Crasher
Heat the piston with a head gun to push the pin out. Make sure you put rags under the pistons so the needles don't fall into the crank case. Count them to make sure one is not somewhere it is not suppose to be. 28 for each piston.
Install caged bearings. Way easier. New pistons with new pins, may as well change bearings anyhow, buy caged.
Warm the pistons with heat gun, oil the pin and slip it right in. Pre-oil the bearing w/ 2 stroke oil.
Rings are tapered. Taper goes up.
Do not hone cylinder with rigid hone. Use a berry bush hone, lightly. Better yet, just wash and wipe with solvent.
Mine has some scratchs down the sides of the pistons also, no damage to cylinders. Just cleaned them up and installed new pistons and rings. Started up first pull and runs good.
Check the base gasket. Make sure you install the same thickness.
Crasher
Pulled the jugs and the cylinders look perfect. Rings are really flaked and were due a long time ago. Sled only had 1100 miles on it! Just need to order parts. Anyone actually loctite their base gasket or base bolts?
I did not use lock tite for anything except the y manifold bolts. Installed the base gasket dry. We did the same on my buddies 03. I think the torque was 27 ft/lbs on the cylinder bolts and 21 on the head bolts.
Pre-oil the cylinders when you install.
Crasher
Pre-oil the cylinders when you install.
Crasher
Has anyone ran the SPI pistons? RK TEK is out of the pistons only drop in kit?
We put SPI in my buddies last year. Worked good all year. I installed SPI in mine this year. Good looking pistons compaired to the stock ones. I found a company on E-Bay Stores that was selling a complete top end rebuild kit. SPI pistons, gasket set, rings, and caged bearings.
My buddy bought his set from Sea-Doo clinic. He also had them rebuild his crank and drill his cases or oil instead of Isoflex.
Crasher
My buddy bought his set from Sea-Doo clinic. He also had them rebuild his crank and drill his cases or oil instead of Isoflex.
Crasher
I would put in the drop-in kit from RK-Tek. I put it in my 02' Summit 800 and you will not beleive the difference. Well worh the money and you will not have the ring flaking anymore.